GMG 1330-ED Service Manual
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GMG 1330-ED Service Manual

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Global Machinery Group, Inc.
SERVICE MANUAL
1330, 1530-ED
Part # 81301.2
October 1, 2021
Serial # Range
2133001073-Current
2153001119-Current

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Summary of Contents for GMG 1330-ED

  • Page 1 Global Machinery Group, Inc. SERVICE MANUAL 1330, 1530-ED Serial # Range Part # 81301.2 2133001073-Current October 1, 2021 2153001119-Current...
  • Page 2 Please refer to the website (www.gogmg.com) for contact information, other serial numbers, the most recent technical manuals, and USB software.
  • Page 3 THIS SAFETY ALERT SYMBOL MEANS ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED. The Safety Alert Symbol identifies important safety messages on MEWPs, safety signs in manuals or elsewhere. When you see this symbol, be alert to the possibility of personal injury or death. Follow the instructions in the safety message.
  • Page 4 @ Notes & 1330ED 1530ED micro...

  • Page 5: Table Of Contents

    Table of Contents .......... Section 1 Scheduled Maintenance . Read and Heed ..............7 1. 1-1 Mobile Elevating Work Platform (MEWP) definition ........7 1. 1- 2 Purpose of Equipment ............7 Use of Equipment ............... 7 1. 1-3 1.
  • Page 6 Section 3 - System Component Identification and Schematics ....31 Platform to Base Control Cable ............3 2 Large Current Wiring Diagram ............3 3 Ground Control Wiring Diagram (Page 1 of 2) ........... 3 4 Ground Control Wiring Diagram (Page 2 of 2) ........... 3 5 Electric Schematic Diagram ............

  • Page 7: Scheduled Maintenance

    2 years or 3000 hours, whichever occurs first. Any defective part will be replaced or repaired by your local GMG dealer at no charge for parts or labor. In addition, all products have a 5-year structural warranty. Contact the GMG Service Department for warranty statement extensions or exclusions.

  • Page 8: Maintenance And Inspection Schedule

    MEWP. relative law provisions obtaining in the country. Consult GMG's Service Department for optional tires Before attempting any repair work, disconnect the specifications and installation. main power conenctors.

  • Page 9: Hydraulic System & Component Maintenance And Repair

    Maintenance and Inspection Schedule Section 1 - Scheduled Maintenance 1.2-4 Hydraulic System & Component 7. All hydraulic components must be disassembled in spotlessly clean surroundings. During Maintenance and Repair disassembly, pay particular attention to The following points should be kept in mind when the identification of parts to assure proper working on the hydraulic system or any component: reassembly.

  • Page 10: Maintenance Hints

    Section 1 - Scheduled Maintenance Maintenance and Inspection Schedule 1.2-5 Maintenance Hints Three simple maintenance procedures have the greatest effect on the hydraulic system performance, efficiency and life. Yet, the very simplicity of them may be the reason they are so often overlooked. They are simply these: 1.

  • Page 11: About This Section

    Maintenance and Inspection Schedule Section 1 - Scheduled Maintenance 1.2-6 About this Section 1.2-7 Maintenance Instructions This section contains the maintenance and inspection This manual consists of four schedules to be done schedule that is to be performed. for maintaining on an MEWP. Inspection schedule frequency is shown below: References are made to the procedures in Section 5 that outline detailed step-by-step instructions for...

  • Page 12: Owner's Annual Inspection Record

    Section 1 - Scheduled Maintenance Owner's Annual Inspection Record Table 1.3 Owner's Annual Inspection Record AwARNING Do not use the MEWP if there is no inspection recorded in the last 13 months. If you do not obey, there is a risk of death or serious injury. IMPORTANT The owner's annual inspection record is located on the scissor assembly.

  • Page 13: Frequent/Periodic/Annual/Pre-Delivery Inspection Checklist

    Frequent/Periodic/Annual/Pre-Delivery Inspection Checklist Section 1 - Scheduled Maintenance 1.4 Frequent/Periodic/Annual/Pre-Delivery Inspection Checklist Frequent/Periodic/Annual/POI Checklist Vertical Mast, Electric Scissor, Micro Scissor & Rough Terrain Product Owner: S erial Number: Starting with serial number 2153001119 and above Product User: Datemme: Model: I n spection Type (Choose one): Pre-delivery Frequent Annual...

  • Page 14: General Inspections

    Section 1 - Scheduled Maintenance General inspections 1.5 General inspections 1.5-1 Service Bulletins Go to www.gogmg.com and use your machine's Do an inspection of the MEWP in this sequence: serial number to find related open service bulletins. AwARNING 1.5-2 Annual Inspections Do not operate a MEWP that does not function Do a check on the machine's service record to find correctly.

