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Introduction
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
maintenance procedure.
Technical Publications
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However,
continuous improvement of our products is a Genie
policy. Therefore, product specifications
are subject to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Printed in U.S.A.
INTRODUCTION
Model: GS-1930
Serial number: GS3005A-12345
Model year: 2005 Manufacture date: 04/12/05
Electrical schematic number: ES0141
Machine unladen weight: 2,714 lb / 1,231 kg
ANSI A92.6-1999
B354.2-01
Genie Industries
Serial number
18340 NE 76th Street (stamped on chassis)
Redmond, WA 98052
USA
PN - 77055
Serial label
(inside cover)
Safety Rules
Danger
Failure to obey the instructions and safety rules
in this manual and the appropriate Operator's
Manual on your machine will result in death or
serious injury.
Many of the hazards identified in the
operator’s manual are also safety hazards
when maintenance and repair procedures
are performed.
SAFETY RULES
Table of Contents
Introduction
Important Information ......................................................................................... ii
Serial Number Legend ...................................................................................... iii
TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS
REV D
Specifications
Machine Specifications Rough Terrain, foam-filled
Wheel lugs 6 @ 1/2 -20 Industrial, foam-filled (before serial number 41200)
SPECIFICATIONS REV D
Platform stowed 3.8 mph Hydraulic oil type Chevron Rykon MV equivalent
6.1 km/h Viscosity grade Multi-viscosity
40 ft / 7.2 sec Viscosity index 200
12.2 m / 7.2 sec
Cleanliness level, minimum 15/13
Platform raised 0.5 mph
0.8 km/h Water content, maximum 200 ppm
40 ft / 54.6 sec
Chevron Rykon MV oil is fully compatible and
12.2 m / 54.6 sec
mixable with Shell Donax TG (Dexron III) oils.
Braking distance, maximum Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
High range on paved surface less than 5 ft systems, have the ability to perform over a wide
less than 1.5 m temperature range, and the viscosity index should
exceed 140. They should provide excellent antiwear,
Gradeability oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
GS-2668 RT 40%
GS-3268 RT 35% Optional fluids
Function speed, maximum from platform controls Biodegradable Petro Canada Environ MV 46
(with maximum rated load in platform) Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
GS-2668 RT
Fire resistant UCON Hydrolube HP-5046
Platform up 28 to 32 seconds
Quintolubric 822
Platform down 33 to 37 seconds
Mineral based Shell Tellus T32
GS-3268 RT
Shell Tellus T46
Platform up 38 to 42 seconds Chevron Aviation A
Platform down 35 to 39 seconds
REV D SPECIFICATIONS
SPECIFICATIONS REV D
Oil capacity (including filter) 5.4 quarts Continuous improvement of our products is a
5.1 liters Genie policy. Product specifications are
subject to change without notice.
Oil viscosity requirements
REV D SPECIFICATIONS
SPECIFICATIONS REV D
Lubrication system
REV D SPECIFICATIONS
Valve clearances, cold 0.0057 to 0.0072 inches Ignition coil primary resistance 1.3 to 1.6Ω
0.145 to 0.085 mm @ 75°F / 24°C
Oil capacity (including filter) 3.9 quarts Spark plug type NGK BCP4ES-11
3.7 liters
Spark plug gap 0.039 to 0.043 inches
Oil viscosity requirements 1.0 to 1.1 mm
SPECIFICATIONS REV D
REV D SPECIFICATIONS
SPECIFICATIONS REV D
Size Class 4.6 4.6 Class 8.8 8.8 Class 10.9 10.9 Class 12.9 12.9
Maintenance Schedule
Indicates that tools will be required to
perform this procedure. There are five types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, semi-annually, annually, and
two year. The Scheduled Maintenance Procedures
Indicates that new parts will be required
Section and the Maintenance Inspection Report
to perform this procedure.
have been divided into five subsections—A, B, C,
D, and E. Use the following chart to determine
which group(s) of procedures are required to
Indicates that a cold engine will be perform a scheduled inspection.
required to perform this procedure.
