Hy-Brid Lifts HB-830 Programming manual

BY CUSTOM EQUIPMENT LLC
MAINTENANCE & TROUBLESHOOTING MANUAL
SELF-PROPELLED AERIAL WORK PLATFORM
SUPO-658
REV A
HB-830
HB-1230
SERIES II

NOTES
B Y C U S TO M EQUIPMENT LLC
MAINTENANCE & TROUBLESHOOTING
HB-830/HB-1230
SUPO-658
REV A
2
If there is a question about application
and/or operation, contact:
Custom Equipment, LLC
2647 Hwy 175
Richfield, WI 53076
U.S.A.
P: [phone]
F: [phone]
www.hybridlifts.com

FOREWORD
MAINTENANCE & TROUBLESHOOTING
HB-830/HB-1230
SUPO-658
REV A
B Y C U S TO M EQUIPMENT LLC
3

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 DIAGRAMS.............................................................................................................................................34
7.1 | SAFETY AND CONTROL DECALS..........................................................................................................................................34
7.2 | MAIN POWER/SAFETY CIRCUIT .............................................................................................................................................35
7.3 | DRIVE CIRCUIT............................................................................................................................................................................39
7.4 | COVERS.........................................................................................................................................................................................50
7.5 | RAILINGS....................................................................................................................................................................................... 51
SECTION 8 | WARRANTY........................................................................................................................................................ 52
NOTES........................................................................................................................................................................................54
B Y C U S TO M EQUIPMENT LLC
MAINTENANCE & TROUBLESHOOTING
HB-830/HB-1230
SUPO-658
REV A
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INDEX OF FIGURES
FIGURE 1: Maintenance Lock Use ........................................................................................................................................................ 7
FIGURE 2: Maintenance Lock Storage ............................................................................................................................................... 7
FIGURE 3: Battery Charger LED Display.............................................................................................................................................. 9
MAINTENANCE & TROUBLESHOOTING
HB-830/HB-1230
SUPO-658
REV A
B Y C U S TO M EQUIPMENT LLC
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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.
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
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
CAUTION
DANGER
WARNING
SECTION 1 | SAFETY
1.1 | SAFETY SYMBOLS
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
B Y C U S TO M EQUIPMENT LLC
MAINTENANCE & TROUBLESHOOTING
HB-830/HB-1230
SUPO-658
REV A
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SECTION 1 | SAFETY
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.
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 o 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.
C
C
FIGURE 1: Maintenance Lock Use FIGURE 2: Maintenance Lock Storage
MAINTENANCE & TROUBLESHOOTING
HB-830/HB-1230
SUPO-658
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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 aects 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% eciency.
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.
B Y C U S TO M EQUIPMENT LLC
MAINTENANCE & TROUBLESHOOTING
HB-830/HB-1230
SUPO-658
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SECTION 2 | MAINTENANCE
How to read the battery displays
