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
2 3
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
16 17
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
18 19
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