Inspection Checklist
Fundamentals Instructions
It is the responsibility of the dealer to perform the Use the operator’s manual on your machine.
Pre-delivery Preparation.
The Pre-delivery Preparation consists of completing
The Pre-delivery Preparation is performed prior to the Pre-operation Inspection, the Maintenance items
each delivery. The inspection is designed to discover if and the Function Tests.
anything is apparently wrong with a machine before it
is put into service. Use this form to record the results. Place a check in
the appropriate box after each part is completed.
A damaged or modified machine must never be used. Follow the instructions in the operator’s manual.
If damage or any variation from factory delivered
condition is discovered, the machine must be tagged If any inspection receives an N, remove the machine
and removed from service. from service, repair and re-inspect it. After repair,
place a check in the R box.
Repairs to the machine may only be made by a
qualified service technician, according to the Legend
manufacturer's specifications. Y = yes, completed
Scheduled maintenance inspections shall be N = no, unable to complete
performed by qualified service technicians, according R = repaired
to the manufacturer's specifications and the Comments
requirements listed in the responsibilities manual.
Pre-Delivery Preparation Y N R
Pre-operation inspection
completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
REV C
Checklist A Procedures
A-1 3 Open the operator's manual to the decals
inspection section. Carefully and thoroughly
Inspect the Manuals and Decals inspect all decals on the machine for legibility
Genie specifications require that this procedure be and damage.
performed every 8 hours or daily, whichever Result: The machine is equipped with all
comes first. required decals, and all decals are legible and
Maintaining the operator’s and safety manuals in in good condition.
good condition is essential to safe machine Result: The machine is not equipped with all
operation. Manuals are included with each required decals, or one or more decals are
machine and should be stored in the container illegible or in poor condition. Remove the
provided in the platform. An illegible or missing machine from service until the decals are
manual will not provide safety and operational replaced.
information necessary for a safe operating
condition. 4 Always return the manuals to the storage
container after use.
In addition, maintaining all of the safety and
instructional decals in good condition is mandatory Note: Contact your authorized Genie distributor or
for safe machine operation. Decals alert operators Genie Industries if replacement manuals or decals
and personnel to the many possible hazards are needed.
associated with using this machine. They also
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could
result in unsafe operating conditions.
A-2 A-3
Perform Pre-operation Inspection Perform Function Tests
Genie specifications require that this procedure be Genie specifications require that this procedure be
performed every 8 hours or daily, whichever performed every 8 hours or daily, whichever
comes first. comes first.
Completing a Pre-operation Inspection is essential Completing the function tests is essential to safe
to safe machine operation. The Pre-operation machine operation. Function tests are designed to
Inspection is a visual inspection performed by the discover any malfunctions before the machine is
operator prior to each work shift. The inspection is put into service. A malfunctioning machine must
designed to discover if anything is apparently never be used. If malfunctions are discovered, the
wrong with a machine before the operator performs machine must be tagged and removed from
the function tests. The Pre-operation Inspection service.
also serves to determine if routine maintenance
procedures are required. Complete information to perform this procedure is
available in the appropriate operator's manual.
Complete information to perform this procedure is Refer to the Operator's Manual on your machine.
available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.
A-4 A-5
Perform Engine Maintenance Inspect the Engine Air Filter
Engine specifications require that this procedure Genie specifications require that this procedure be
be performed every 8 hours or daily, whichever performed every 40 hours or weekly, whichever
comes first. comes first.
Required maintenance procedures and additional Maintaining the engine air filter in good condition is
engine information is available in the essential to good engine performance and service
Kubota DF750 Operator's Manual life. Failure to perform this procedure can lead to
(Kubota part number EG261-8916-1) OR the poor engine performance and component damage.
Kubota DF752 Operator's Manual
(Kubota part number EG601-8916-1) OR the Perform this procedure with the engine off.
Kubota D905 Operator's Manual 1 Kubota D905 models: Pull up on the engine
(Kubota part number 16622-8916-5) OR the tray locking pin, located under the radiator on
Perkins 403C-11 User's Handbook the engine pivot tray. Swing the engine pivot
(Perkins part number 100816460). tray out and away from the machine for access.
