Hy-Brid Lifts ZERO-TURN Series Programming manual

BY CUSTOM EQUIPMENT LLC
MAINTENANCE &
TROUBLESHOOTING
MANUAL
ZT-1230
ZT-1630
SERIAL NO.
MOBILE
ELEVATING
WORK
PLATFORMS
ANSI A92.20
CSA B354.6:17
ZERO-
TURN
SERIES
ZT5.0-M | REV A
ZERO-TURN
SERIES
INFORMATION
DE1317
To view machine specific information on your
mobile device, scan the code to the left.
Decals with this code can also be found on the
manual box and base of the machine.

ZERO-TURN SERIES ZT-1230 ZT-1630
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MAINTENANCE & TROUBLESHOOTING MANUAL ZT5.0-M REV A
FORWARD
This manual refers to Serial Number(s):
ZT-1230 ZT12-50001 -
ZT-1630 ZT16-50001 -
For older Serial Numbers refer to our website,
www.hybridlifts.com/Manuals.htm
General Information
2647 Hwy 175
Richfield, WI 53076
U.S.A.
[phone]
[phone]
www.hybridlifts.com
Service Information
[phone]
[email protected]
Parts Information
[phone]
THE OPERATION AND SAFETY MANUAL MUST BE
READ AND UNDERSTOOD PRIOR TO OPERATING THE
MACHINE.
ANY MODIFICATION ON THIS MACHINE WITHOUT
THE EXPRESS WRITTEN CONSENT OF THE
MANUFACTURER IS PROHIBITED.
Original instructions are 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.
• 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.
Register your Hy-Brid Lift at:
www.hybridlifts.com/RegisterOnline.htm
Register your Hy-Brid Lift to:
• Recieve product updates and recalls
• Recieve service bulletins, product and part
recalls, and other important notifications
• Comply with ANSI A92.20 Standards
• Provide better records for service
REGISTERING YOUR MEWP WITH THE
MANUFACTURER IS AN ANSI A92.20
REQUIREMENT.

ZERO-TURN SERIES ZT-1230 ZT-1630
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MAINTENANCE & TROUBLESHOOTING MANUAL ZT5.0-M REV A
TABLE OF CONTENTS INDEX OF FIGURES
FORWARD ....................................................................................................................................................................................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 ............................................................................................................................12
3.1 | PRESTART INSPECTION CHECKLIST................................................................................................................................... 12
3.2 | PREDELIVERY/ANNUAL/FREQUENT INSPECTION CHECKLIST.................................................................................. 14
SECTION 4 TECHNICAL REFERENCES..................................................................................................................................16
4.1 | HYDRAULIC SCHEMATIC ......................................................................................................................................................... 16
4.2 | WIRING SCHEMATIC................................................................................................................................................................. 18
4.3 | CONTROL BOARD DIAGNOSTIC..........................................................................................................................................20
SECTION 5 WIRING DIAGRAMS............................................................................................................................................ 22
5.1 | WIRING DIAGRAM ......................................................................................................................................................................22
5.2 | LOWER CONTROL WIRING DIAGRAM.................................................................................................................................24
5.3 | UPPER CONTROL WIRING DIAGRAM..................................................................................................................................26
SECTION 6 TROUBLESHOOTING FLOWCHARTS.............................................................................................................. 28
6.1 | MAIN POWER/SAFETY CIRCUIT.............................................................................................................................................28
6.2 | DRIVE CIRCUIT...........................................................................................................................................................................30
6.3 | ELEVATE CIRCUIT ......................................................................................................................................................................32
6.4 | LOWER CIRCUIT.........................................................................................................................................................................34
SECTION 7 PARTS.................................................................................................................................................................... 36
SECTION 8 WARRANTY.......................................................................................................................................................... 38
8.1 | LIMITED WARRANTY..................................................................................................................................................................38
8.2 | LIMITED WARRANTIES..............................................................................................................................................................38
8.3 | EXCLUSIONS/WHAT IS NOT COVERED ..............................................................................................................................38
8.4 | MAKING A WARRANTY CLAIM................................................................................................................................................38
8.5 | EXCLUSIVE WARRANTY REMEDIES.......................................................................................................................................39
8.6 | DISCLAIMER OF OTHER EXPRESS AND IMPLIED WARRANTIES...................................................................................39
8.7 | LIMITATION OF LIABILITY ........................................................................................................................................................39
SECTION 9 INSPECTION & REPAIR LOG............................................................................................................................. 40
REVISION LOG:
REV A......................................................................................................................................................................................October 2020
INDEX OF FIGURES
FIGURE 1: Maintenance Lock Use .........................................................................................................................................................7
FIGURE 2: Maintenance Lock Storage.................................................................................................................................................. 7
FIGURE 3: Charger Cord Location ........................................................................................................................................................8
FIGURE 4: Battery Charger LED Display...............................................................................................................................................9
FIGURE 5: LED Light Diagnostic Location........................................................................................................................................ 20
FIGURE 6: EZ Cal Handheld Controller............................................................................................................................................. 20