  • Page 15: Base Inspection

    Make sure there are no loose or missing parts. ■ WARNING • Make sure there is no visible damage. Do not use tires other than the tires that GMG Make sure there is no dirt and blockages. ■ specifies for this MEWP. Do not mix different types Tilt Switch of tires or use tires that are not in good condition.
  • Page 16 Section 1 - Scheduled Maintenance Base inspection Steer cylinder Make sure that the steer cylinder assembly is ■ correctly installed. Make sure there are no loose or missing ■ fasteners. Make sure there is no visible damage. ■ Steer linkages assembly Make sure there are no loose or missing ■...

  • Page 17: System Components Tray

    Base inspection Section 1 - Scheduled Maintenance 1.6-1 System components tray AwARNING OTray Only use original or manufacturer-approved parts ■ Make sure that the system components tray and components for the MEWP. If you do not obey, latches correctly and is in good condition. there is a risk of death, serious injury, or machine Base controls damage.
  • Page 18 Section 1 - Scheduled Maintenance Base inspection ·- � Hydraulic pump and motor Motor controller ■ Make sure there are no loose or missing parts. ■ Make sure the motor controller is correctly attached, and there is no visible damage. •...

  • Page 19: Lift Mechanism Inspection

    Lift mechanism inspection Section 1 - Scheduled Maintenance 1. 7 Lift mechanism inspection Scissor bumpers Make sure that the bumpers are correctly ■ 1. Raise the platform and deploy the maintenance attached and have no visible damage. supports. Lift cylinder and pressure transducer Maintenance support Make sure that the lift cylinder is correctly ■...
  • Page 20 3. If there is no structural damage to the scissor immediately removed from service and repaired arms, replace the pins and bushings with new by a qualified technician. Speak to the GMG components. service department for directions on how to repair the unit.
  • Page 21 Lift mechanism inspection Section 1 - Scheduled Ma· t enance � - - - Center Pin - Middle ® - - - Center Pin - Outer Center Pin - Inner & 1330ED 1530ED micro...
  • Page 22 Section 1 - Scheduled Maintenance Lift mechanism inspection Upper cylinder mount area Lower cylinder mountarea Examples of damaged pin connections: Cylinder mount inspection This inspection must be done as part of the scissor Broken retainer bolt assembly inspection. 1. Do a structural inspection of the cylinder mount areas.

  • Page 23: Platform Inspection

    Platform inspection Section 1 - Scheduled Maintenance 1.8 Platform inspection AC power socket Make sure there is no visible damage. ■ AwARNING Platform control console Fall Hazard. Use the three points of contact Make sure that the control console is locked with ■...

  • Page 25: Maintenance Tables And Diagrams

    Section 2 - Maintenance Tables and Diagrams & 1330ED 1530ED micro...

  • Page 26: Torque Specifications For Fasteners

    Torque specifications for fasteners (US) Section 2 - Maintenance Tables and Diagrams Table 2.1 Torque specifications for fasteners (US) SAE2 SAES SAEB SAE2 SAES SAE 8 Torque Torque Size Size Ty p e Ty p e Lubed Lubed Lubed Lubed Lubed Lubed ( 4 )

  • Page 27: Torque Specifications For Fasteners (Metric)

    Torque specifications for fasteners (metric) Section 2 - Maintenance Tables and Diagrams Table 2.2 Torque specifications for fasteners (metric) 10.9 Torque Size Type Lubed Lubed ( in-lb ) (54) (41) (78) (59) MS x 0.80 (in-lb) (92) (69) (133) (99) M6 X 1.00 10.4 11.2...

  • Page 28: Torque Specifications For Hydraulic Couplings & Hoses

    & Section 2 - Maintenance Tables and Diagrams Torque specifications for hydraulic couplings hoses Table 2.3 Torque specifications for hydraulic couplings & hoses Hydraulic Coupling Torque Chart O-Ring Port Connectors Steel Ports Non-ferrous Ports SAE Size ft-lb ft-lb 14-16 20-22 9-10 12-13 24-26...

  • Page 29: Specifications & Features

    & Specifications Features Section 2 - Maintenance Tables and Diagrams Table 2.4 Specifications & Features & Models 1530ED 1330ED micro Weight* 820 kg ( 1 808 lb) Overall width 0.76 m ( 2 9.92 in) Overall length ( P latform Retracted) 1.49 ( 5 8.66 in) Overall length ( P latform Extended)

  • Page 30: Maximum Platform Capacities (Evenly Distributed)

    Section 2 - Maintenance Tables and Diagrams Maximum platform capacities (evenly distributed) Table 2.5 Maximum platform capacities (evenly distributed) T ilt cutout Extension platform Manual side setting (side-to-side x Model Wind rating Total platform capacity force capacity front-to-back) 1530ED 0 m/s 240 kg 100 kg 400N...