2 Kubota D905 models: Remove the wingnut
Kubota DF750 Operator's Manual
securing the end cap to the air cleaner canister.
Genie part number 97359
Remove the end cap.
Kubota DF752 Operator's Manual All other models: Disconnect the retaining
Genie part number 84250 clamps securing the end cap to the air cleaner
canister. Remove the end cap.
Kubota D905 Operator's Manual
Genie part number 84240 3 Remove the air filter element.
4 Clean the inside of the air filter canister and the
Perkins 403C-11 User's Handbook canister gasket with a damp cloth.
Genie part number 97360
5 Inspect for and remove any blockage or debris
from the intake air passages.
9 Secure the end cap to the air cleaner cannister 1 Perform the following maintenance procedures:
with the retaining clamps. Kubota models:
10 Kubota D905 models: Swing the engine pivot · B-3 Inspect the Tires, Wheels and
tray back to its original position and make sure Lug Nut Torque
the engine tray locking pin locks into place.
· D-2 Replace the Hydraulic Tank
Return Filter
Perkins 403C-11 models:
· B-3 Inspect the Tires, Wheels and
Lug Nut Torque
· B-4 Perform Engine Maintenance -
Perkins 403C-11 Models
· C-4 Perform Engine Maintenance -
Diesel Models
· D-2 Replace the Hydraulic Tank
Return Filter
A-7 A-8
Perform Engine Maintenance - Perform Engine Maintenance -
Kubota D905 Models Kubota Models
Engine specifications require that this one time Engine specifications require that this procedure
procedure be performed after the first 50 hours of be performed every 50 hours or
operation. weekly, whichever comes first.
Required maintenance procedures and additional Required maintenance procedures and additional
engine information is available in the engine information is available in the
Kubota D905 Operator's Manual Kubota D905 Operator's Manual
(Kubota part number 16622-8916-5). (Kubota part number 16622-8916-5) OR the
Kubota DF750 Operator's Manual
(Kubota part number EG261-8916-1) OR the
Kubota D905 Operator's Manual
Genie part number 84240 Kubota DF752 Operator's Manual
(Kubota part number EG601-8916-1).
A-9 A-10
Perform Engine Maintenance - Perform Engine Maintenance -
Kubota Models Kubota Models
Engine specifications require that this procedure Engine specifications require that this procedure
be performed every 100 hours. be performed every 200 hours.
Required maintenance procedures and additional Required maintenance procedures and additional
engine information is available in the engine information is available in the
Kubota D905 Operator's Manual Kubota D905 Operator's Manual
(Kubota part number 16622-8916-5) OR the (Kubota part number 16622-8916-5) OR the
Kubota DF750 Operator's Manual Kubota DF750 Operator's Manual
(Kubota part number EG261-8916-1) OR the (Kubota part number EG261-8916-1) OR the
Kubota DF752 Operator's Manual Kubota DF752 Operator's Manual
(Kubota part number EG601-8916-1). (Kubota part number EG601-8916-1).
A-11 a b
REV D
Checklist B Procedures
B-1 6 Check the ambient air temperature and adjust
the specific gravity reading for each cell as
Inspect the Battery follows:
• Add 0.004 to the reading of each cell for
every 10° / 5.5° C above 80° F / 26.7° C.
Genie requires that this procedure be performed • Subtract 0.004 from the reading of each cell for
every 250 hours or quarterly, whichever comes every 10° / 5.5° C below 80° F / 26.7° C.
first.
Result: All battery cells display an adjusted
Proper battery condition is essential to good specific gravity of 1.277 or higher. The battery
machine performance and operational safety. is fully charged. Proceed to step 10.
Improper fluid levels or damaged cables and
Result: One or more battery cells display a
connections can result in component damage and
specific gravity of 1.217 or below. Proceed to
hazardous conditions.
step 7.
Electrocution hazard. Contact with 7 Perform an equalizing charge OR fully charge
electrically charged circuits could the batteries and allow the battery to rest at
result in death or serious injury. least 6 hours.
