GMG 1530-ED, Parts And Service Manual

Page 1: ...PARTS AND SERVICE MANUAL 1530 ED Part 1PS1530EN January 26 2019 Serial Range 2153001000 Current Global Machinery Group Inc...

Page 2: ...Release Date November 20 2018 Date Reason for Update 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 G...

Page 3: ...Machine Maintenance General 1 2 Pre Start Inspection Checklist 1 3 30 Day Service 1 3 Frequent Inspection Checklist 1 3 Hydraulic Fluid 1 3 Batteries 1 4 Electrical Wiring 1 5 Tires Wheels 1 6 Emergen...

Page 4: ...ly Diagram 4 9 Module Assebmly Parts List 4 10 Module Assebmly Parts List continued 4 11 Drive Wheel Assembly Diagram Parts List 4 12 Steering Cylinder Assembly Diagram Parts List 4 13 Scissor Stack M...

Page 5: ...rds We recommend that you use genuine GMG parts to ensure proper operation and reliable performance To obtain maximum benefits from your GMG Aerial Work Platform always follow the proper operating and...

Page 6: ...m Toeboard height 6 7 0 17 m Height stowed rails lowered 79 9 62 6 2 03 m 1 59 m Length stowed w o ladder 58 5 50 5 1 48 m 1 28 m Width 29 9 76 m Wheelbase 41 3 1 05 m Ground clearance center pothole...

Page 7: ...INJURY OR DEATH GMG s policies and procedures demonstrate our commitment to quality and our ongoing efforts towards continuous improvement Product specifications are subject to change without notice...

Page 8: ...VOIDED WILL RESULT IN DEATH OR SERIOUS INJURY THIS SIGNAL WORD IS LIMITED TO THE MOST EXTREME SITUATIONS WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED COULD RESULT IN DEATH...

Page 9: ...nts or hoses open They must be protected from contamination including rain at all times Never open a hydraulic system when there are contaminants in the air Always clean the surrounding area before op...

Page 10: ...sitive battery cable first When the negative cable is installed a spark will occur if contact is made between the positive side of the battery and a metal surface on the machine This can cause damage...

Page 11: ...n Manuals Case Platform Tie Down Lift Points Lower Controls Battery Charger Emergency Stop Switch Emergency Lowering Knob Lift Cylinder Deck Extension Release Entry Gate Maintenance Lock Forklift Pock...

Page 12: ...0 26 38 46 61 74 5 97 5 114 142 167 188 228 255 409 523 607 802 1003 8 25 10 5 18 5 23 35 41 55 68 86 102 127 148 168 203 318 365 466 543 716 894 9 5 12 20 25 37 45 60 75 96 112 140 164 185 224 350 40...

Page 13: ...omponents Torque Table parts drawings and service instructions in this manual packaging and instruction sheets provided with new parts instruction manuals provided by the manufacturer of the component...

Page 14: ...MERGENCY LOWERING IF THE CONTROL SYSTEM FAILS WHILE THE PLATFORM IS ELEVATED USE THE EMERGENCY LOWERING PROCEDURE TO SAFELY LOWER THE PLATFORM DO NOT CLIMB DOWN THE ELEVATING ASSEMBLY OR EXIT THE PLAT...

Page 15: ...ES The machine can be winched Before winching the machine it is necessary to release the brakes Make sure the brakes are re engaged after winching 1 Lower machine to the stowed position 2 Chock the wh...

Page 16: ...a rating of two 2 tons or more TO RAISE THE MACHINE 1 Move machine to a firm level surface capable of supporting the weight of the machine 2 Chock tires on one end of machine and raise the other end...

Page 17: ...ion Checklist 1 3 Hydraulic Fluid 1 3 Batteries 1 4 Electrical Wiring 1 5 Tires Wheels 1 6 Emergency Stop 1 6 Key Switch 1 7 Horn 1 7 Drive Brakes 1 7 Drive Speed Stowed 1 8 Drive Speed Raised 1 8 Dri...

Page 18: ...SCISSOR ASSEMBLY WITH THE MAINTENANCE LOCK SEE THE INTRODUCTION PORTION OF THIS MANUAL PERFORM SCHEDULED MAINTENANCE AT RECOMMENDED INTERVALS FAILURE TO PERFORM SCHEDULED MAINTENANCE AT RECOMMENDED IN...