  • Page 31: Section 3 - System Component Identification And Schematics

    Section 3 - System Component Identification and Schematics & 1330ED 1530ED micro...

  • Page 32: Platform To Base Control Cable

    Section 3 - System Component Identification and Schematics Platform to Base Control Cable Platform to Base Control Cable �--ot:= =1 .- --ot:: =1 "-- -O IJ: ===1 1 4 '--- -[J IJ: ===1 1 5 Note: Unmarked wires or connectors or terminal s are sel f -contained components. &...

  • Page 33: Large Current Wiring Diagram

    Large Current Wiring Diagram Section 3 - System Component Identification and Schematics 3.2 Large Current Wiring Diagram BATTERIES GB!(2/2) FUSE BATTERY DISCONNECT Note: 1. Unmarked wires or connectors or terminals are s�f.contained components. 2. • External demand for tin & 1330ED 1530ED micro...

  • Page 34: Ground Control Wiring Diagram (Page 1

    3.3 Ground Control Wiring Diagram (Page 1 of 2) 24V- 24V- 2◄V- 24V- 24V- P9-S P9-3 P9-2 P9-8 + 2◄V KEY SWITCH P()V,iB?RELAY Broke Bro e & 1330ED 1530ED micro...

  • Page 35: Ground Control Wiring Diagram (Page 2

    1l'OTHO.. SIIITCII 3.4 Ground Control Wiring Diagram (Page 2 of 2) CHASSIS HARNESS GB\tl/Zl ! .. ,,,. . , 4- GROUND HARNESS Ncte:UrmcrkedlWt'Sorameaorsamrinal s .reSElkmanecanime� & 1330ED 1530ED micro...

  • Page 36: Electric Schematic Diagram

    3.5 Electric Schematic Diagram Platloml control box Platlormemergencysltl) 4 24V- steerleftvalve Buzzer HA1 P12- Leftmotorbrake'l'V5 Righlmcci:r brake vve P9-8 P12- """' P12- �allormmode PU-1 Basemode P12-1 OffJPlatform/Base Key switch Hourmeter DrivemOOllS 8asellffl8l'gencystop TS200 & 1330ED 1530ED micro...

  • Page 37: Hydraulic Schematic Diagram

    12Mp • 3.6 Hydraulic Schematic Diagram C1 LIFT CYLINDER C2 STEER CYLINDER L ______ _ ----- � l_J ___________ � & 1330ED 1530ED micro...
  • Page 38 @ Notes & 1330ED 1530ED micro...

  • Page 39: Section 4 - Troubleshooting Information

    Section 4 - Troubleshooting Information Introduction The following pages contain a table of Troubleshooting for locating and correcting most service trouble which can develop. Careful and accurate analysis of the systems listed in the table of Troubleshooting will localize the trouble more quickly than any other method.

  • Page 40: Electrical System

    Section 4 - Troubleshooting Information Electrical System Electrical System NOTE Functions may be disabled by the load sense system. Please first ensure the platform is fully lowered, free of added weight, and there are no faults in the load sense system NOTE Functions may be disabled by the machine control system.

  • Page 41: No Lift Or Steer Functions

    Electrical System Section 4 - Troubleshooting Information 16. Open or defective Platform emergency sop Close switch. Replace if defective switch SB2. 17. Loose or broken 24VE wire from Platform control Check continuity. Replace if defective. E-stop switch SB2 to 7S02 pin 2. 18.

  • Page 42: No Lift From Base Or Platform

    Section 4 - Troubleshooting Information Electrical System 4.2-3 No Lift from base or platform 1. Loose or broken wire from TS200 machine controller pin P9-1 to YV3 lift valve coil + Check continuity. Replace if defective. (connector 2S03 pin 1) 2.

  • Page 43: No Lower From Base Controls

    Electrical System Section 4 - Troubleshooting Information 4.2-7 No lower from base controls 1. Loose or broken wire from lift/lower switch SA2 to Check continuity. Replace if defective. TS200 machine controller pin p12_5 2. Open or defective lift/lower switch SA2 Replace if defective 4.2-8 No functions from platform controls 1.

