Hy-Brid Lifts HB-830 Programming manual

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TableofContents
Safety.........................................................................................................................................................................5
SafetySymbols............................................................................................................................... .......................5
GeneralRulesandPrecautions..............................................................................................................................5
SafetyGuidelines............................................................................................................................... ....................6
MaintenanceLock............................................................................................................................... ..................6
Maintenance............................................................................................................................... ...............................7
BatteryMaintenance.............................................................................................................................................7
ChargingtheBattery............................................................................................................................... ...............7
Lubrication............................................................................................................................... ..............................8
Componentsrequiringadjustment.......................................................................................................................9
Examination,repair,replacementoflimitedlifecomponents.............................................................................9
Safetydevicesandsystemsrequiringchecks........................................................................................................9
Storage............................................................................................................................... ....................................9
MajorAlterationsorRepairs.................................................................................................................................9
InspectionandRegularMaintenanceChecklists.....................................................................................................10
MonthlyBatteryCare..........................................................................................................................................10
PrestartInspectionChecklist...............................................................................................................................11
FrequentInspectionChecklist............................................................................................................................. 12
PreͲDelivery/AnnualInspectionChecklist...........................................................................................................13
TechnicalReferences...............................................................................................................................................14
JoystickServiceFlashCodes................................................................................................................................14
TechnicalReferences...............................................................................................................................................15
HydraulicSchematic............................................................................................................................................15
ElectricalSchematic............................................................................................................................... ..............16
WiringDiagrams............................................................................................................................... .......................18
WiringDiagram....................................................................................................................................................18
MainPower&Safety............................................................................................................................... ............20
DriveCircuit.........................................................................................................................................................22
Elevate/LowerCircuit..........................................................................................................................................24
Troubleshooting......................................................................................................................................................26
TroubleshootingFlowchart............................................................................................................................... ..26
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TroubleshootingFlowchart—Drive&SteerCircuit..............................................................................................28
TroubleshootingFlowchart—Elevate&LowerCircuit........................................................................................30
ReplacementParts............................................................................................................................... ...................32
SafetyandControlDecals............................................................................................................................... .....32
MainPower/SafetyCircuit..................................................................................................................................34
DriveCircuitParts............................................................................................................................... .................35
Elevate/LowerCircuitParts.................................................................................................................................36
Warranty............................................................................................................................... ...................................38
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Figure1:MaintenanceLockPinUse......................................................................................................................... 6
Figure2:MaintenanceLockPinStorage...................................................................................................................6
Figure3:BatteryMaintenance............................................................................................................................... ...7
Figure4:BatteryChargerLEDDisplay....................................................................................................................... 8
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RevisionTable:
RevisionA(08/02/2010):InitialRelease
RevisionE(10/24/2012):Revisedlogos
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OriginalinstructionsarewritteninEnglish
Foreword