Page 19: ...or cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracks 3 Remove the wheel covers and check each center lock nut for proper torque Castle nut torue dry 19 ft lbs 26 Nm...

Page 20: ...nate corrosion on the battery terminals and cables 4 Be sure that the battery retainers and cable connections are tight 5 Fully charge the batteries Allow the batteries to rest 24 hours before perform...

Page 21: ...he red Emergency Stop button to the on position at both the ground and platform controls 3 Raise the platform approximately 7ft 2 1 m from the ground 4 Lift the safety arm move it to the center of the...

Page 22: ...perating red Emergency Stop button will fail to shut off power and stop all machine functions resulting in a hazardous situation As a safety feature selecting and operating from the ground controls wi...

Page 23: ...functioning horn will prevent the operator from alerting ground personnel of hazards or unsafe conditions 1 Turn the key switch to platform control and pull the red Emergency Stop button to the on po...

Page 24: ...art and finish lines 6 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 7 Continue at full speed and not...

Page 25: ...should be 18 22 sec HYDRAULIC OIL ANALYSIS Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil may cause the machine to perform poorly and...

Page 26: ...Annual Inspection Checklist page from the Operator s Manual to keep record of this inspection Keep inspections records up to date Record and report all discrepancies to your supervisor Perform all ch...

Page 27: ...g the oil is necessary Hydraulic oil should be tested yearly and replaced if it fails If the hydraulic oil is not replaced at the Annual Inspection test the oil quarterly Replace the oil when it fails...

Page 28: ...raulic tank retaining fasteners dry 35 in Ibs 4 Nm Hydraulic tank drain plug lubricated 26 in Ibs 3 Nm 10 Install the hydraulic power pack into the component tray Install the fitting and hydraulic hos...

Page 29: ...2 1 January 26 2019 1530 ED Parts and Service Manual SECTION 2 CONTROL SYSTEM CONTENTS PAGE Control Component Locations 2 2 Fault Code Display 2 3 Fault Codes Overview 2 4 Troubleshooting Table 2 5...

Page 30: ...s Case Platform Tie Down Lift Points Lower Controls Battery Charger Emergency Stop Switch Emergency Lowering Knob Lift Cylinder Deck Extension Release Entry Gate Maintenance Lock Forklift Pocket Batte...

Page 31: ...Manual FAULT CODE DISPLAY Fault Codes when present appear on the LED Indicator at the Upper Controls station and on the LCD Screen at the Lower Controls station FAULT CODE DISPLAY Upper Controls Lower...

Page 32: ...OT IN NEUTRAL AT DIAGNOSTIC MESSAGE ONLY 53 OUTPUT TO ZAPI FORWARD SIGNAL FAULTY DISABLE LIFTING AND DRIVING 54 OUTPUT TO ZAPI REVERSE SIGNAL FAULTY DISABLE LIFTING AND DRIVING LIFT UP COIL FAULT 55 D...

Page 33: ...red Check wiring to sensor or replace sensor 42 Left steer switch fault at startup Failure of left steer switch Check left steer switch 43 Right steer switch fault at startup Failure of right steer sw...

Page 34: ...Solution 90 Weight reaches 90 of nominal value Approaching maximum overload Pay attention to load 99 Weight reaches 99 of nominal value Approaching maximum overload Pay attention to load LL Off level...

Page 35: ...26 2019 1530 ED Parts and Service Manual SECTION 3 SCHEMATICS CONTENTS PAGE Hydraulic Schematic 3 2 Hydraulic Unit 3 3 Electrical Schematic 3 4 Logic Diagram 3 5 ECU Pin Legend 3 6 Motor Controller Pi...

Page 36: ...nd Service Manual HYDRAULIC SCHEMATIC HYDRAULIC SHEMATIC C H16 1 5 7 180bar 4 1 160bar 33kw DC24V 4L L___________J DOWN VALVE EMER DOWN INTEGRATED LIFT CYLINDER STEER CYLINDER STEER VALVE STEER RELIEF...