  • Page 44: 11 No Steer Right

    Section 4 - Troubleshooting Information Electrical System 4.2-1 O No steer left 1. Loose or broken wire from TS200 machine Check continuity. Replace if defective. controller pin P9-9 to steer left YV1 coil connector 2S01 pin 1 Replace coil 2. Defective steer left YV1 coil 3.
  • Page 45 Electrical System Section 4 - Troubleshooting Information 5. Loose or broken wire from connector 12S01 pin Check continuity. Replace if defective. 2 to right and/or left motor brake brake connector 2P04 and/or 2P05 pin 2 6. Loose or broken 24V- wire from right and/or left Check continuity.

  • Page 46: Hydraulic System

    Section 4 - Troubleshooting Information Hydraulic System 4.3 Hydraulic System 4.3-1 All Hydraulic Controls Inoperative (No Lift or Steer functions) Refer to Electrical troubleshooting. Replace pump 1. Pump motor not engaged motor if defective. 2. Pump motor coupler defective Check coupler. Replace if defective 3.

  • Page 47: Section 5 - Procedures

    Section 5 - Procedures General AwARNING The following information is provided to assist you in Fall Hazard. Use the three points of contact the use and application of servicing and maintenance principle when you use the MEWP to enter or exit procedures contained in this chapter.

  • Page 48: Pgt Setting File Upload Process

    Section 5 - Procedures *.PGT Setting File Upload Process 5.2 *.PGT Setting File Upload 7. On each machine that needs the settings uploaded from the *.pgt file, plug the EZCal Pro Process into the control board. The location of the EZCal connector is at the bottom right of the control 1.
  • Page 49 17. Update is completed. Perform any function checks and tests recommended in the task. 18. If any errors occur during the process, stop the upload and contact GMG for support. 12. Scroll right through the pgt files on the EZCal until you locate the intended file. The example used in the image below is called "Settings Push.pgt".

  • Page 50: Ts200 Pin Chart

    Section 5 - Procedures TS200 5.3 TS200 B,.. � � � � OLEO "·" ••• "·" •• • ••• ••• • •• • •• •:=i• •Q• •Q• 5.3-1 TS200 Pin Chart PLUG PIN OUT Output to YV3 lift valve Output to YV4 lower valve and hour meter P1 through diode D3 Output to brake release Not Used Output to KM1 contactor and hour meter P1 through diode D4...
  • Page 51 Section 5 - Procedures TS200 TS200 Pin Chart (Continued) PLUG � Input from Off/Platform/Base keyswitch SA1: Base mode Not Used Not Used Input from lift/lower switch SA2: Lift Input from lift/lower switch SA2: Lower Switched ground output to buzzer HA 1 Input from scisso angle (height) sensor AS1 (PP1-2) Not Used Not Used...

  • Page 52: Display Messages And Codes

    Section 5 - Procedures TS200 5.3-2 Display Messages and Codes Under most normal operating conditions the LED light on the TS200 controller will be on steady and the Platform control box display will indicate the approximate bateery charge. Some machine conditions will flash a code on the TS200 controller LED and may also display on the Platform Control Box.
  • Page 53 TS200 Section 5 - Procedures Display Messages and Codes (Continued) Display EZcal Display Message Description Code The platform and ground EMS inputs indicate the mode in which the TS200 must operate. If neither input is active, or SHUTDOWN - CHECK EMS SWITCHES! if both are active together, the TS200 does not know how to function Check EMS switch wiring to P15-1 and P12-1.
  • Page 54 Section 5 - Procedures TS200 Display Messages and Codes (Continued) Display EZcal Display Message Description Code 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).
  • Page 55 TS200 Section 5 - Procedures Display Messages and Codes (Continued) Display EZcal Display Message Description Code There is a problem with load measurement - the height and/or pressure sensor measurements are out of range, or the elevation switch disagrees with the height sensor Check that the output from height and pressure sensors (P12-10, P12-12) is in range (between 0.5V and 4.5V) FAULT: CHECK HEIGHT1 SENSOR...
  • Page 56 Section 5 - Procedures TS200 Display Messages and Codes (Continued) EZcal Display Message Description When an EZcal is connected to the TS200 machine controller 232 port then there are information only messages available for which there are no LED blink/Platform Control box display codes. The TS200 has just been powered on and is carrying out some initialization steps prior to being ready to operate.