ThepurposeofthisMaintenanceManualistoprovidequalifiedservicepersonnelwithinformationforservicing
andmaintainingHyͲBridLifts.Allinformationinthismanualmustbereadandunderstoodbeforeanyattemptis
madetoservicethismachine.
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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HyͲBrid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.
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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WITHOUTTHEEXPRESS
WRITTENCONSENTOFTHEMANUFACTURERISPROHIBITED.
Ifthereisaquestiononapplicationand/oroperation,contact:
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CustomEquipment,Inc.
2647Hwy175
Richfield,WI53076
USA
Phone:262Ͳ644Ͳ1300
Fax:262Ͳ644Ͳ1320
www.hybridlifts.com
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Safety
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SafetySymbols
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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.
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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EQUIPMENT
"CAUTION"indicatesapotentiallyhazardous
situationwhich,ifnotavoided,couldresultin
minorormoderateinjuryordamagetoequipment
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GeneralRulesandPrecautions
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CustomEquipment,Inc.designedtheHyͲBridLiftselfͲpropelledscissorlifttobesafeandreliable.Itisintended
forelevatingpersonnel,alongwiththeirnecessarytoolsandmaterialstooverheadworklocations.
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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.
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AlthoughCustomEquipment,Inc.conformstospecifiedAmericanNationalStandardsInstituteANSI/SIA
A92.6Standard,itistheresponsibilityoftheownertoinstructoperatorswiththesafetyrequirementsmade
notonlybyCustomEquipment,Inc.,butbythevarioussafetyboardsinyourarea,aswellasadditional
requirementssetforthbyANSIA92.6.Ifyoucomeacrossasituationthatyouthinkmightbeunsafe,stopthe
platformandrequestfurtherinformationfromqualifiedsourcesbeforeproceeding.
WARNING
MAINTENANCEINFORMATIONISFORUSEBYTRAINEDPERSONNELONLY
WARNING
NEVERREACHBETWEENSCISSORSLINKSORPROPUPPLATFORMUNLESS
MAINTENANCEPINSAREINPLACE.
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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.
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Figure1:MaintenanceLockPinUse
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Figure2:MaintenanceLockPinStorage
WARNING
FAILURETOCOMPLYWITHTHELISTEDSAFETYPRECAUTIONSMAY
RESULTINMACHINEDAMAGE,PERSONNELINJURYORDEATH.
xNeverworkunderanelevatedplatformuntilmaintenancelockshavebeenengaged.
xRemoveallrings,watches,andjewelrywhenperforminganymaintenance.
xDonotwearlonghairunrestrainedorloosefittingclothingandnecktieswhichmaybecomecaughton
orentangledinequipment.
xObserveandobeyallwarningsandcautionsonmachineandinmanual.
xKeepoil,grease,water,etc.wipedfromstandingsurfacesandhandholds.
xBeforemakinganyadjustments,lubricatingorperforminganyothermaintenance,shutoffallpower
controls.
xBatteryshouldalwaysbedisconnectedduringreplacementofelectricalcomponents.
xKeepallsupportequipmentandattachmentsstowedintheirproperplace.
xUseonlyapprovednonflammablecleaningsolvents.
xAftermaintenance,inspectthemachineasdescribedforPreͲdelivery.
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MaintenancePin
LocationWheninUse
PinStorage Location
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Maintenance
BatteryMaintenance
Thisunitisequippedwithdeepcycle12Ͳvoltbatteries.Thecareandmaintenanceofyourbatteryhasmuchto
dowithhowwellthisunitfunctions.Batterywiringandwaterlevelshouldbecheckedmonthly.Donotoverfill.
Whenthecellsaretoofull,fluidwillseepoutwhencharging.Thesolutionisatitsproperstrengthwhenthe
batteryismanufactured.Usedistilledwaterandkeepfluiduptoproperlevel.Whenrequired,watershouldbe
addedtobatteryaftercharging,unlesswaterlevelisbelowtheplates.
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xRemovebatterycabinetcover.
xRemovebatterycapsandcheckfluidlevel.
xFilleachcell(ifneeded)tosplitringwithdistilledwater.
xReinstallcaps.
xWashalldirt,debris,acid,etc.,offbatterywhenevercorrosion
isdetected.Useasolutionof5Ͳtsp.bakingsodaperquartof
warmwater.
xCoatterminalswithacommerciallyavailablecoating.
CAUTION
NEVER ADD ACID TO BATTERY!
ChargingtheBattery
Thisunitisequippedwithdeepcycle12Ͳvoltbatteries.Thecareandmaintenanceofyourbatteryhasmuchto
dowithhowwellthisunitfunctions.Batterywiringandwaterlevelshouldbecheckedmonthly.Donotoverfill.
Whenthecellsaretoofull,fluidwillseepoutwhencharging.
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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(Ͳ18°C),thisbattery
willdropto40%efficiency.
WARNING
LEAD-ACID BATTERIES GENERATE EXPLOSIVE GASES. KEEP SPARKS AND
FLAME AWAY FROM BATTERIES. DO NOT SMOKE WHILE CHARGING.
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xParkthemachineonalevelsurface.
xPlugchargerintoACoutletuntilcharged.
xUnplugcharger.
Figure3:BatteryMaintenance
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Thechargerwillnotbeginchargingonseverelydischargedbatteries.Thiswillbeevidentbythethree
indicatorsblinkingsimultaneously.
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Figure4:BatteryChargerLEDDisplay
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50% 75% 100% GEL
Charger LED Display
Charging State
0 to 50% charged Blinking Off Off NA
50% to 75% charged On Blinking Off NA
75% to 100% charged On On Blinking NA
100% charged On On On NA
Charge for flooded type batteries NA NA NA Off
Charge for Sealed type batteries NA NA NA On
Abnormal Cycle Off Off Blinking NA
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WARNING
DO NOT OPERATE UNIT WHILE CHARGING.
DO NOT DISABLE CHARGER INTERLOCK.
Thesolutionisatitsproperstrengthwhenthebatteryismanufactured.Usedistilledwaterandkeepfluidupto
properlevel.Whenrequired,watershouldbeaddedtobatteryaftercharging,unlesswaterlevelisbelowthe
plates.
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Lubrication
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ItemSpecificationFrequencyofLubrication
WheelsTeflonSprayQuarterly
CAUTION
NEVER ADD ACID TO BATTERY!
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Componentsrequiringadjustment
Undernormaluse,nocomponentsshouldrequireadjustment.Contactthemanufacturerifadjustmentsare
required.
Examination,repair,replacementoflimitedlifecomponents
Withproperuse,batterymaintenance,andregularinspection,therearenolimitedlifecomponentsthatrequire
routinereplacement.
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Safetydevicesandsystemsrequiringchecks
Checksafetyfunctionsaspartofdailyinspection.Checkthattheelectromagneticbrakesareholding.
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Storage
Afterperiodsofstorage,exposuretoextremesofambientconditionsͲheat,cold,moisture,dustetc.,inspectthe
machine.RefertothePreͲDelivery/FrequentInspectionChecklistintheMaintenanceManual.
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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.
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InspectionandRegularMaintenanceChecklists

