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Section 5 - Procedures

5.3 TS200

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5.3-1 TS200 Pin Chart

PLUG

PIN

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

Not Used

Output to YV2 steer right valve

Input from pothole switches SO1 and SO2

Output to YV1 steer left valve

TS200

1330ED

1530ED micro

GMG

Содержание 1330-ED

Страница 1: ...SERVICE MANUAL 1330 1530 ED Part 81301 2 October 1 2021 Serial Range 2133001073 Current 2153001119 Current Global Machinery Group Inc...

Страница 2: ..._J 7 Please refer to the website www gogmg com for contact information other serial numbers the most recent technical manuals and USB software L...

Страница 3: ...hazardous situation which if not avoided will result in death or serious injury AwARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious inju...

Страница 4: ...Notes 4 1330ED 1530ED micro GMG...

Страница 5: ...structions 11 1 3 Owner s Annual Inspection Record 1 2 1 4 Frequent Periodic Annual Pre Delivery Inspection Checklist 1 3 1 5 General inspections 1 4 1 5 1 Service Bulletins B 14 1 5 2 Annual Inspecti...

Страница 6: ...s 4 2 4 2 6 No lift from base controls 4 2 4 2 7 No lower from base controls 4 3 4 2 8 No functions from platform controls 4 3 4 2 9 No lift lower from platform controls 4 3 4 2 1 0 No steer left 4 4...

Страница 7: ...kmanship for the first 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 ha...

Страница 8: ...oved from service until proper repairs are completed 8 Maintenance and Inspection Schedule 1 2 3 Maintenance and Service Safety Tips Maintenance and repair should only be performed by personnel who ar...

Страница 9: ...may indicate the possibility of imminent component failure A very small amount of fine particles is normal 5 All containers and funnels used in handling hydraulic oil must be absolutely clean Use a fu...

Страница 10: ...oked They are simply these 1 Change filters annually The filters will need to be changed more often depending on the operating conditions Dirty dusty high moisture environments may cause the hydraulic...

Страница 11: ...evel surface Disconnect the batteries by disconnecting the main power connectors Repair any damaged or malfunction components before operating MEWP Keep records on all inspections Section 1 Scheduled...

Страница 12: ...ths 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 It must be filled out after an annual inspection has...

Страница 13: ...Wheel Tire Assembly Do a check of all tires for damage wear correctly aligned Wheel Tire Assembly Wheel nuts torqued as recommended Axles Correctly attached no missing components Tight fittings and h...

Страница 14: ...on a firm level surface before you do the visual and daily maintenance inspections If you do not obey there is a risk of machine damage General inspections 1 5 1 Service Bulletins B Go to www gogmg co...

Страница 15: ...Only replace the tires with the same types that are approved by GMG The use of other tires can make the MEWP less stable If you do not obey there is a risk of death or serious injury Section 1 Schedul...

Страница 16: ...ners Make sure there is no visible damage 0 Steer linkages assembly B Make sure there are no loose or missing fasteners and lock pins Make sure that the steer linkages and bushings are correctly attac...

Страница 17: ...h the area with cold water and get medical aid 1 Do an inspection of the battery case for damage 2 Make sure all the battery connections are tight Section 1 Scheduled Maintenance AwARNING Only use ori...

Страница 18: ...hydraulic filler cap Add oil if it is necessary C Annual inspection Do a check of the hydraulic oil for contamination and make sure the filter is in good condition Replace the hydraulic oil and filte...

Страница 19: ...Make sure all the pins and fasteners are correctly installed Make sure that the cables and wires have the correct routing and show no signs of wear and or physical damage Section 1 Scheduled Maintena...

Страница 20: ...s of adjacent metals Dust or metal shaving from worn components Broken or missing pin retainer bolts Broken or missing pin retainers Rotated pin Elongated or enlarged pin hole 20 Lift mechanism inspec...

Страница 21: ...Lift mechanism inspection _____ Center Pin Outer I 1 I I I I Section 1 Scheduled Ma tenance 1 i I I 1 rl Center Pin Middle Center Pin Inner 21 1330ED 1530ED micro GMG...

Страница 22: ...ylinder mountarea Lift mechanism inspection 0 Cylinder mount inspection B This inspection must be done as part of the scissor assembly inspection 1 Do a structural inspection of the cylinder mount are...

Страница 23: ...tection anchorages are correctly installed Make sure there is no visible damage 0 0 AC power socket B Make sure there is no visible damage G Platform control console B Make sure that the control conso...

Страница 24: ......

Страница 25: ...Section 2 Maintenance Tables and Diagrams 25 1330ED 1530ED micro GMG...

Страница 26: ...3 8 12 1 2 13 Nm 68 47 102 75 149 108 ft lb 55 40 90 65 120 90 1 1 2 6 1 2 20 Nm 75 54 122 88 163 122 1 1 2 12 NOTE Lubed includes lubricants such as lubrizing oil grease or uncured Loctite 26 Torque...