Remove all rings, watches and
other jewelry. 8 Remove the battery vent caps and check the
specific gravity of each battery cell with a
Bodily injury hazard. Batteries hydrometer. Note the results.
contain acid. Avoid spilling or
contacting battery acid. Neutralize 9 Check the ambient air temperature and adjust
battery acid spills with baking soda the specific gravity reading for each cell as
and water. follows:
1 Put on protective clothing and eye wear. • Add 0.004 to the reading of each cell for
every 10° / 5.5° C above 80° F / 26.7° C.
2 Be sure that the battery cable connections are
free of corrosion. • Subtract 0.004 from the reading of each cell for
every 10° / 5.5° C below 80° F / 26.7° C.
Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate corrosion Result: All battery cells display a specific gravity
on the battery terminals and cables. of 1.277 or greater. The battery is fully charged.
Proceed to step 10.
3 Be sure that the battery retainers and cable
connections are tight. Result: The difference in specific gravity
readings between cells is greater than 0.1 OR
4 Fully charge the battery. Allow the battery to the specific gravity of one or more cells is less
rest 24 hours before performing this procedure than 1.217. Replace the battery.
to allow the battery cells to equalize.
10 Check the battery acid level. If needed,
5 Remove the battery vent caps and check the replenish with distilled water to 1/8 inch / 3 mm
specific gravity of each battery cell with a below the bottom of the battery fill tube. Do not
hydrometer. Note the results. overfill.
11 Install the vent caps and neutralize any
electrolyte that may have spilled.
· Scissor arms
· Platform controls
2 Inspect for a liberal coating of dielectric grease
in the following locations:
· Between the ECM and platform controls
· All wire harness connectors
· Level sensor
B-3 B-4
Inspect the Tires, Wheels and Perform Engine Maintenance -
Lug Bolt Torque Perkins 403C-11 Models
B-5 B-6
Test the Key Switch Test the Emergency Stop
Genie requires that this procedure be performed Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes every 250 hours or quarterly, whichever comes
first. first.
Proper key switch action and response is essential A properly functioning Emergency Stop is essential
to safe machine operation. The machine can be for safe machine operation. An improperly
operated from the ground or platform controls and operating red Emergency Stop button
the activation of one or the other is accomplished will fail to shut off power and stop all machine
with the key switch. Failure of the key switch to functions, resulting in a hazardous situation.
activate the appropriate control panel could cause
a hazardous operating situation. Note: As a safety feature, selecting
and operating the ground controls will override the
1 Pull out the red Emergency Stop button to the platform controls, except the platform red
ON position at both the ground and platform Emergency Stop button.
controls.
1 Start the engine from ground controls.
2 Turn the key switch to platform control.
2 Push in the red Emergency Stop button to the
3 Check the platform up/down function from the off position.
ground controls.
Result: The engine should shut off and no
Result: The machine functions should not machine functions should operate.
operate.
3 Start the engine from platform controls.
4 Turn the key switch to ground control.
4 Push in the red Emergency Stop button to the
5 Check the machine functions from the platform off position.
controls.
Result: The engine should shut off and no
Result: The machine functions should not machine functions should operate.
operate. Note: The red Emergency Stop button at the
6 Turn the key switch to the OFF position. ground controls should stop all machine operation,
even if the key switch is switched to platform
Result: The engine should stop and no control.
functions should operate.
B-7
Test the Automotive-style Horn
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes
first.
Proper drive function movement is essential to 7 Raise the platform to full height.
safe machine operation. The drive function should 8 Fully extend the platform extension.
respond quickly and smoothly to operator control.
Drive performance should also be free of 9 Slowly move the joystick to the full drive
hesitation, jerking and unusual noise over the position.
entire proportionally controlled speed range. Result: The drive function should not operate.
1 Create start and finish lines by marking two 10 Lower the platform or retract the platform
lines on the ground 40 feet / 12.2 m apart. extension to drive.
2 Start the engine from the platform controls.
3 Raise the platform to approximately
6 feet / 2 m.