CAUTION
FAILURE TO PERFORM INSPECTIONS AND PREVENTITIVE MAINTENANCE AT
RECOMMENDED INTERVALS MAY RESULT IN THE UNIT BEING OPERATED
WITH A DEFECT THAT MAY RESULT IN INJURY OR DEATH OF THE OPERATOR.
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requiredandincludedinthismanual:
PreͲStart(Requiredbeforeoperationateachworkshift)
MonthlyBatteryMaintenance
Frequent(Requiredatintervalsnotmorethanthreemonths)
PreͲDelivery/Annual(Requiredatintervalsnotmorethantwelvemonths)

MonthlyBatteryCare
WARNING
THISCHECKLISTMUSTBEUSEDATMONTHLYORAFTEREVERY100HOURSOFUSE.
FAILURETODOSOCOULDAFFECTTHESAFETYOFTHEOPERATOR.
MODELNUMBER_____________SERIALNUMBER______________

1. KeepinspectionrecordsupͲtoͲdate.
2. Recordandreportalldiscrepanciestoyoursupervisor.
3. Adirtymachinecannotbeproperlyinspected.
YͲYes/AcceptableNͲNo/UnacceptableRͲRepaired
Description Y N R
MonthlyBatteryCare:
1. Removebatterycabinetcover.
2. Removebatterycapsandcheckfluidlevel.
3. Filleachcell(ifneeded)tosplitringwithdistilledwater.
4. Reinstallcaps.
5. Washalldirt,debris,acid,etc.,offbatterywhenevercorrosionisdetected.Usea
solutionof5Ͳtsp.bakingsodaperquartofwarmwater.
6. Coatterminalswithacommerciallyavailablecoating.

Part #SUPO-613
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


PrestartInspectionChecklist
WARNING
THISCHECKLISTMUSTBEUSEDATTHEBEGINNINGOFEACHSHIFTORAFTEREVERYSIXTO
EIGHTHOURSOFUSE.FAILURETODOSOCOULDAFFECTTHESAFETYOFTHEOPERATOR.
MODELHBǦ830SERIALNUMBER______________
1. Keep inspection records up-to-date.
2. Record and report all discrepancies to your supervisor.
3. A dirty machine cannot be properly inspected.
Y-Yes/Acceptable N-No/Unacceptable R-Repaired
DescriptionYNR
VisualInspections
Checkthattherearenodamaged,dented,orbentstructuralmembers.
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.Checkthathosesandthecableshavenowornareasor
chafing.
Checkthehydraulicfluidlevelwiththeplatformfullylowered.
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(alignmentcanbeadjustedwithscrewontoeboardorrailingifnecessary).
PlatformControls:Checkallswitchesandpushbuttonsforproperoperation.
EmergencyStop(Stopsallmovement)
DriveEnable(Mustbeactivatedtodrive)
Joystick(Returntoneutral,drivesforward,reverse,left,right)
LiftEnable(Mustbeactivatedtoelevate)
RockerSwitch(Elevates,Lowers)
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)
Hourmeter(DisplaysDriveHours)
Alarms(Notdamaged,soundsfordescent)
Wheels:Frontandrearwheelsrotate,pivotfreely.
Drivesinslowspeedwhenelevated.
Brakes:Machinestopswhenjoystickreleased.
Potholeguardsdeployandlockwhenplatformisraised.
Liftdoesnotelevatewhenpotholeguardsareblocked.