Page 37: ...3 3 January 26 2019 1530 ED Parts and Service Manual HYDRAULIC UNIT HYDRAULIC UNIT Main Relief Steer Relief Pump Motor Steer Valve Lift Valve Breather Cap Dipstick Hydraulic Reservoir...

Page 38: ...IVE double wire A2 NOT USED A3 NOT USED A9 OUTPUT LIFTING SPEED A10 NOT USED A11 NOT USED A12 INPUT DOWN FOR LOWER CONTROL B1 CAN HIGH COM UPPER CONTROLS B4 INPUT ANGLE TRANSDUCER 0 5V B6 OUTPUT DOWN...

Page 39: ...AN LOW CAN LINE M M ELECTRIC DRIVE MOTORS MOTOR CONTROLLER C9 Brake Supply R 1B Brake Supply L 5B Brake Supply L 24V Platform down 6A B supply B PWM B negative supply P Platform down C12 Angle transdu...

Page 40: ...CONTROL SELECTED B3 INPUT B NEGATIVE SUPPLY B4 INPUT VAR ANGLE TRANSDUCER 0 5V B5 NOT USED B6 OUTPUT DOWN VALVE B7 OUTPUT STEERING VALVE RIGHT B8 OUTPUT HORN OPTIONAL NOT CONNECTED B9 OUTPUT ALARM B10...

Page 41: ...NAL LOOP TO 14A 14A EXTERNAL LOOP TO 10A TERMINAL TYPE DESCRIPTION 1B OUTPUT LEFT BRAKE 2B INPUT STATE CHECK LINE CONTACTOR 4B INPUT DRIVE FORWARD 5B OUTPUT LEFT BRAKE 6B OUTPUT LINE CONTACTOR 8B INPU...

Page 42: ...11 Drive Wheel Assembly Diagram Parts List 4 12 Steering Cylinder Assembly Diagram Parts List 4 13 Scissor Stack Mid Section Scissor Mount Diagram Parts List 4 14 Scissor Arm Assembly Diagram 4 15 Sc...

Page 43: ...4 2 January 26 2019 1530 ED Parts and Service Manual Chassis Assembly Diagram Section 1 C B A A B Not Pictured PARTS CHASSIS...

Page 44: ...1015 Plate cable mount 1 14B 71094 Cable E down 1 14C 71080 Handle cable 1 15 REF page 1 6 2 16 61005 Assembly drawer 1 17 11054 Screw socket countersunk M6X16 8 18 11052 Nut nylock M6 8 19 71020 Slid...

Page 45: ...Description Qty 33 31049 Cover chassis rear 1 34 11071 Bolt hex M12X25 2 35 11023 Washer flat 12 2 36 31170 Ladder 1 37 71218 Key lower controls selector switch 1 38 71220 Key compartment door lock 1...

Page 46: ...4 5 January 26 2019 1530 ED Parts and Service Manual Chassis Assembly Diagram Section 2 PARTS CHASSIS...

Page 47: ...Pin 10X60 2 14 11080 Pin cotter 2 15 11100 Washer flat 14 2 16 71032 Bushing 14X20X14 2 17 31056 Plate PHP 2 18 11066 Stop position 2 19 11077 Nut nylock M16 2 20 11092 Screw socket M10X50 4 21 11017...

Page 48: ...4 7 January 26 2019 1530 ED Parts and Service Manual Steer Wheel Assembly Diagram PARTS CHASSIS...

Page 49: ...Screw socket M5X10 2 7 11045 Washer flat 5 2 8 71009 Bushing tie rod 2 9 11072 Bolt hex M4X12 8 10 11103 Washer lock 4 8 11 11040 Washer flat 4 8 12 71012 Cover hub 2 13 11042 Bolt hex M8X35 12 14 11...

Page 50: ...4 9 January 26 2019 1530 ED Parts and Service Manual Module Assembly Diagram B see below A D F E A C B C PARTS CHASSIS...

Page 51: ...t pump assembly 1 8 41012 Contactor Line 1 9 41016 Alarm 1 10 41019 Fuse 300A 1 11 41061 Fuse 10A 1 12 11057 Screw socket M6X30 2 13 41007 Connector Anderson 1 14 11027 Screw socket M5X10 3 15 11045 W...