ZERO-TURN SERIES ZT-1230 ZT-1630
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MAINTENANCE & TROUBLESHOOTING MANUAL ZT5.0-M REV A
SECTION 1 SAFETY SECTION 1 SAFETY
1.1 | SAFETY SYMBOLS
MAINTENANCE INFORMATION IS FOR USE BY
TRAINED PERSONNEL ONLY.
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.
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, & CSA 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, OSHA, & CSA. If
you come across a situation that you think might be unsafe, stop the platform and request further information
from qualified sources before proceeding.
NEVER REACH BETWEEN SCISSORS LINKS OR PROP
UP PLATFORM UNLESS MAINTENANCE PINS ARE IN
PLACE.
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 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.

ZERO-TURN SERIES ZT-1230 ZT-1630
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MAINTENANCE & TROUBLESHOOTING MANUAL ZT5.0-M REV A
SECTION 2 MAINTENANCE SECTION 2 MAINTENANCE
NEVER ADD ACID TO BATTERY!
BATTERIES GENERATE EXPLOSIVE GASES. KEEP
SPARKS AND FLAME AWAY FROM BATTERIES. DO NOT
SMOKE WHILE CHARGING.
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.
2.2 | CHARGING THE BATTERY
The charger may include an interlock circuit. If so
equipped, the unit will not operate while charging.
Operating while charging will shorten battery life.
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.
FIGURE 3: Charger Cord Location
FIGURE 4: Battery Charger LED Display
DO NOT OPERATE UNIT WHILE CHARGING.H
Battery Charge Displays: Standard Charger
Charge
Status
Light (OFF) (FLASHING) (SOLID) (SOLID) (FLASHING)
Power
Light (SOLID) (SOLID) (SOLID) (SOLID) (FLASHING)
Meaning Standby Mode
(Or battery
connection error)
Normal Charging
Bulk Charging
Normal Charging
Absorption Stage
Charge Complete
Flat/Maintenance
Mode
Charger Error

ZERO-TURN SERIES ZT-1230 ZT-1630
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MAINTENANCE & TROUBLESHOOTING MANUAL ZT5.0-M REV A
SECTION 2 MAINTENANCE
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.
THIS PAGE WAS INTENTIONALLY LEFT BLANK

ZERO-TURN SERIES ZT-1230 ZT-1630
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MAINTENANCE & TROUBLESHOOTING MANUAL ZT5.0-M REV A
SECTION 3 MAINTENANCE CHECKLISTS SECTION 3 MAINTENANCE CHECKLISTS
FAILURE TO PERFORM INSPECTIONS AND
PREVENTATIVE MAINTENANCE AT RECOMMENDED
INTERVALS MAY RESULT IN THE UNIT BEING
OPERATED WITH A DEFECT THAT MAY RESULT IN
INJURY OR DEATH OF THE OPERATOR.
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).
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.
Pre-Start Inspection (Zero-Turn Series)
Model:
Serial No.
• 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 N/A-Not Equipped Y N R N/A
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 any set
screw(s) 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,)
Enable Trigger (Must be activated for joystick-operated movement)
Elevates & lowers
If so equipped, horn sounds when button is pressed.
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)
Descent Alarm (Not damaged, sounds for descent; may also sound for drive &
elevate, if so equipped)
Tilt Alarm (Not damaged, sounds when tilted and machine elevated above
designated height)
Master Power Switch disconnects battery
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:
3.1 | PRESTART INSPECTION CHECKLIST