4 Choose a point on the machine; i.e., contact
patch of a tire, as a visual reference for use
when crossing the start and finish lines.
5 Bring the machine to maximum drive speed
before reaching the start line. Begin timing
when your reference point on the machine
crosses the start line.
B-13 B-14
Perform Hydraulic Oil Analysis Test the Flashing Beacons
(if equipped)
Genie requires that this procedure be performed
Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes
every 250 hours or quarterly, whichever comes first.
first.
Flashing beacons are used to alert operators and
Replacement or testing of the hydraulic oil is ground personnel of machine proximity and
essential for good machine performance and motion. The flashing beacons are located on both
service life. Dirty oil and a clogged suction strainer sides of the machine.
may cause the machine to perform poorly and
continued use may cause component damage. 1 Turn the key switch to ground control and pull
Extremely dirty conditions may require oil changes out the red Emergency Stop button to the on
to be performed more often. position at both the ground and platform
controls.
Note: Before replacing the hydraulic oil, the oil may
be tested by an oil distributor for specific levels of Result: The beacons should flash.
contamination to verify that changing the oil is 2 Turn the key switch to platform controls.
necessary. If the hydraulic oil is not replaced at
the two year inspection, test the oil quarterly. Result: The beacons should flash.
Replace the oil when it fails the test. See E-1,
Test or Replace the Hydraulic Oil.
B-15
Perform Engine Maintenance -
Kubota D905 Models
Torque specifications
C-4 C-5
Perform Engine Maintenance - Perform Engine Maintenance -
Diesel Models Kubota D905 and DF750 Models
Engine specifications require that this procedure Engine specifications require that this procedure
be performed every 500 hours. be performed every 800 hours.
Required maintenance procedures and additional Required maintenance procedures and additional
engine information is available in the engine information is available in the
Kubota D905 Operator's Manual Kubota D905 Operator's Manual
(Kubota part number 16622-8916-5) OR the (Kubota part number 16622-8916-5) OR the
Perkins 403C-11 User's Handbook Kubota DF750 Operator's Manual
(Perkins part number 100816460). (Kubota part number EG261-8916-1).
Genie requires that this procedure be performed 4 Measure the thickness of each platform scissor
every 1000 hours or annually, whichever comes arm wear pad at the non-steer end of the
first. machine.
Maintaining the scissor arm wear pads in good Result: The measurement is 5/16 inch / 8 mm or
condition is essential to safe machine operation. more.
Continued use of worn out wear pads may result in
component damage and unsafe operating Result: The measurement is less than
5/16 inch / 8 mm. Replace both wear pads.
conditions.
D-2 2 Apply a thin layer of fresh oil to the new oil filter
gasket.
Replace the Hydraulic Tank
3 Install the new filter and tighten it securely by
Return Filter hand.
4 Use a permanent ink marker to write the date
and number of hours from the hour meter on
Genie requires that this procedure be performed the filter.
every 1000 hours or annually, whichever comes
first. 5 Clean up any oil that may have spilled during
the replacement procedure.
Replacement of the hydraulic tank return filter is
6 Turn the key switch to ground controls and pull
essential for good machine performance and
out the red Emergency Stop button to the on
service life. A dirty or clogged filter may cause the
position at both the ground and platform
machine to perform poorly and continued use may
controls. Start the engine.
cause component damage. Extremely dirty
conditions may require that the filter be replaced 7 Raise the platform approximately 3 feet / 1 m.
more often.
8 Inspect the filter and related components to
Bodily injury hazard. Beware of be sure that there are no leaks.
hot oil. Contact with hot oil may
cause severe burns.
1 Remove the filter with an oil filter wrench. Clean
the area where the hydraulic oil filter meets the
filter head.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
Note: The hydraulic filter is mounted on the
hydraulic tank.
D-3 D-4
Perform Engine Maintenance - Perform Engine Maintenance -
Perkins 403C-11 Models Kubota DF752 Models
Engine specifications require that this procedure Engine specifications require that this procedure
be performed every 1000 hours. be performed every 1000 hours.