Page 52: ...1 31 11028 Screw socket M4X14 2 32 71214 Guide cable track 1 33 41020 Motor controller 1 34 11096 Screw socket M6X20 4 35A 41013 Block relay 1 35B 41050 Relay 2 36 41120 Motor electric 1 37 71244 Brea...

Page 53: ...ption Qty 1 11069 Bolt hex M10X50 8 2 11017 Washer lock 10 8 3 11019 Washer flat 10 8 4 71038 Mount wheel motor 2 5 41021 Motor drive 2 6 11075 Key square 2 7 11023 Washer flat 12 2 8 11044 Nut nylock...

Page 54: ...Steering Cylinder Assembly Parts List Item Part Description Qty 1 11032 Screw socket countersunk M6X12 2 2 31021 Weldment pin steering 2 3 71006 Bushing 12X17X12 2 4 71013 Tie rod steering 2 5 71017...

Page 55: ...Service Manual Item Part Description Qty 1 11073 Bolt hex M8X25 2 2 11030 Washer flat 8 2 3 11105 Pin retaining 2 4 11086 Pin scissor upper 1 5 11085 Pin scissor lower 1 Scissor Mount Diagram Scissor...

Page 56: ...4 15 January 26 2019 1530 ED Parts and Service Manual Scissor Arm Assembly Diagram PARTS SCISSOR STACK...

Page 57: ...1045 Arm outer 2 1 15 11090 Screw socket countersunk M8X16 2 16 71005 Stop arm 2 17 11073 Bolt hex M8X25 2 18 11030 Washer flat 8 2 19 31063 Weldment cylinder upper 1 20 31041 Arm inner 2 1 21 11039 B...

Page 58: ...ual Scissor Arm Assembly Parts List Continued Item Part Description Qty 37 11088 Screw pan head M4X12 8 38 41011 Switch limit 2 39 71247 Seal kit lift cylinder 51007 1 N S 41059 Switch pressure CE 1 N...

Page 59: ...4 18 January 26 2019 1530 ED Parts and Service Manual Platform Assembly Diagram PARTS PLATFORM...

Page 60: ...countersunk M5X10 16 13 11062 Hinge gate 2 14 31065 Weldment entry gate 1 15 71036 Latch gate 1 16 71022 Latch Stricker 1 17 31061 Weldment column right rear 1 18 11024 Bolt hex M8X50 2 19 31069 Weld...

Page 61: ...4 20 January 26 2019 1530 ED Parts and Service Manual Platform Extension Assembly Diagram PARTS PLATFORM...

Page 62: ...11026 Washer flat 6 8 10 11052 Nut nylock M6 4 11 71001 Stop slide 2 12 71016 Roller platform 2 13 31026 Weldment roller bracket left deck 1 14 11024 Bolt hex M8X50 8 15 11030 Washer flat 8 14 16 1107...

Page 63: ...agram Item Part Description Qty 1 41048 Joystick 1 2 71065 Box upper control housing only 1 3 21002 Decal upper control panel 1 4A 41001 Switch emergency stop 1 4B 41084 Base contact 1 4C 41057 Contac...

Page 64: ...MACHINE HAS BEEN CONSTRUCTED IN ACCORDANCE WITH SECTION 4 OF ANSI SIA A92 6 2006 AND WITH SECTION 4 OF CSA B354 4 02 268307 ELECT VOLTAGE MAX SIDE LOAD MAX PLAT HEIGHT MAX DRIVE HEIGHT POWER SUPPLY MA...

Page 65: ...4 24 January 26 2019 1530 ED Parts and Service Manual 268591 268603 ANSI CE AUS CSA 268518 ANSI CE AUS CSA Left Side View ANSI CE AUS CSA ANSI CE AUS CSA Right Side View PARTS SAFETY DECALS...

Page 66: ...attachment 4 14 268562 Decal 1530 platform side 2 15 268560 Decal GMG logo platform side 2 16 268557 Decal crushing pictorial 2 17 268626 M Decal crushing pictorial 4 18 268569 Decal electric drive 2...

Page 67: ...4 26 January 26 2019 1530 ED Parts and Service Manual NOTES...

Page 68: ...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 Global Machinery Group Inc...