  • Page 57: Ts200 Menu Table With £Zeal

    Section 5 Procedures TS200 5.3-3 TS200 Menu Table with EZcal When the EZcal hand-held device is connected to the TS200 control module, a two line display shows various menus and settings. At any time the top line of the display describes the currently selected menu and the bottom line shows the currently selected item in that menu.
  • Page 58 Section 5 - Procedures TS200 TS200 Menu Table with EZcal (continued) DIAGNOSTICS SYSTEM Select this menu to see general TS200 system information PLATFORM Select this menu to see platform input status :::; Select this menu to see ground input status (during calibration, separate measurements are collected during GROUND lifting and lowering) INPUTS...
  • Page 59 Section 5 - Procedures TS200 TS200 Menu Table with EZcal (continued) Menu Selection Description DIAGNOSTICS TRIGGER Displays ON when platform trigger pressed Displays drive / lift mode (from drive / lift switch) JOY F/R Displays joystick position in the forward/reverse (or up/down) direction (%) Cl..
  • Page 60 Section 5 - Procedures TS200 TS200 Menu Table with EZcal (continued) DIAGNOSTICS vP9-1 Displays state of P9-1 output C(V3 LIFT valve) vP9-2 Displays state of P9-2 output C(V4 LOWER valve) vP9-3 Displays state of P9-3 output (brake release) vP9-4 Not used. vP9-5 Displays state of P9-5 output (KM1 contactor) vP9-6...
  • Page 61 TS200 Section 5 - Procedures TS200 Menu Table with EZcal (continued) Menu Selection Sub-Menu Description ACCESS LEVEL When the EZcal hand-held device is connected to the 232 port of the TS200 control module, the initial "ACCESS LEVEL:' is 3 - no adjustments can be altered or calibrations carried out. Before adjustments or calibrations can be made, the "ACCESS LEVEL:' must be changed to 2 using the correct access code (3939).
  • Page 62 Section 5 - Procedures TS200 TS200 Menu Table with EZcal (continued) ADJUSTMENTS UP MIN(*) Determines the slowest lifting speed (when the joystick is at 0% demand) UP MAX(*) Determines the fastest lifting speed (when the joystick is at 100% demand) DOWN MIN(*) Determines the slowest lowering speed (when the joystick is at 0% demand) DOWN MAX(*)

  • Page 63: Calibrate Level Procedure

    Section 5 - Procedures TS200 5.3-4 Calibrate Level Procedure 5.3-5 Calibrate Load Procedure The integral tilt sensor of the TS200 control module must be calibrated when the machine is perfectly The TS200 control module requires calibration before level; an EZcal hand-held device is required to carry it can estimate platform load;...
  • Page 64 Section 5 - Procedures TS200 1. Ensure machine parked on level ground, and C. When the UP switch is released, the TS200 TS200 leveled. records the maximum height of the platform 2. Ensure machine both platform and base e-stop 10. The display now shows "PLEASE LOWER ... " switches are pulled out.
  • Page 65 TS200 Section 5 - Procedures 21. When the system detects the DOWN switch Similar to the "LOWER LOADED" phase closed, the display will show "LOWER LOADED" the lowering ... stopping ... measuring ... lowering process will continue until the with the current height (from 100% to 0%) platform is fully lowered, then the DOWN 22.

  • Page 66: Callibration Fault Codes

    Section 5 - Procedures TS200 5.3-6 Callibration Fault Codes During calibration, the TS200 control module repeatedly checks for possible problems which might prevent successful calibration, or subsequently give inaccurate platform load estimates. If any problem is detected, a flashing error message is immediately displayed and calibration is terminated - the problem must be resolved, and calibration re-started.
  • Page 67 TS200 Section 5 - Procedures Fault Code List (continued) Fault Code Description The EZfit height sensor output is bad during dynamic lifting (must be between 0.6V and 4.4V F14: BAD HEIGHT1 always) The ELEVATION switch (P4-6) is open with platform fully lowered at the end of the dynamic raising / lowering cycle - or the switch changed state more than once (it should go from closed F15: CHECK ELEV to open just once, as the platform is raised, and from open to closed just once, as the platform is...
  • Page 68 Section 5 - Procedures TS200 Fault Code List (continued) Fault Code Description At the end of all static calibrations, the loaded and empty heighVpressure curves are compared - F40: REJECT DELTA the loaded curve should be higher than the empty curve, due to the additional platform load. This DOWN @ error indicates there is less than 0.2V difference between the loaded and empty curves (or that the loaded curve is below the empty curve), at the indicated height...
  • Page 69 @ Notes & 1330ED 1530ED micro...
  • Page 70 Global Machinery Group, Inc. 3428 Bullock Lane • San Luis Obispo • CA 93401 USA Phone: 1-800-301-0499 • 1-805-303-2066 • FAX: 1-805-293-6211 E-mail: info@goGMG.com • Website: www.goGMG.com...

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