FIGURE 3: Battery Charger LED Display
DO NOT OPERATE UNIT WHILE
CHARGING. DO NOT DISABLE
CHARGER INTERLOCK.
Power
Power
Power
Power
Green LED (ON)
Green LED (ON)
Green LED (ON)
Green LED (ON)
Red LED (OFF)
Red LED (ON)
Red LED (OFF)
Red LED
(FLASHING)
Green LED (OFF)
Green LED (OFF)
Green LED (ON)
Green LED (ON)
Red LED (OFF)
Red LED (ON)
Red LED (OFF)
Red LED
(FLASHING)
Green LED (OFF)
Green LED (OFF)
Green LED (ON)
Green LED (ON)
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.
This display indicates that
power is on and that both
outputs are delivering D/C
current to the batteries.
This display indicates that
power is on and that both
outputs are finished charging
and are in a float maintenance
mode.
A flashing red light indicates
there is a problem with a
battery, such as low voltage or
a bad cell.
Battery 1 Status
Charging Ready
Battery 2 Status
Charging Ready
Battery 1 Status
Charging Ready
Battery 2 Status
Charging Ready
Battery 1 Status
Charging Ready
Battery 2 Status
Charging Ready
Battery 1 Status
Charging Ready
Battery 2 Status
Charging Ready
MAINTENANCE & TROUBLESHOOTING
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2.3 | LUBRICATION
Item Specification Frequency of Lubrication
Wheels Teflon Spray 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 aect 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 2 | MAINTENANCE
B Y C U S TO M EQUIPMENT LLC
MAINTENANCE & TROUBLESHOOTING
HB-830/HB-1230
SUPO-658
REV A
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SECTION 3 | MAINTENANCE CHECKLISTS
Regular inspection and conscientious maintenance is important to ecient 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
HB-830/HB-1230
SUPO-658
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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 Y N R
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 O) □ □ □
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:
SECTION 3 | MAINTENANCE CHECKLISTS
3.1 | PRESTART INSPECTION CHECKLIST
B Y C U S TO M EQUIPMENT LLC
MAINTENANCE & TROUBLESHOOTING
HB-830/HB-1230
SUPO-658
REV A
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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: Y N R Extending platform: Y N R
Inspect slide tracks for damage □ □ □ Extends freely □ □ □
All frame bolts tight □ □ □ Cables in place/secure □ □ □
Pump Secure □ □ □ Locks in Stowed Position □ □ □
DC motors secure □ □ □ Locks in Extended Position □ □ □
Covers screwed on □ □ □ Functions: □ □ □
Batteries Fully Charged □ □ □ All Functions Operational □ □ □
Wheels: □ □ □ Emergency Stop Breaks Circuits □ □ □
Snap Rings Secure □ □ □ Slow Speed limit switch Set properly □ □ □
Bolts/Nuts Tight □ □ □ Wiring: □ □ □
Scissors: □ □ □ Switches secure □ □ □
Broken Welds □ □ □ Contactor(s) secure □ □ □
Bent Beam Members □ □ □ Tight on terminals (No loose wiring) □ □ □
All rollers Turn Freely □ □ □ Pothole guards deploy when platform elevated □ □ □
Ret. Rings Secure On Pivots □ □ □ Pothole interlock functions correctly □ □ □
Emergency Down Operational □ □ □ Oil: Level 1” from top (when platform is
stowed) □ □ □
Maintenance Locks: □ □ □ Brakes: Operational □ □ □
Pins in cabinet □ □ □ Check all hose for leaks □ □ □
Platform: □ □ □ Check all fittings for leaks □ □ □
Bent rails □ □ □ Battery Charger: □ □ □
Broken welds □ □ □ Secure/Operational □ □ □
All rails in place/secure □ □ □ Tilt sensor □ □ □
110V outlet safe/working (if applicable) □ □ □ Warning Horn (if applicable) □ □ □
Entrance gate Closes Freely □ □ □ Hour meter operational □ □ □
Decals: □ □ □ Battery indication operational □ □ □
Legibility □ □ □ All Shields/Guards in place □ □ □
Correct capacity noted □ □ □ Operator/Service Manual □ □ □
Proper placement quantity □ □ □
Date: Inspected By:
SECTION 3 | MAINTENANCE CHECKLISTS
MAINTENANCE & TROUBLESHOOTING
HB-830/HB-1230
SUPO-658
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SECTION 4 | TECHNICAL REFERENCES
4.1 | HYDRAULIC SCHEMATIC
B Y C U S TO M EQUIPMENT LLC
MAINTENANCE & TROUBLESHOOTING
HB-830/HB-1230
SUPO-658
REV A
14