ZERO-TURN SERIES ZT-1230 ZT-1630
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MAINTENANCE & TROUBLESHOOTING MANUAL ZT5.0-M REV A
SECTION 3 MAINTENANCE CHECKLISTS SECTION 3 MAINTENANCE CHECKLISTS
Model:
Serial No.
• Check each item listed below.
• Use proper operating, service, and
maintenance manual for specifi c 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.
• 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.
3.2 | PREDELIVERY/ANNUAL/FREQUENT INSPECTION CHECKLIST
FEATUREWORK 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,
AND ANNUALLY.
Y-Yes/Acceptable N-No/Unacceptable R-Repaired N/A-Not Equipped Y N R N/A
BASE:
Inspect slide tracks for damage
All frame bolts tight
Pump secure
DC motors secure
Batteries fully charged
WHEELS:
Snap rings secure
Bolts/nuts tight
All shields/guards in place
SCISSORS:
No broken welds
No bent beam members
All rollers turn freely
Ret. rings secure on pivots
Maintenance locks: Stored in designated location
PLATFORM:
No bent rails
No broken welds
All rails in place/secure
110V outlet safe/working
Entrance gate closes freely
Y-Yes/Acceptable N-No/Unacceptable R-Repaired N/A-Not Equipped Y N R N/A
DECALS:
Legibile
Correct capacity noted
Proper placement & quantity.
RAILS/EXTENDING PLATFORM:
Extends freely
Cables in place/secure
Locks in stowed position
Locks in extended position
FUNCTIONS:
All functions (Drive,Elevate,Steer) operational (see Pre-Start Inspection for details)
Pothole guards deploy when platform elevated
Emergency stop breaks circuits
Slow speed limit switch set properly
Pothole interlock functions correctly
BRKAES:
Operational
EMERGENCY DOWN:
Operational
WIRING:
Switches secure
Contactor(s) secure
Tight on terminals (No loose wiring)
OIL:
Level 1” from top (when platform stowed)
OTHER:
Check all hose for leaks
Check all fittings for leaks
Battery charger secure/operational
Tilt sensor
Warning horn
Hour meter operational
Battery indication operational
Operator’s Manual is on the unit
Overload light & alarm sounds when overloaded
DATE: INSPECTED BY:

ZERO-TURN SERIES ZT-1230 ZT-1630
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MAINTENANCE & TROUBLESHOOTING MANUAL ZT5.0-M REV A
SECTION 4 TECHNICAL REFERENCES SECTION 4 TECHNICAL REFERENCES
4.1 | HYDRAULIC SCHEMATIC
Part No. HS-129-20-501-50
M
2 GPM
AIR
DESCRIPTION
SCALE WEIGHT (LBS.)
SHEET
THIRD ANGLE PROJECTION
DRAWN
NAME DATE
P: 1-262-644-1300
F: 1-262-247-0073
HS, ZT, S5
HS-129-20-501
1:1 N/A 1 OF 1
T.VUE 06/05/2020
SIZE
B
DWG NO.
A
REV
DO NOT SCALE DRAWING
06/11/2020 T.VUE APPROVED
DATE REV BY DESCRIPTION OF CHANGE
REVISION HISTORY
ECO #
THE INFORMATION CONTAINED IN THIS DRAWING IS
THE SOLE PROPERTY OF CUSTOM EQUIPMENT AND
IS LOANED IN EXPECTATION THAT IT WILL BE KEPT
CONFIDENTIAL. ANY REPRODUCTION IN PART OR
AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF
CUSTOM EQUIPMENT IS PROHIBITED.
04/16/2020 T.VUE
REV
A
CONFIGURATIONS
-50: GENERAL ASSEMBLY