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


FrequentInspectionChecklist
WARNING
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______________
xCheckeachitemlistedbelow.
xUseproperoperating,service,andmaintenancemanualforspecificinformationandsettings
xIfanitemisfoundtobeunacceptablemakethenecessaryrepairsandcheckthe“repaired”box.
xWhenallitemsare“acceptable”,theunitisreadyforservice.


Description Y N R
VisualInspections
PerformallchecksonthePreͲStartInspectionChecklist. 
Inspecttheconditionofhydraulicfluidinreservoir.Oilshouldhaveaclearambercolor. 
Inspecttheentiremachineforsignsofdamage,brokenwelds,loosebolts,orimproperrepairs.(Check
forcorrosion,cracking,abrasion,etc.)

Checkthatallsnapringsaresecureingroovesonpivotpins. 
Checkiftiresareleaninginorout.
Checkelectricalmotorbrushes(every150hours) 
Verifythatmaintenanceandinspectionrecordsareuptodate. 
FunctionalTests
PerformallchecksonthePreͲStartInspectionChecklist. 
Functionsoperatesmoothly.
Functionsoperateoverfullrangeofmotion.
ElevatedandLowereddrivespeedsdonotexceedspecificationslistedinOperatorsmanual. 
EmergencyLowering—Manualoverridefunctionsproperly. 
GroundControlsoverrideplatformcontrols.
Checkthattheplatformdoesnotdriftdownwithafullload. 
Wheelslubricatedifneeded.
Comments:






DATE_______________INSPECTEDBY_______________________________ 

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



PreǦDelivery/AnnualInspectionChecklist
WARNING
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12MONTHS.
MODELNUMBER:HBǦ830SERIALNUMBER______________
xCheckeachitemlistedbelow.
xUseproperoperating,service,andmaintenancemanualforspecificinformationandsettings
xIfanitemisfoundtobeunacceptablemakethenecessaryrepairsandcheckthe“repaired”box.
xWhenallitemsare“acceptable”,theunitisreadyforservice.

CheckYNRCheckYNR
Base:
Inspect roller tracks for damage
Decals:
All frame bolts tight
Legibility
Pump Secure
Correct capacity noted
DC motor
s
secure
Proper placement quantity
Battery Hold Downs Secure
Wiring:
Batteries Fully Charged
Switches secure
Wheels: Snap Rings Secure
Contactor(s) secure
Wheels: Bolts/Nuts Ti
ght
Tight on terminals
(No loose wiring)
Maintenance Locks: Pins in cabinet
Functions:
All Shields/Guards in place
Drive, Lift, Steer Functions
Operational
Hydraulic Oil
Level 1
”
from top
Emergency Stop Breaks Circuits
Check all
hy
draulic
hose
s
for leaks
Slow Speed limit switch Set properly
Check all
hydraulic
fittings for leaks
Emergency Down Operational
Scissors:
Pothole guards deploy when platform
Broken Welds
Pothole interlock functions correctly
Bent Beam Members
Brakes: Operational
All rollers Turn Freely
Tilt sensor
Functional
Ret. Rings Secure On Pivots
Motion Alarms Functional
Broken welds
Hour meter operational
Platform:
Battery indication operational
All ra
ils in place/secure
Battery Charger Secure/Operational
No bent rails
No broken welds
110V outlet safe/working
(if installed)
Entrance gate Closes Freely
Operator/Service Manual Included
Cables in place/secure
Extending platform e
xtends freely
Extending platform
Locks in Stowed Position
ExtendingplatformLocksinExtendedPosition
Comments:


Part #SUPO-613
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


TechnicalReferences
JoystickServiceFlashCodes


TheamberServiceIndicatorLEDdisplays
diagnosticcodes.

Aflashcodeisasequenceofflashes,separatedbyapause,followedbyarepetitionofthesequence.The
numberofflashesindicatesacondition.

FlashCodeDescriptionNotes
1UserFaultPossiblestalltimeoutorusererror.Releasethejoystickto
neutralandtryagain.
2BatteryFaultTrychargingbatteries.Batteriesmayrequirereplacing.Check
batteriesandcables.
3LeftMotorFaultCheckleftmotor,connections,andcabling
4RightMotorFaultCheckrightmotor,connections,andcabling.
5LeftParkBrakeFaultCheckleftparkbrake,connections,andcabling.
6RightParkBrakeFaultChecktherightparkbrake,connectionsandcabling
7RemoteFaultChecktheCommunicationsBusconnectorsandwiring.
ReplacetheRemote(Joystick).
8PowerModuleFaultChecktheCommunicationsBusconnectorsandwiring.
ReplacethePowerModule.
9CommunicationsFaultOnecauseofthiserroriswhentheunitispowereddown
withoutturningoffthejoystick(i.e.usingtheemergencystop).
Toclear,withthemachineon(usingthekeyswitch),turnthe
joystickoffandbackon(joystickon/offbutton).

