HY-BRID LIFTS HB-1230 Series III Self Propelled Aerial Work Platform Instruction Manual

HY-BRID LIFTS HB-1230 Series III Self Propelled Aerial Work Platform

Instruction Manual

HB-1230
SERIES III

If there is a question about application and/or operation, contact:
Custom Equipment, LLC
2647 Hwy 175
Richfield, WI 53076
U.S.A.
P: +1-262-644-1300
F: +1-262-644-1320
www.hybridlifts.com

FOREWORD

Original instructions written in English

The purpose of this Maintenance Manual is to provide qualified service personnel with information for servicing and maintaining Hy-Brid Lifts. All information in this manual must be read and understood before any attempt is made to service this machine.

The operation and safety manual is considered a part of the work platform and contains instructions and operating procedures essential to properly and safely operate the Custom Equipment Hy-Brid Lift. Users must read and understand all information in the Safety and Operations Manual before operation.

DANGER

THE OPERATION AND SAFETY MANUAL MUST BE READ AND UNDERSTOOD PRIOR TO OPERATING THE MACHINE.

• The user/operator should not accept operating responsibility until the manual has been read and understood as well as having operated the lift under supervision of an experienced and qualified operator.
• Because the manufacturer has no direct control over machine application and operation, proper safety practices are the responsibility of the user and all operating personnel.

WARNING

ANY MODIFICATION ON THIS MACHINE WITHOUT THE EXPRESS WRITTEN CONSENT OF THE MANUFACTURER IS PROHIBITED.

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

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 off all power controls.
• Battery should always be disconnected during replacement of electrical components.
• Keep all support equipment and attachments stowed in their proper place.
• Use only approved nonflammable cleaning solvents.
• After maintenance, inspect the machine as described for Pre-delivery.

SECTION 2 | MAINTENANCE

2.1 | BATTERY MAINTENANCE
This unit is equipped with 12-volt AGM maintenance-free batteries.
NOTE: The surrounding temperature greatly affects the power reserve within a battery.
EXAMPLE: A battery that is 100% charged at 80° F (27°C) drops to 65% at 32°F (0°C). At 0°F (-18°C), this battery will drop to 40% efficiency.

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.

How to read the battery displays

2.3 | LUBRICATION

2.4 | COMPONENTS REQUIRING ADJUSTMENT
Under normal use, no components should require adjustment. Contact the manufacturer if adjustments are required.

2.5 | EXAMINATION, REPAIR, REPLACEMENT OF LIMITED LIFE COMPONENTS
With proper use, regular battery charging, and regular inspection, there are no limited life components that require routine replacement.

2.6 | SAFETY DEVICES AND SYSTEMS REQUIRING CHECKS
Check safety functions as part of daily inspection. Check that the brakes are holding.

2.7 | STORAGE
After periods of storage, exposure to extremes of ambient conditions-heat, cold, moisture, dust etc. inspect the machine. Batteries will need to be charged. Refer to the Pre-Delivery/ Frequent Inspection Checklist in the Maintenance Manual.

2.8 | MAJOR ALTERATIONS OR REPAIRS
Any alterations must be approved by the manufacturer. Major repairs, which affect the stability, strength, or performance of the machine must also be approved by the manufacturer, recorded, and include machine inspection and testing. Never attach pipe racks, material lifting devices, or make any other alteration that is not part of the intended design of the machine.

SECTION 3 | MAINTENANCE CHECKLISTS

Regular inspection and conscientious maintenance is important to efficient economical operation of this machine. It will help to assure that equipment will perform satisfactorily with a minimum of service and repair. Make checks at the stated intervals or more frequently if required by local operating conditions. The following inspection checklists are included in this manual:

• Pre-Start (required before operation at each work shift)
• Pre-Delivery/Frequent/Annual (Required every 3 months, after periods of storage, and after any alterations or repairs)
  The rated life of the machine is Light Intermittent Duty (typical use 10 years, 40 weeks per year, 20 hours per week, 5 load cycles per hour).

3.1 | PRE-START INSPECTION CHECKLIST

THIS CHECKLIST MUST BE USED AT THE BEGINNING OF EACH SHIFT OR AFTER EVER SIX TO EIGHT HOURS OF USE. FAILURE TO DO SO COULD AFFECT THE SAFETY OF THE OPERATOR.

MODEL NUMBER: SERIAL NUMBER:
Keep inspection records up-to-date.
Record and report all discrepancies to your supervisor.
A dirty machine cannot be properly inspected.
Y — Yes/Acceptable N — No/Unacceptable R — Repaired

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.