SECTION 4 | TECHNICAL REFERENCES
MAINTENANCE & TROUBLESHOOTING
HB-830/HB-1230
SUPO-658
REV A
B Y C U S TO M EQUIPMENT LLC
15

+
-
+
-
-
+
M
M
M
NO
NC
NC
E-STOP
NC
E-STOP
OFF
OFF
UP/DOWN ROCKER
LOWER CONTROL
NO
ELEV. ENABLE
JOYSTICK
BRAKE SWITCH
(CTL SIDE)
BRAKE SWITCH
(PUMP SIDE)
TS-100
B+
B- M1+ M1- M2+ M2-
P15-7 P15-10 P15-12
P15-9
P15-14P15-13
P15-8
P15-6 P15-5
P15-15
P15-3
P15-11
P15-4
P15-2 P15-1
P9-9
P9-8
P9-6
P9-7 P9-5 P9-3 P9-4
P9-2 P9-1
P12-12 P12-11P12-10 P12-9
P12-8
P12-7
P12-6
P12-5 P12-4
P12-3P12-2 P12-1
NC
DRIVE ENABLE
NO NO
V
NO
NC
ANG. SENS. 1
BRAKE
(PUMP
SIDE)
BRAKE
(CTL
SIDE)
PH LS-L
1
4
2
5 6
3
KEYSWITCH
PH LS-R
(OPTIONAL FLASHING BEACON)
1K
1W
C
B
A
A
B
C
D
1
2
3
4
5
6
7
8
8
7
6
5
4
3
2
1
B-SIZE
ORIGINALLY DRAWN BY:
Custom Equipment, Inc.
Richfield, WI 53076
Phone: [phone]
DATE:
ELEC SCH,HB-1230 S2
SCALE:1:1
WELDING TOLERANCES: .X= .060 .XX= .030 .XXX= .010
MACHINING TOLERANCES: .X=
.030 .XX= .015 .XXX= .005
DO NOT SCALE DRAWING
THIS DRAWING IS CONFIDENTIAL AND PROPRIETARY TO CUSTOM, EQUIPMENT AND IS LOANED IN EXPECTATION THAT IT WILL BE KEPT CONFIDENTIAL AND USED ONLY FOR THE PURPOSE FOR WHICH IT IS LOANED.
SPEC/MATL: Schematic
DRAWING #: WS-129-20-201-50
FORMING TOLERANCES: .X= .06 .XX= .020 .XXX= .010
PART NUMBER
WS-129-20-201-50
REV
DESCRIPTION OF CHANGE
DATE REV BY
D Add Caster Lock LED
10/02/2015
GLH
ECO #
2014-2321
DEBURR ALL EDGES/CORNERS FOR SAFE HANDLING PER UL 1439
SHEET 1 OF 1
WEIGHT: APPROX. 0.00 LB.
D
LASER TOLERANCES: = .005
SECTION 4 | TECHNICAL REFERENCES
4.2 | ELECTRICAL SCHEMATIC
WS-129-20-201-50
B Y C U S TO M EQUIPMENT LLC
MAINTENANCE & TROUBLESHOOTING
HB-830/HB-1230
SUPO-658
REV A
16

+
-
+
-
-
+
M
M
M
NO
NC
NC
E-STOP
NC
E-STOP
OFF
OFF
UP/DOWN ROCKER
LOWER CONTROL
NO
ELEV. ENABLE
JOYSTICK
BRAKE SWITCH
(CTL SIDE)
BRAKE SWITCH
(PUMP SIDE)
TS-100
B+
B- M1+ M1- M2+ M2-
P15-7 P15-10 P15-12
P15-9
P15-14P15-13
P15-8
P15-6 P15-5
P15-15
P15-3
P15-11
P15-4
P15-2 P15-1
P9-9
P9-8
P9-6
P9-7 P9-5 P9-3 P9-4
P9-2 P9-1
P12-12 P12-11P12-10 P12-9
P12-8
P12-7
P12-6
P12-5 P12-4
P12-3P12-2 P12-1
NC
DRIVE ENABLE
NO NO
V
NO
NC
ANG. SENS. 1
BRAKE
(PUMP
SIDE)
BRAKE
(CTL
SIDE)
PH LS-L
1
4
2
5 6
3
KEYSWITCH
PH LS-R
(OPTIONAL FLASHING BEACON)
1K
1W
C
B
A
A
B
C
D
1
2
3
4
5
6
7
8
8
7
6
5
4
3
2
1
B-SIZE
ORIGINALLY DRAWN BY:
Custom Equipment, Inc.
Richfield, WI 53076
Phone: [phone]
DATE:
ELEC SCH,HB-1230 S2
SCALE:1:1
WELDING TOLERANCES: .X= .060 .XX= .030 .XXX= .010
MACHINING TOLERANCES: .X=
.030 .XX= .015 .XXX= .005
DO NOT SCALE DRAWING
THIS DRAWING IS CONFIDENTIAL AND PROPRIETARY TO CUSTOM, EQUIPMENT AND IS LOANED IN EXPECTATION THAT IT WILL BE KEPT CONFIDENTIAL AND USED ONLY FOR THE PURPOSE FOR WHICH IT IS LOANED.
SPEC/MATL: Schematic
DRAWING #: WS-129-20-201-50
FORMING TOLERANCES: .X= .06 .XX= .020 .XXX= .010
PART NUMBER
WS-129-20-201-50
REV
DESCRIPTION OF CHANGE
DATE REV BY
D Add Caster Lock LED
10/02/2015
GLH
ECO #
2014-2321
DEBURR ALL EDGES/CORNERS FOR SAFE HANDLING PER UL 1439
SHEET 1 OF 1
WEIGHT: APPROX. 0.00 LB.
D
LASER TOLERANCES: = .005
SECTION 4 | TECHNICAL REFERENCES
MAINTENANCE & TROUBLESHOOTING
HB-830/HB-1230
SUPO-658
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SECTION 4 | TECHNICAL REFERENCES
4.3 | CONTROL BOARD DIAGNOSTIC
LED Code Possible Cause
Fast Flash Control Module is not calibrated, Do not operate unit.
Steady
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.
1-1 The control module is not calibrated. Do not use this unit.
2-1
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.
2-2
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.
3-x
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
3-2 Check P9 wiring. One or more signals showing outputs when all should be o.
3-3 Check B+ stud connections on controller. Voltage is too high.
3-4 There is voltage on safe pre-valve supply when there should not be.
Controller may need to be replaced.
3-5 The drive brake current is too high.
Motor overload. Check for a siezed motor or for power wiring to motors.
4-x
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
4-2 Functions Locked: Board is overheated. Check pump, drive motor wiring.
Problem with controller internal voltage. Controller may need to be replaced.
When using the LED for diagnosis, note that a DUAL FLASH
code is indicated. The LED will flash on/o a certain number
of times, pause o for a short delay, then flash on/o a
second certain number of times, followed by a much longer
pause o. The sequence will then repeat.
Example: The LED flash code 3-2 will look like: on/o/on/
o/on/o-short-delay/on/o/on/o-long-delay/repeat
B Y C U S TO M EQUIPMENT LLC
MAINTENANCE & TROUBLESHOOTING
HB-830/HB-1230
SUPO-658
REV A
18