ZERO-TURN SERIES ZT-1230 ZT-1630
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MAINTENANCE & TROUBLESHOOTING MANUAL ZT5.0-M REV A
SECTION 4 TECHNICAL REFERENCES SECTION 4 TECHNICAL REFERENCES
4.2 | WIRING SCHEMATIC
Part No. WS-129-20-501-50
-
+
M
M
M
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
P12-4 P12-5
P12-3P12-2 P12-1
V
1
2
43
+
-
1K
1W
NO
-
+
NO
NO
NC
PH LS-R
K-3 K-2 K-6 K-5
K-13 K-14
K-8
K-12 K-15
K-1
NO NO
K-11
K-9
K-4
K-10
K-7
H-9H-3
H-2
H-12
H-7
H-10
H-1
H-8 H-6
H-11
OFF
OFF
H-4 H-5
J-3
J-7
J-8
J-9 J-6 J-2 J-5
J-4J-1
NC
E-STOP UPR
G-4 M-9
NC NO
M-14
G-5
N-1
N-6
N-4
N-3
M-5
M-8
M-6
M-1
M-13
M-7
M-2
M-11
G-2
A-1
C-1
B-1 D-1
B-3 C-3
A-3
D-3
D-2
C-2
A-2
T-3 T-4
T-1
T-2
T-5
T-6
BUTT-6
2
1
2
1
BUTT-4
H-6
(OPTIONAL FLASHING BEACON)
BUTT-1
1 2
20A
NO
NC
PH LS-L
N-2
NC
E-STOP LWR
I-5
I-2 I-1 I-4
G-6
B-2
M-3
N-5
E-2
E-1
F-2
F-1
Q-2
R-2
S-2
Q-1
R-1
S-1
Q-3
R-3
S-3
I-6
I-7
I-3
+
-
+
-
SIG
-
+
AS1
SIG
-
+
PS1
PS2
+
-
SIG
AS2
+
-
SIG
CHR INT'LK
IF EQUIPPED
DESCRIPTION
SCALE WEIGHT (LBS.)
SHEET
THIRD ANGLE PROJECTION
DRAWN
NAME DATE
P: 1-262-644-1300
F: 1-262-247-0073
WIRNG SCH, ZT, S5
WS-129-20-501
1:1 N/A 1 OF 1
Admin 05/08/2020
SIZE
B
DWG NO.
A
REV
DO NOT SCALE DRAWING
08/05/2020 T.VUE APPROVED
DATE REV BY DESCRIPTION OF CHANGE
REVISION HISTORY
ECO #
2019-3300
THE INFORMATION CONTAINED IN THIS DRAWING IS
THE SOLE PROPERTY OF CUSTOM EQUIPMENT AND
IS LOANED IN EXPECTATION THAT IT WILL BE KEPT
CONFIDENTIAL. ANY REPRODUCTION IN PART OR
AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF
CUSTOM EQUIPMENT IS PROHIBITED.
INITIAL RELEASE
05/20/2020 T.VUE
REV
A
CONFIGURATIONS
-50: GENERAL ASSEMBLY

ZERO-TURN SERIES ZT-1230 ZT-1630
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MAINTENANCE & TROUBLESHOOTING MANUAL ZT5.0-M REV A
SECTION 4 TECHNICAL REFERENCES 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/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.
FIGURE 5: LED Light Diagnostic Location
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
LED Code Possible Cause
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.
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.
FIGURE 6: EZ Cal Handheld Controller
If a handheld controller (Part no: ELEC-646-5)
is available, it will display error codes and their
description
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