Checkthatbatteryvoltageisgreaterthan17V.ChecktheBus
Cable.ReplacethePowerModule.ReplacetheRemote
(Joystick).
10UnknownFaultCheckallconnectionsandwiring.Contactmanufacturer.
11IncompatibleRemoteTheRemoteisincompatiblewiththePowerModule.Ensure
thatthecorrectpartnumberisused.

Seealso“UpperControlBatteryGaugeIndicator”codeslistedintheOperator’sManual.


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Part #SUPO-613
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WIRING DIAGRAM
MAIN POWER/SAFETY CIRCUIT
Part #SUPO-613
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WIRING DIAGRAM
MAIN POWER/SAFETY CIRCUIT
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WIRING DIAGRAM
DRIVE CIRCUIT
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WIRING DIAGRAM
DRIVE CIRCUIT
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WIRING DIAGRAM
ELEVATE/LOWER CIRCUIT
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WIRING DIAGRAM
ELEVATE/LOWER CIRCUIT
Part #SUPO-613
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Does the machine have any
function:
(Drive, Steer Elevate/Lower)
Are the batteries
connected?
Check per wiring diagram.
Connect batteries.
See wiring diagram & battery
connection sequence.
No
Are the batteries fully
charged?
(Check voltmeter at lower control or check
voltage across battery terminals using
voltmeter/multi-meter)
Charge batteries.
Replace batteri
e
Or
Replace charg
e
(Load test batteries, individually, disc
o
If batteries do
not take charge
No
Is short protection fuse at
pump blown?
Replace Fuse
Yes
Is key switch turned on?
Turn key switch on
No
Is there a different
problem? Contact CEI for further troubleshooting
See Drive & Steer Problems Flowchart
See Elevating & Lowering Problems Flowcharts
Yes, but some
function(s) are
not working properly
Yes Yes
Yes
Does Platform
Control Display a
Fault Code?
Check Component
or Condition
Referenced by
Fault Code
Part #SUPO-613
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Page 26 of 38
a
tteries
h
arger
disconnected from machine)
Are both E-Stop buttons
off?
Reset E-Stop buttons. Pull
out at both upper control and
lower control locations.
No
Check for loose wiring connections. Check for ground connection at pump.
See wiring diagrams. Check for continuity in connections use Voltmeter/
Multi-meter at 400V setting.
Contact CEI for further troubleshooting
Consider charger failure (interlock contacts)
Still no
functions?
Is unit overloaded?
Remove load. Safety function
activated.
Yes
No
Is charger plugged in?
Unplug charger. Unit will not
operate while charging.
Yes
Is Upper Control
plugged in?
Connect Upper Control box.
No
s
Yes Yes
Yes
No
SUPO-613 HB-830 Troubleshooting Flowchart
Revision A: Initial Release 08/02/2010
Is unit in Sleep Mode?
Turn the power off and back
on using the key switch at the
base controls.
No
Part #SUPO-613
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Does the machine
drive?
(Elevate, Lower, and
Steer OK)
Is either or two brakes
manually released?
Is either of two brake
switches damaged or
disconnected?
Is drive unit d
a
Flip brake handle(s) at rear of
machine to engage brakes.
Yes
No
Replace brake switch. Note that
brake limit switch tabs are
delicate. Use caution not to
break off.
Yes
No
Replace dri
v
Yes
Driving slowly? Are batteries fully charged?
If resistor is installed, check using Ohmmeter/Mul
t
setting). Resistance across resistor should be
a
Drives slow when
lowered?
Drives fast when elevated?
Does not drive when
elevated?
Is mode limit switch
damaged or blocked wit
h
debris?
Do pothole guards and
lock deploy properly?
Clean any debris from pothole arm
mechanism
Yes
Contact
C
Consider board
Is mode limit switch
damaged or blocked with
debris?
Yes
Are brakes hot?
Drives intermittently? Check wiring connection
integrity.
Is there moisture or
corrosion in any
connections?
Check
connections at
both pump and
board. See wiring
diagrams.
Yes, but not properly
Is machine tilted?
Is there a trouble
code displayed?
Refer to trouble
code table
Part #SUPO-613
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u
nit damaged?
c
e drive unit
Yes
Are all connections to
drive joystick and drive
control board secure?
Reconnect
No
Is there moisture or
corrosion in any
connections?
No
Yes
Allow to dry for 24 hours and try again.
Board probably will need replacement.
Apply dielectric grease to connectors at
main wire harness.
Yes
Replace drive control board
and/or joystick.
No
Contact CEI for further troubleshooting.
Consider brake damage, broken joystick
handle (drive enable), bad hour meter, loose
connections in lower and upper control
Still no drive?
r
/Multi-meter (400 ȍ
d
be approx. 4 ȍ)
t
ch
d
with
Clean any debris from limit switch area.
Check for proper connection inside limit switch. (See wiring
diagram).
Replace mode limit switch.
Yes Contact CEI for further troubleshooting.
Consider board failure or loose wiring.
t
act CEI for further troubleshooting.
b
oard failure, pothole interlock limit switch
failure
Clean any debris from limit switch area.
Check for proper connection inside limit switch. (See wiring diagram).
Replace mode limit switch.
Contact CEI for further troubleshooting.
Consider board failure or incorrect wiring.
o
r Allow to dry for 24 hours and try again.
Board probably will need replacement.
Apply dielectric grease to connectors at
main wire harness.
Contact CEI for further troubleshooting.
Consider board failure
SUPO-613 HB-830 Troubleshooting Flowchart
Drive Problems
Revision A: Initial Release 08/02/2010
Is a drive motor
damaged?
Replace drive
motor.
Part #SUPO-613
REV E
Page 29 of 38