SECTION 4 | TECHNICAL REFERENCES

4.1 | HYDRAULIC SCHEMATIC

4.2 | ELECTRICAL SCHEMATIC

4.3 | CONTROL BOARD DIAGNOSTIC

When using the LED for diagnosis, note that a DUAL FLASH code is indicated. The LED will flash on/off a certain number of times, pause off for a short delay, then flash on/off a second certain number of times, followed by a much longer pause off. The sequence will then repeat.

Example: The LED flash code 3-2 will look like: on/off/on/off/on/off-short- delay/on/off/on/off-long-delay/repeat

5.1 | WIRING DIAGRAM

Part No. WD-129-20-301-50

5.2 | LOWER CONTROLS WIRING DIAGRAM

5.3 | UPPER CONTROLS WIRING DIAGRAM
Part No. 129-21-249-50

SECTION 6 | TROUBLESHOOTING FLOWCHARTS

6.1 | MAIN POWER/SAFETY CIRCUIT

6.2 | DRIVE CIRCUIT

6.3 | ELEVATE CIRCUIT

6.4 | LOWER CIRCUIT

SECTION 7 | PARTS

USE ONLY MANUFACTURER APPROVED REPLACEMENT PARTS. USE OF NON-OEM PARTS WILL VOID WARRANTY.

REPLACEMENT OF THE FOLLOWING COMPONENTS WILL AFFECT THE STRENGTH, STABILITY, OR SAFETY FUNCTION OF THE UNIT: BATTERY (ELEC-047-5), HYDRAULIC CYLINDER (129-21-002-90-K), CONTROL BOARD (129-21-227-50), AND ALL STRUCTURAL COMPONENTS.

Refer to the Hy-Brid Lifts Operation and Safety Manual for decal part numbers and locations.
In addition to the decals listed in the Operation and Safety Manual, a partial list of replacement parts . These represent current model revisions. A full parts manual, part# SUPO-684 is available from Hy-Brid Lifts.

Refer to our website, www.hybridlifts.com for more complete part listings and earlier revisions. Several parts are model-, serial number-, or manufacture date-specific. Contact your dealer for replacement part availability and pricing.

SECTION 8 | WARRANTY

LIMITED WARRANTY
WARRANTY STATEMENT—NORTH AMERICA ONLY

1. LIMITED WARRANTIES
   Subject to the terms, conditions and limitations set forth herein, Custom Equipment, LLC (the “Company”) warrants to the first end-user (“Buyer”) that:
   a. Limited Product Warranty
   For a period of 12 months from the date that a new product manufactured by the Company (“Product”) is delivered to the Buyer, the Product will (i) conform to the specifications published by the Company for such Product as of the date of delivery; and (ii) be free of any defect in material and/or workmanship under normal use and maintenance; and
   b. Extended Structural and Chassis Warranty
   For a period of 60 months from the date that the Product is delivered to the Buyer, the chassis and other structural components of such Product will be free from defects in material and/or workmanship under normal use and maintenance.

2. EXCLUSIONS / WHAT IS NOT COVERED
   The following items are NOT covered under this Limited Warranty:
   • Defects in, and damage or loss relating to, any batteries incorporated by the Company into or made a part of the Product. Any such defects, damage or loss shall be exclusively covered by the battery manufacturer’s warranty, if any. For more information regarding the battery warranty, the Buyer should contact the battery manufacturer using the contact information shown on the battery;
   • Damage or loss resulting from or caused by carrier handling;
   • Damage or loss resulting from or caused by normal wear and tear, weathering, lack of use or use with incompatible equipment or software;
   • Damage resulting from or caused by improper maintenance, improper handling or storage, improper use, abuse, neglect, operation beyond rated capacity, or operation after discovery of defective or worn parts;
   • Any part, component or assembly altered or modified in any way not approved in writing by the Company;
   • Damage to any equipment or parts not manufactured by the Company; and
   • Acts of God, accidents or any other causes beyond the Company’s reasonable control.