ZERO-TURN SERIES ZT-1230 ZT-1630
22 23
MAINTENANCE & TROUBLESHOOTING MANUAL ZT5.0-M REV A
SECTION 5 WIRING DIAGRAMS SECTION 5 WIRING DIAGRAMS
5.1 | WIRING DIAGRAM
Part No. WD-129-20-501-50
232
CAN P9
P12
P15
B+
M2+ M2- B- M1- M1+
TS100
NC NC
L. STEER
LIMIT
SWITCH
R. STEER
LIMIT
SWITCH
NC
NC
1
2
3
4
-
+
KTI PUMP
RESERVOIR
UP VALVE
BATTERY
BATTERY
+
-
M
BRAKE
M
-
+
BRAKE
PRES. SENS. #1
4
2
3
1
SOLENOID 1
1
2
3
651 2 43
LOWER
E-STOP
NC
12
MASTER
DISCONNECT
SWITCH
LOWER CONTROL
WD-129-21-507
BUTT
20 AMP FUSE
129-21-206-98
LOWER
CONTROL
HARNESS
129-21-305
129-21-306
ANGLE
SENSOR #1
ANGLE
SENSOR #2
LOWER
CONTROL
HARNESS
PRESSURE
SENSOR #2
(SPARE)
129-21-311-50
UPPER CONTROL
WD-129-21-504
129-21-004-94
129-21-016
LOWER
CONTROL
HARNESS
BUTT
BATTERY
CHARGER
6 AWG
6 AWG
6 AWG
6 AWG
10 AWG
10 AWG
10 AWG
10 AWG
6 AWG
HIRSCHMANN
CONNECTION
(DOWN VALVE)
DESCRIPTION
SCALE WEIGHT (LBS.)
SHEET
THIRD ANGLE PROJECTION
DRAWN
NAME DATE
P: 1-262-644-1300
F: 1-262-247-0073
WD, ZT, S5
WD-129-20-501
1:1 N/A 1 OF 1
T.VUE 05/29/2020
SIZE
B
DWG NO.
A
REV
DO NOT SCALE DRAWING
06/11/2020 APPROVED
DATE REV BY DESCRIPTION OF CHANGE
REVISION HISTORY
ECO #
THE INFORMATION CONTAINED IN THIS DRAWING IS
THE SOLE PROPERTY OF CUSTOM EQUIPMENT AND
IS LOANED IN EXPECTATION THAT IT WILL BE KEPT
CONFIDENTIAL. ANY REPRODUCTION IN PART OR
AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF
CUSTOM EQUIPMENT IS PROHIBITED.
06/11/2020
REV
A
CONFIGURATIONS
-50: GENERAL ASSEMBLY

ZERO-TURN SERIES ZT-1230 ZT-1630
24 25
MAINTENANCE & TROUBLESHOOTING MANUAL ZT5.0-M REV A
SECTION 5 WIRING DIAGRAMS
5.2 | LOWER CONTROL WIRING DIAGRAM
Part No. WD-129-21-507-50
651 2 43
1210 119865 73 421
TS100 P12
(D)
R. STEER
LIMIT
SWITCH
L. STEER
LIMIT
SWITCH
1K-OHM
-
+
2
1
LOWER
E-STOP
NC
ROCKER
SWITCH
VOLTAGE
METER
1
3
2
4
KEY SWITCH
NO
UPPER
4 3
3 4
KEY SWITCH
NO
LOWER
HOUR
METER
1 2
3 4
20 AMP FUSE
BUTT
1 2 43 5 6
MAIN CABLE
(E)
1
2
(L)
1 2 43 75 6 8
TS100 P9
(C)
2 31
SPARE
PRESSURE
SENSOR #2
(J)
BUTT
2
1
(K)
BUTT
1 32
ANGLE
SENSOR #1
(F)
TS100 / B-
129-21-305
129-21-306
PRESSURE
SENSOR #1
(G)
2 31
CHARGER INTERLOCK
(NOT USED)
MAIN CONTACT
SOLENOID
MASTER
DISCONNECT
SWITCH
-
+
LED
BUTT
ANGLE
SENSOR #2
(H)
2 31
12345678
23
9
8
7
456
1
10 11 12
23
6
5
4
123 12 1
TS100 / M1+
SOLENOID
SOLENOID
UP VALVE SIGNAL
DOWN VALVE SIGNAL
(JUMPER TO HIRSCHMANN CONNECTOR)
PUMP SOLENOID
UP VALVE COIL
DOWN VALVE COIL
(JUMPER TO HIRSCHMANN CONNECTOR)
TS100 / M1-
TS100 / M2-
TS100 / M2+
R. MOTOR (DRIVE)
R. MOTOR (DRIVE)
L. MOTOR (DRIVE)
L. MOTOR (DRIVE)
NEGATIVE @ PUMP SOLENOID
DESCRIPTION
SCALE WEIGHT (LBS.)
SHEET
THIRD ANGLE PROJECTION
DRAWN
NAME DATE
P: 1-262-644-1300
F: 1-262-247-0073
WD, ZT LWR CTRL, S5
WD-129-21-507
1:1 N/A 1 OF 1
T.VUE 05/27/2020
SIZE
B
DWG NO.
A
REV
DO NOT SCALE DRAWING
06/05/2020 T.VUE APPROVED
DATE REV BY DESCRIPTION OF CHANGE
REVISION HISTORY
ECO #
THE INFORMATION CONTAINED IN THIS DRAWING IS
THE SOLE PROPERTY OF CUSTOM EQUIPMENT AND
IS LOANED IN EXPECTATION THAT IT WILL BE KEPT
CONFIDENTIAL. ANY REPRODUCTION IN PART OR
AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF
CUSTOM EQUIPMENT IS PROHIBITED.
05/28/2020 T.VUE
REV
A
CONFIGURATIONS
-50: GENERAL ASSEMBLY
C D E F, G, H, J K, L
SECTION 5 WIRING DIAGRAMS