Страница 27: ...0 Nm 301 226 ft lb 314 235 M20 X 2 50 Nm 426 319 ft lb 428 321 M22x2 50 Nm 580 435 ft lb 543 407 M24x3 00 Nm 736 552 ft lb 796 597 M27x3 00 Nm 1079 809 ft lb 1079 809 M30x3 50 Nm 1463 1097 ft lb 1468...

Страница 28: ...24 26 33 35 15 16 20 21 8 50 60 68 78 30 36 41 47 10 72 80 98 110 43 48 60 66 12 125 135 170 183 75 81 102 110 16 200 220 270 300 120 132 162 180 20 210 280 285 380 126 168 171 228 24 270 360 370 490...

Страница 29: ...50 39 in x29 92 in 1 8 m x0 76 m 70 87 in x29 92 in Height ANSI CE Working Height 6 23 m 20 ft5 23 in 6 4 m Platform Elevated Height 4 4 m 14 ft5 23 in 4 4 m Stowed Height Railings Down 1 59 m 62 60...

Страница 30: ...eight Unloaded platform no options attachments Max Maximum MEWP weight Platform loaded to capacity with options attachments Wheel is the weight that can be experienced on one wheel Note This is more t...

Страница 31: ...Section 3 System Component Identification and Schematics 31 1330ED 1530ED micro GMG...

Страница 32: ...entification and Schematics 3 1 Platform to Base Control Cable Note Unmarkedwiresorconnectorsorterminalsareself contained components Platform to Base Control Cable ot 1 1 2 ot 1 1 3 OIJ 11 4 JIJ 11 5...

Страница 33: ...Wiring Diagram Note 1 Unmarkedwires or connectors orterminalsare s f contained components 2 Externaldemandfortin 1330ED 1530ED micro GMG Section 3 System Component Identification and Schematics BATTER...

Страница 34: ...3 3 Ground Control Wiring Diagram Page 1 of 2 A B 1 2 V C Broke Bro e D SAi KEY SWITCH P V iB RELAY E G H 24V Z 1 24V Z 2 V 2 V 24V 24V P9 S w P9 3 P9 2 P9 8 X y z 1330ED 1530ED micro GMG 34...

Страница 35: ...round Control Wiring Diagram Page 2 of 2 A B D CHASSIS HARNESS 1l OTHO ESIIITCII GB tl Zl 4 GROUND HARNESS Ncte UrmcrkedlWt Sorameaorsamrinals reSElkmanedcanime E F G H V w X y z 1330ED 1530ED micro G...

Страница 36: ...memergencysltl 4 24V C D steerleftvalve P12 P9 8 P12 P12 PU 1 P12 1 DrivemOOllS TS200 E Buzzer HA1 allormmode Basemode P1 Hourmeter Leftmotorbrake l V5 Righlmcci rbrakevve 1 OffJPlatform Base Key swit...

Страница 37: ...3 6 Hydraulic Schematic Diagram A B C D E C1 LIFT CYLINDER C2 STEER CYLINDER L_______ I T 1 I I 12Mp I I RV1 I I I I l_J___________ F G H V w X y z 1330ED 1530ED micro GMG...

Страница 38: ...Notes 1330ED 1530ED micro GMG...

Страница 39: ...es that may occur If a specific trouble is not listed isolate the major component in which the trouble occurs isolate whether the problem is electrical or hydraulic and then isolate and correct the sp...

Страница 40: ...7 Loose or broken 24VA wire from contactor KM1 common to fuse F2 8 Fuse F2 defective or open 9 Loose or broken 24VB wire from fuse F2 to charger interupt 10 Open or defective charger interrupt 11 Loos...

Страница 41: ...oose or broken wire 24VB from Fuse F2 to power relay KA1 coil common 4 2 2 No Lift or Steer functions 1 Loose or broken M2 cable from TS200 machine controller to Pump motor M3 2 Defective Pump motor M...

Страница 42: ...er valve coil Replace coil 4 Loose or broken 24 wire from YV4 lower valve Check continuity Replace if defective coil to connector 12S01 pin 12 s Loose or broken 24 wire from connector 12P01 Check cont...

Страница 43: ...rm control box joystick 9 Loose or broken CAN H and or CAN L wires from Platform control box joystick to 7S02 pin 5 and 6 10 Loose or broken CAN H and or CAN L wires from connector 7S01 Pins 5 and 6 t...

Страница 44: ...connector 8P02 pin 6 to battery 5 Defective left steer switch or wiring on upper contol joystick 4 2 12 No drive 1 Defective platform control box wiring select switches and or Joystick 2 Loose or bro...

Страница 45: ...tery 9 Defective right and or left motor brake 10 Loose or defective wiring from TS200 machine controller M1 to right and or left drive motor 11 Loose or defective wiring from TS200 machine controller...