SECTION 4 | TECHNICAL REFERENCES
4-3 Problem with controller internal voltage. Controller may need to be replaced.
4-4
Battery supply is too low or too high.
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.
6-x
There is a problem with the height measurements, or the elevation switch disagrees with the
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
HB-830/HB-1230
SUPO-658
REV A
B Y C U S TO M EQUIPMENT LLC
19

TS-100
M2+ M2- B- M1-
M1+
B+
BATTERY
CHARGER
+
-
DOWN
UP
-
+
PUMP
RESERVOIR
HYD PUMP
M
PUMP
GND STUD
BATTERY
BATTERY
UPPER
CONTROL
129-21-249-50
654321
L0WER CONTROL
129-21-206-50
MICROSWITCH
BRAKE
M
DRIVE
BRAKE
MICROSWITCH
DRIVE
M
NO NC
ANGLE
SENSOR #1
POWER
SWITCH
NO NC
ELEC-641C
ELEC-641A
ELEC-641E
129-01-090-51
(129-01-090-51)
129-01-090-50
ELEC-641A
BLUE
RED
TAN
TAN
WHITE
BLACK
TB #2
P12-8
P9-9
C
B
A
A
B
C
D
1
2
3
4
5
6
7
8
8
7
6
5
4
3
2
1
B-SIZE
ORIGINALLY DRAWN BY:
Custom Equipment, Inc.
Richfield, WI 53076
Phone: [phone]
DATE:
WD,HB-1230 S2
SCALE:1:1
DO NOT SCALE DRAWING
THIS DRAWING IS CONFIDENTIAL AND PROPRIETARY TO CUSTOM, EQUIPMENT AND IS LOANED IN EXPECTATION THAT IT WILL BE KEPT CONFIDENTIAL AND USED ONLY FOR THE PURPOSE FOR WHICH IT IS LOANED.
SPEC/MATL: Schematic
DRAWING #: WD-129-20-201-50
REV
DESCRIPTION OF CHANGE
DATE REV BY
B REVISED UPR CTL WD #
04/09/2015
GLH
ECO #
2014-2321
SHEET 1 OF 7
WEIGHT: APPROX. 0.00 LB.
B
SECTION 5 | WIRING DIAGRAMS
5.1 | WIRING DIAGRAM
Part No. WD-129-20-201-50
B Y C U S TO M EQUIPMENT LLC
MAINTENANCE & TROUBLESHOOTING
HB-830/HB-1230
SUPO-658
REV A
20