ZERO-TURN SERIES ZT-1230 ZT-1630
26 27
MAINTENANCE & TROUBLESHOOTING MANUAL ZT5.0-M REV A
SECTION 5 WIRING DIAGRAMS
5.3 | UPPER CONTROL WIRING DIAGRAM
Part No. WD-129-21-504-50
+
-
USB TYPE A
POWER PORT
+
-
LED
JOY STICK
653 421 9 1087 (A)
6 7 8 9 10 1211 13 141 2 43 5 (B)
12
22 23
11
E-STOP
12
13 14
11
PUSHBUTTON
SWITCH
11
1413
12
SELECTOR
SWITCH KNOB
+
-
AUDIBLE
DEVICE
BUTT BUTT
4
9
1 2 63
86 107
123
4567
8 9 10 11
12 13 14
DESCRIPTION
SCALE WEIGHT (LBS.)
SHEET
THIRD ANGLE PROJECTION
DRAWN
NAME DATE
P: 1-262-644-1300
F: 1-262-247-0073
WD, ZT UPR CTRL, S5
WD-129-21-504
1:1 N/A 1 OF 1
T.VUE 05/20/2020
SIZE
B
DWG NO.
A
REV
DO NOT SCALE DRAWING
06/05/2020 T.VUE APPROVED
DATE REV BY DESCRIPTION OF CHANGE
REVISION HISTORY
ECO #
THE INFORMATION CONTAINED IN THIS DRAWING IS
THE SOLE PROPERTY OF CUSTOM EQUIPMENT AND
IS LOANED IN EXPECTATION THAT IT WILL BE KEPT
CONFIDENTIAL. ANY REPRODUCTION IN PART OR
AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF
CUSTOM EQUIPMENT IS PROHIBITED.
06/01/2020 T.VUE
REV
A
CONFIGURATIONS
-50: GENERAL ASSEMBLY
A B
SECTION 5 WIRING DIAGRAMS

ZERO-TURN SERIES ZT-1230 ZT-1630
28 29
MAINTENANCE & TROUBLESHOOTING MANUAL ZT5.0-M REV A
SECTION 6 TROUBLESHOOTING FLOWCHARTS SECTION 6 TROUBLESHOOTING FLOWCHARTS
6.1 | MAIN POWER/SAFETY CIRCUIT

ZERO-TURN SERIES ZT-1230 ZT-1630
30 31
MAINTENANCE & TROUBLESHOOTING MANUAL ZT5.0-M REV A
SECTION 6 TROUBLESHOOTING FLOWCHARTS SECTION 6 TROUBLESHOOTING FLOWCHARTS
6.2 | DRIVE CIRCUIT
Are the brakes
released?
Cycle power to
reengage brakes.
Contact Hy-Brid Lifts for further
troubleshooting.
Consider brake damage, broken joystick
handle (drive enable), bad hour meter, loose
connectiions in lower and upper control, and
control board failure.
Contact Hy-Brid Lifts for further troubleshooting.
Consider board failure, pothole interlock limit switch
failure

ZERO-TURN SERIES ZT-1230 ZT-1630
32 33
MAINTENANCE & TROUBLESHOOTING MANUAL ZT5.0-M REV A
SECTION 6 TROUBLESHOOTING FLOWCHARTS SECTION 6 TROUBLESHOOTING FLOWCHARTS
6.3 | ELEVATE CIRCUIT