Does machine raise/
lower? Does pump operate?
Check for power connection. See Main Troubleshooting
Replace pump assembly
No
Ascent speed slow or
erratic?
Is emergency down
valve open?
Close emergency down
valve or cable connections
Is hydraulic fluid lo
w
With platform lowere
pump reservoir to 1"
b
top of reservoir
Yes
No
Is battery fully charged? Is emergency down
valve open?
Are any structural
members bent?
Contact manufacturer to
arrange replacement.
Is
t
Re
p
Charge battery. Close emergency down
valve.
Yes, but
not properly
Is power solenoid
damaged?
Replace
solenoid.
Are diodes functioning
properly?
Measure resistance across diode—Ohm meter/multi-meter at 40 kȍs
e
Will not descend?
Creeps down?
Has key switch been
turned off? Is an E-Stop activated? Is battery charged?
Turn key to on position. Pull out emergency stop button
at upper and lower controls. Charge batteries.
Is emergency down
valve open?
Close emergency down valve.
Check cable connections.
Disassemble and clean. Look for residue in
screen and on O-ring or damage to O-ring.
Replace down valve.
Faulty down
valve?
Electrical
problem?
Foreign matter
lodged in up or
down valve?
Disconnect coil. Check if unit sto
p
drifting. Check voltage at coil—sh
o
be 0 V when not energized.
Run unit up and
t
Might be able to re
walls inside cylind
e
Starts elevating,
then stops?
Are pothole guards
blocked?
Is pothole limit switch
functionning?
Remove
obstruction.
Replace limit
switch or repair
connections.
Part #SUPO-613
REV E
Page 30 of 38
Is down valve stuck
open?
u
id low?
o
wered, fill
t
o 1" below
e
rvoir
Flush valve by simultaneously
pressing up switch at base and down
switch on platform control for 30 sec.
Contact CEI for further
troubleshooting.
Check integrity of electrical
connections, There may be a
loose connection or momentary
short.
Flush down valve by
simultaneously pressing up switch
at base and down switch on
platform control for 30 sec.
There may be foreign matter
lodged.
Is there a restriction in
hydraulic hose? Replace pump. May
be worn or defective.
Replace hydraulic hose.
Is up/down switch
damaged?
Replace rocker switch at
upper or lower control.
k
ȍsetting. With black lad on stripe side and red on other side, should get a resistance reading. Switch leads, no reading.
Replace bad diode.
SUPO-613 HB-830 Troubleshooting Flowchart
Elevate & Lower Problems
Revision A: Initial Release 08/02/2010
Replace down coil. Check for loose electrical
connections.
it stops
—
should
e
d.
Damaged cylinder or
damaged seal in
cylinder?
Coil mounting nut too
tight?
and then check for oil flow out of return line. Bad cylinder
seal if oil is flowing from return line.
to repair with seal kit;, probably need to replace cylinder. If
y
linder are scratched or pitted, cylinder needs replacement.
Nut should only be lightly snug:
30 in.-lb. Replace coil and lightly
tighten nut.
Faulty check valve in
pump?
Listen carefully near motor when
not energized—may be running
backwards. Replace pump
Part #SUPO-613
REV E
Page 31 of 38