3. MAKING A WARRANTY CLAIM
   As a prerequisite to making any claim under this Limited Warranty, Buyer must give the Company written notice of any suspected defect promptly after discovery. Such notice shall specifically identify the suspected defect, the original delivery date and complete Buyer identification and location information. The Company will not accept any Product for warranty service without receiving Buyer’s written notice and issuing a return goods authorization. If requested by the Company, Buyer shall return the defective Product, or parts, components or assemblies thereof, to the Company, F.O.B, Company’s designated location. All returned Products or parts, components or assemblies thereof that are replaced under this Limited Warranty shall become the property of the Company. The Company reserves the right to review Buyer’s maintenance and operation records and procedures to determine if the alleged defect(s) were due to any of the items listed in Sections 2 of this Limited Warranty. The Company shall not be liable for any claim under this Limited Warranty if Buyer fails to satisfy the conditions set forth in this Section.

4. EXCLUSIVE WARRANTY REMEDIES
   a. Exclusive Repair or Replace Remedy
   The Company’s sole obligation and Buyer’s exclusive remedy with respect to any defect in the Product occurring during the warranty periods set forth in Section 1 of this Limited Warranty shall be for the Company, at its option, to repair or replace (or have one of its designated authorized dealers repair or replace) the Product or part, component or assembly thereof that contains a defect in materials or workmanship. The Company reserves the right, at its discretion, to use new, re-manufactured or refurbished replacement parts. Notwithstanding anything in this Limited Warranty to the contrary, the Company shall not be obligated to replace the entire Product if a covered defect can be remedied by the repair or replacement of a defective part, component or assembly. The Company shall be responsible for the cost of all parts and labor charges, up to the Maximum Labor Amount determined in accordance with Section 4(b) of this Limited Warranty, necessary to remedy such defect.
   b. Labor Charges
   If field repairs or parts replacement are necessary on any Product covered by this Limited Warranty, the Company will reimburse its designated authorized dealer for those direct labor costs incurred to perform such field repairs or parts replacement up to the maximum amount specified in the Company’s current Field Service Rate (hereinafter, the “FSR”) or in any ‘Flat Rate Guides’ or similar agreement established with the authorized dealer (such maximum amount shall be referred to in this Limited Warranty as the “Maximum Labor Amount”). Current versions of the Company’s FSR and Flat Rate Guides are incorporated by reference into this Limited Warranty. For a current copy of the Company’s FSR and Flat Rate Guides, Buyer should contact the Company at 1-866-334-0756. Buyer shall be responsible for any costs or fees due to the authorized dealer in excess of the Maximum Labor Amount.

5. DISCLAIMER OF OTHER EXPRESS AND IMPLIED WARRANTIES
   EXCEPT FOR THE LIMITED WARRANTIES SET FORTH IN SECTION 1 ABOVE, THE COMPANY MAKES NO OTHER REPRESENTATIONS OR WARRANTIES AND HEREBY DISCLAIMS ALL EXPRESS OR IMPLIED REPRESENTATIONS OR WARRANTIES REGARDING THE PRODUCT, INCLUDING, WITHOUT LIMITATION, ANY IMPLIED WARRANTY OF MERCHANTABILITY, NON-INFRINGEMENT OF PROPRIETARY OR 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 modification is made in writing and signed by an officer of the Company.

6. LIMITATION OF LIABILITY
   NOTWITHSTANDING ANYTHING IN THIS WARRANTY TO THE CONTRARY, IN NO EVENT SHALL THE COMPANY OR ANY OF ITS AFFILIATES OR SUBSIDIARIES BE LIABLE TO BUYER FOR ANY INDIRECT, SPECIAL, EXEMPLARY, PUNITIVE OR CONSEQUENTIAL DAMAGES (INCLUDING LOST PROFITS, LOST REVENUE, DOWN TIME, LOSS OF BUSINESS OPPORTUNITY OR OTHER ECONOMIC LOSSES), WHETHER IN AN ACTION IN CONTRACT OR TORT (INCLUDING NEGLIGENCE AND STRICT LIABILITY) OR OTHERWISE, EVEN IF THE COMPANY HAS BEEN SPECIFICALLY ADVISED OF THE POSSIBILITIES OF SUCH DAMAGES.

Self-Propelled Aerial Work Platform
Maintenance & Troubleshooting Manual
HB-1230
Series III

© 2015 Custom Equipment, LLC
2647 Highway 175
Richfield, WI 53076
U.S.A.
Tel.: +1-262-644-1300
Fax: +1-262-644-1320
www.hybridlifts.com
Service@Customequipmentlifts.com
“Hy-Brid Lifts” is a trademark of Custom Equipment, LLC.
These machines comply with specified ANSI/SIA A92.6 requirements
Revision Date: July 2015
Printed In The USA

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References

• Hy-Brid Lifts | Scissor Lift Manufacturer | Scissor Equipment

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