ZERO-TURN SERIES ZT-1230 ZT-1630
34 35
MAINTENANCE & TROUBLESHOOTING MANUAL ZT5.0-M REV A
SECTION 6 TROUBLESHOOTING FLOWCHARTS SECTION 6 TROUBLESHOOTING FLOWCHARTS
6.4 | LOWER CIRCUIT

ZERO-TURN SERIES ZT-1230 ZT-1630
36 37
MAINTENANCE & TROUBLESHOOTING MANUAL ZT5.0-M REV A
SECTION 7 PARTS
USE ONLY MANUFACTURER APPROVED
REPLACEMENT PARTS. USE OF NONOEM PARTS
WILL VOID WARRANTY.
SECTION 7 PARTS
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42250K, 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 no. ZT5.0-P) 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.
Description Part Number Notes
ALARM, CONTINUOUS ELEC-635-4
BOARD,DRIVE/LIFT CTL ZERO-TURN S4 129-21-533-50-K
BUTTON,PUSH/PULL RED E-STOP ELEC-071-KIT
BUTTON,PUSH/TWIST RED E-STOP ELEC-065 USED ON SOME UPPER CONTROLS
CHARGER,24V ELEC-795
CORD,NEMA 5-15P/5-15R,12.0 ELEC-639
CTL,ASM LWR 129-21-407-51
CTL,ASM UPR 129-21-404-55
CTL,WIRE HARNESS MAIN ZT-1230/
ZT-1630
129-21-311-50/
129-21-532-50
DECALS,ZT S5 ANSI 129-21-517-50/
129-21-517-55
DRIVE MOTOR,24VELE,HB AUB ELEC-790
HYDRAULIC OIL HYDR-032
Not available as a replacement part.
Replace with Flomite #150, Dexron II,
Mobil-DTE 2 or equivalent.
KEY,SPARE ELEC-073EKEY
MANUAL BOX HARD-603
METER,HOUR ELEC-610-2
METER,VOLT,24V ELEC-610-4
SWITCH KNOB,MASTER DISCONNECT ELEC-633-5
SWITCH,KEY,3-POS MAINTAINED ELEC-073D-KIT
SWITCH,LIMIT,ROT LVR,NO/NC PO ELEC-123-5
SWITCH,MASTER DISCONNECT ELEC-633-4
SWITCH,ROCKER DPDT ELEC-133B
SWITCH,ROTARY MAINTAINED ELEC-002C-KIT
SWITCH,ROTARY MAINTAINED ELEC-068 USED ON SOME UPPER CONTROLS
WHL,12X4 NM RUBBER W/HUB WHEE-625-KIT
WHL,8X2,GREY NM RUBBER WHEE-706-KIT
ASM,SCISSOR CYL HB12-ANSI 129-21-002-90-K
MANUAL,PARTS ZERO-TURN SERIES 5 ZT5.0-P

ZERO-TURN SERIES ZT-1230 ZT-1630
38 39
MAINTENANCE & TROUBLESHOOTING MANUAL ZT5.0-M REV A
SECTION 8 WARRANTY SECTION 8 WARRANTY
8.1 | LIMITED WARRANTY
Warranty Statement - Two Year Agreement
8.2 | 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:
Limited Product Warranty
For a period of 24 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 specifi cations 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
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.
8.3 | 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 modifi ed 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.
8.4 | 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 specifi cally identify the suspected
defect, the original delivery date and complete Buyer identifi cation 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 8.3 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.
8.5 | EXCLUSIVE WARRANTY REMEDIES
Exclusive Repair or Replace Remedy
The Company’s sole obligation and Buyer’s exclusive remedy with respect to any defect in the Product
occurring during the warranty periods set forth in Section 8.1 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 8.5
of this Limited Warranty, necessary to remedy such defect.
Labor Charges
If fi eld 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 specifi ed 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.
8.6 | 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 third-
party 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 modifi cation is
made in writing and signed by an ocer of the company.
8.7 | LIMITATION OF LIABILITY
Notwithstanding anything in this warranty to the contrary, in no event shall the company or any of its a
liates 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 1.15.16