Страница 46: ...k valve CV1 stuck closed 4 3 2 No Lift function 1 Stuck or defective lift valve YV3 2 Check valve CV2 stuck closed 4 3 3 No Lower function 3 Stuck or defective lower valve YV3 4 Blocked lower orifice...

Страница 47: ...surface 2 Fully lower the machine 3 Push in the i emergency stop buttons on the platform control console and the base control console 4 Turn the off platform base key switch to the Q off position Remo...

Страница 48: ...nnect the EZCal Pro unit to the PC laptop that has the p t file intended for u load I 5 Upload pgt file onto the EZCal Pro Note do not create folders leave the file at the top level of the EZCal direc...

Страница 49: ...the name of the correct file being uploaded for the task Press the up IJlarrow to select YES Hit Enter Section 5 Procedures 13 The screen will update as the upload happens Depending on the size of th...

Страница 50: ...ft valve pg 2 Output to YV4 lower valve and hour meter P1 through diode D3 pg 3 Output to brake release pg 4 Not Used pg 5 Output to KM1 contactor and hour meter P1 through diode D4 pg 6 Not Used pg 7...

Страница 51: ...ot Used P12 9 Not Used P12 10 Input from lift cylinder prssure sensor PS1 P12 11 Not Used P12 12 Input from scissor angle height sensor AS1 PP2 2 P15 1 Input from Off Platform Base keyswitch SA1 Platf...

Страница 52: ...ntinuously flash quickly until it is set up and calibrations are performed Display Messages and Codes Display EZcal Display Message Code TS200 Description 1 X The TS200 has not been properly calibrate...

Страница 53: ...OCKED ARMGUARD CE figurable time see ADJUSTMENTS LIFT ARMGUARD to ONLY allow a safety check that no one is close to the vehicle The operator must release and then re select DOWN to continue lowering a...

Страница 54: ...to protect MOTOR OVERLOAD from extreme overload Check for short circuit power wiring check for a seized motor Here is a problem with battery supply the height and or pressure sensors the supply to th...

Страница 55: ...uit wiring check for loose eleva tion switch cam re calibrate height if necessary CANbus messages expected from one or more modules Platform controm box to TS200 are not being received or messages int...

Страница 56: ...ed out until you release then re select it The TS200 is ready to operate in platform mode when a tune EVERYTHING OK tion is selected NOTE If this is the HELP message when a function is se lected check...

Страница 57: ...YSTEM TEST ADJUSTMENTS SETUPS CALIBRATIONS SERIAL NUMBER help message LOGGED HELP Select this menu to see a description of current TS200 status Select this menu to see switch sensor input status logge...

Страница 58: ...estimated battery charge see SETUPS BATTERY NOTE BCI is also displayed on the platform control box Display Module Displays motor voltage of both motors will be equal unless steering Displays motor cur...

Страница 59: ...CASTERlock Displays YES when steer switch is pressed Cl UP Displays ON when BASE up switch pressed 0 a DOWN Displays ON when BASE down switch pressed Cl P12 1 Shows P12 1 input status BASE mode from k...

Страница 60: ...e output Select this sub menu to view feedback status of outputs Press eor e to turn on test mode which allows each output in this menu to be manually turned on off using eand e Displays voltage measu...

Страница 61: ...the forward direction when the joystick is at 100 demand in forward direction Determines the fastest drive speed in the reverse direction when the joystick is at 100 demand in reverse direction Determ...

Страница 62: ...height IMPORTANT If armguard function is not needed choose 101 to disable w UP Determines the fixed lifting speed in ground mode Cl 0 DOWN Determines the fixed lowering speed in ground mode Cl ACCEL...

Страница 63: ...cedures 5 3 5 Calibrate Load Procedure The TS200 control module requires calibration before it can estimate platform load calibration records the lift cylinder pressure at various platform heights bot...

Страница 64: ...S to a bigger time to increase the delay between each measurement 64 TS200 C When the UP switch is released the TS200 records the maximum height of the platform 10 The display now shows PLEASE LOWER A...

Страница 65: ...g stopping measuring lifting process will continue until the platform reaches full height then the UP switch can be released D The display shows TOTAL DATA xx to indicate the number of measurements ta...

Страница 66: ...BAD HEIGHTS During calibration the two height sensors disagreed too much F0B CHECK ELEV The ELEVATION switch P4 6 is closed with platform fully raised or the switch changed state more than once it sh...

Страница 67: ...0 After fully raising and fully lowering the platform during dynamic or static calibration we should F20 HEIGHT2 0 always be back at 0 height F22 HEIGHT1 100 After fully raising the platform during st...

Страница 68: ...ring static loaded or empty calibration the lift cylinder pressure is out of range below 0 4V or above 4 6V During dynamic calibration the elevation switch changed state closed to open or open to clos...

Страница 69: ...Notes 69 1330ED 1530ED micro GMG...

Страница 70: ...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...

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