ReplacementParts

CAUTION
USEONLYMANUFACTURERAPPROVEDREPLACEMENTPARTS.USEOFNONͲOEMPARTSWILL
VOIDWARRANTY.


DANGER
REPLACEMENTOFTHEFOLLOWINGCOMPONENTSWILLAFFECTTHESTRENGTH,STABILITY,
ORSAFETYFUNCTIONOFTHEUNIT:BATTERY,HYDRAULICCYLINDER,JOYSTICKAND
CONTROLMODULES,ANDALLSTRUCTURALCOMPONENTS.

Listedbelowarereplacementpartsthatmaybeavailableandlistedforreference.Theserepresent
currentrevisions.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.

SafetyandControlDecals
RefertoOperator’sManualfordecalpartnumbersandlocations.
Part #SUPO-613
REV E
Page 32 of 38

Covers/Other

Item#Part#Description
11000501001Cover,Side
2HARDͲ633CCabinetLatchCam
3HARDͲ633BCabinetLatchHandle
41000103001Step
51000500901Cover,PumpTop
61000501001Cover,Side
71000500601Cover,PumpEnd

Part #SUPO-613
REV E
Page 33 of 38


MainPower/SafetyCircuit

Item#Part#Description
1NABͲ“Ground”ConnectiononPump
2NAB+PowerConnectiononPump
3(ELECͲ047)Notavailableasareplacementpart.Replacewith12V,Group27Deep
CycleMarineBattery.Replacementweightmustbeminimum50lb.
4ELECͲ629TiltSensor
5ELECͲ645BatteryCharger
6ELECͲ639Ͳ1ChargerCord(NEMA5Ͳ15ͲP/IEDͲ320C13)
7ELECͲ071ͲKITEmergencyStopButtonwithContactBlock
8ELECͲ073EKeySwitch
8ELECͲ073EKEYSpareKey
91002101050LowerControlAssembly
101002101350UpperControlAssembly
11ELECͲ551Joystick
12ELECͲ071ͲKITEmergencyStopButtonwithContactBlock
NotPicturedSUBA13MainCable
NotPicturedELECͲ670Ͳ220AAGCFuse
NotPicturedELECͲ819SleepTimer
NotPictured1002101550BatteryCableKit
NotPictured1002101099DrivePowerCableKit
Part #SUPO-613
REV E
Page 34 of 38

DriveCircuitParts

Item#Part#Description
11000108202Caster
21000106451DriveControlBoard(specifictothismodel/seriesonly)
3NABrakeConnectionTerminals
4LASͲM248Ͳ1ͲPCLimitSwitchMountingBracket
5ELECͲ123Ͳ2LimitSwitch
6ELECͲ627Ͳ4BrakeMicroswitch
7ELECͲ627Ͳ3LBrake(Right)
8ELECͲ627Ͳ3RBrake(Left)
9ELECͲ551Joystick
10ELECͲ602&ELECͲ072 DriveEnableButton&ContactBlocks
11ELECͲ826Ͳ3LElectricDriveMotor(LeftSide)
12ELECͲ826Ͳ3RElectricDriveMotor(RightSide)
13WHEEͲ707Wheel,10”
14ELECͲ610Ͳ2HourMeter
15ELECͲ631Relay
16WHEEͲ706&HARDͲ001Ͳ2Wheel,8”&Bearing
(NotPictured)ELECͲ809120OhmResistor
Part #SUPO-613
REV E
Page 35 of 38


Elevate/LowerCircuitParts


Part #SUPO-613
REV E
Page 36 of 38


Item#Part#Description
1HYDRͲ050Ͳ3HydraulicPump
21000101701PotholeBarͲR
3HBͲM215ͲPMaintenanceLockPin
41002100350HydraulicCylinderAssembly
5HARDͲ644LowFrictionCable(EͲDown)
6ELECͲ133BUp/DownRockerSwitch
7ELECͲ635Ͳ3Alarm,Tilt
8ELECͲ635Alarm,Descent
91000101601PotholeBarͲL
101000202004EͲDownValveActuator
11HARDͲ650ShaftCollar,7/16
12HYDRͲ044ͲFLͲ3HirschmannConnectorwithDiode
13HYDRͲ007Ͳ2EDownValvewithCoil
13HYDRͲ007Ͳ2EͲ1Coil,24V
13HYDRͲ007Ͳ2EͲ2DownValve
14HYDRͲ600Ͳ5HighPressureHydraulicHose
15ELECͲ602&ELECͲ871LiftEnableButton&ContactBlocks
16ELECͲ133BUp/DownRockerSwitch
17HBͲPHͲ13GuideBlock
181000102004PHRetainingSleeve
19HARDͲ702Spring
20HBͲPHͲ7ͲPPHLock
21ELECͲ123Ͳ2LimitSwitch
22LASͲM222ͲPLSPlate
231000105902PHPickͲUpArm
24LASͲM220ͲPPHArm
25ELECͲ629TiltSensor
26HYDRͲ66418VCoil
27HYDRͲ665UpValve
281000104401PumpMountPlate
29HYDRͲ666Ͳ124VSolenoid
(NotPictured)HARDͲ701Spring
(NotPictured)(HYDRͲ032)HydraulicFluid
Notavailableasareplacementpart.ReplacewithFlomite
#150,DexronII,MobilͲDTE2,orequivalent.
(NotPictured)HYDRͲ627PressureCompensatedFlowControlValve
(NotPictured)HARDͲ022RetainingRing

Part #SUPO-613
REV E
Page 37 of 38


Warranty

LIMITED WARRANTY – Warranty Statement—North America Only

Custom Equipment, Inc. (the “Company”) warrants that all new units of equipment manufactured and sold
by it conform to the Company’s latest published specifications. Also, that all purchased components and
sub-assembled parts and assemblies shall be free from defect in material and/or workmanship for a period of
12 months from the date a new unit is placed into service, with the exception of batteries which are covered
by the battery manufacturer for a period of ninety (90) days (pro-rated for one (1) year) on batteries. Further,
that all structural components manufactured, purchased, and installed by Custom Equipment, Inc. shall be
free of any defect in material and/or workmanship for a period of 60 months from the date a new unit is
placed into service.
If the equipment owner/end-user experiences a failure or deficiency within the specified warranty period they
must promptly notify an authorized Dealer service repair facility.
During the Warranty period, Custom Equipment, Inc. reserves the right to replace, repair, exchange, or to
provide a new, used, or rebuilt component, assembly, sub-assembly, or weldment at their discretion,
dependent upon circumstance, situation, and/or availability. For battery warranty, call the number listed on
the battery for further instructions.
This Warranty Policy does NOT cover damage caused by: shipment, misuse of unit (includes operation beyond
Factory established limits, loads, and/or specifications), or failure to properly service and maintain the unit in
accordance with the Company’s manuals or Factory Service Bulletins. Custom Equipment, Inc. DOES NOT
accept any responsibility for alterations or modifications to the unit, or, damages caused by any natural
disasters (such as fire, flood, wind and lightning).
THE PREVIOUS WARRANTY STATEMENT IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING
BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
If field repair or parts replacement is necessary on any warranted components, Custom Equipment, Inc. will
reimburse Authorized Dealers for direct labor costs incurred according to the Company’s current authorized
Field Service Rate (FSR) and/or any established ‘Flat Rate Guides’. Custom Equipment does not pay labor on
any consumable items such as batteries, brakes, or tire wear. In no event shall the Company be liable for any
indirect, incidental, consequential, or special damage (including without limitation to loss of profits, loss of
revenue, cost of capital, cost of substitute equipment, downtime, examination fees, claims of third parties,
and injury to person or property) based upon any claim of breach of warranty, breach of contract,
negligence, strict liability in tort, or any other legal theory. This limited warranty statement recognizes the risks
and limitations of product failure between Custom Equipment, Inc. and the Buyer.
This written warranty is also understood to be the complete and exclusive agreement between the parties,
superseding all prior agreements, oral or written and all other communications between the parties relating to
the subject matter of this warranty. No employee, agent or distributor of the Company, or any other person is
authorized to state or imply any additional warranties on behalf of the Company, nor to assume for the
Company any other liability in connection with any of its products, unless made in writing, dated, and signed
by an officer of the Company.

Part #SUPO-613
REV E
Page 38 of 38