Required maintenance procedures and additional Required maintenance procedures and additional
engine information is available in the engine information is available in the
Perkins 403C-11 User's Handbook Kubota DF752 Operator's Manual
(Perkins part number 100816460). (Kubota part number EG601-8916-1).
D-5 D-6
Perform Engine Maintenance - Perform Engine Maintenance -
Kubota Models Kubota D905 Models
Engine specifications require that this procedure Engine specifications require that this procedure
be performed annually. be performed every 1500 hours.
Required maintenance procedures and additional Required maintenance procedures and additional
engine information is available in the engine information is available in the
Kubota D905 Operator's Manual Kubota D905 Operator's Manual
(Kubota part number 16622-8916-5) OR the (Kubota part number 16622-8916-5).
Kubota DF750 Operator's Manual
(Kubota part number EG261-8916-1) OR the Kubota D905 Operator's Manual
Kubota DF752 Operator's Manual Genie part number 84240
(Kubota part number EG601-8916-1).
E-3 E-4
Perform Engine Maintenance - Perform Engine Maintenance -
Gasoline/LPG Models Perkins 403C-11 Models
Engine specifications require that this procedure Engine specifications require that this procedure
be performed every two years. be performed every 3000 hours.
Required maintenance procedures and additional Required maintenance procedures and additional
engine information is available in the Kubota engine information is available in the
DF750 Operator's Manual (Kubota part number Perkins 403C-11 User's Handbook
EG261-8916-1) OR the Kubota DF752 Operator's (Perkins part number 100816460).
Manual (Kubota part number EG601-8916-1).
Perkins 403C-11 User's Handbook
Kubota DF750 Operator's Manual Genie part number 97360
Genie part number 97359
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey: Perform disassembly procedures to the point
where repairs can be completed. Then to
Repair procedures shall be completed by a
re-assemble, perform the disassembly steps in
person trained and qualified on the repair of this reverse order.
machine.
Symbols Legend
Immediately tag and remove from service a
damaged or malfunctioning machine. Safety alert symbol—used to alert
personnel to potential personal
Repair any machine damage or malfunction
injury hazards. Obey all safety
before operating the machine.
messages that follow this symbol
Before Repairs Start: to avoid possible injury or death.
Indicates an imminently hazardous
Read, understand and obey the safety rules
situation which, if not avoided, will
and operating instructions in the appropriate result in death or serious injury.
operator’s manual on your machine.
Indicates a potentially hazardous
Be sure that all necessary tools and parts are situation which, if not avoided,
available and ready for use. could result in death or serious
Use only Genie approved replacement parts. injury.
Indicates a potentially hazardous
Read each procedure completely and adhere
situation which, if not avoided,
to the instructions. Attempting shortcuts may
may cause minor or moderate
produce hazardous conditions.
injury.
Unless otherwise specified, perform each
Indicates a potentially hazardous
repair procedure with the machine in the situation which, if not avoided,
following configuration: may result in property damage.
· Machine parked on a firm, level surface
Indicates that a specific result is expected after
· Platform in the stowed position
performing a series of steps.
· Key switch in the off position with the key
removed Indicates that an incorrect result has occurred
after performing a series of steps.
· The red Emergency Stop button in the off
position at both ground and platform controls
· Wheels chocked
· All external AC power supply disconnected
from the machine
a alarm H1
b function enable/high speed select button for
platform up/down function BN12
c function enable/low speed select button for
platform up/down function BN13
d platform up/down toggle switch TS20 OR
platform up/down and outrigger up/down
toggle switch TS21
e circuit board U3
f DIP switch SW25
g joystick controller JC1
h potentiometer
i red Emergency Stop button P2
1-1 1-2
Circuit Boards Joystick Controller
How to Remove the Platform Maintaining the joystick at the proper setting is
essential to safe machine operation. The joystick
Controls Circuit Board should operate smoothly over its entire range of
1 Push in the red Emergency Stop button to the motion.
off position at both the ground and platform Machines after serial number GS6803-42381 are
controls. equipped with Hall-effect joysticks, which do not
2 Loosen the platform control box lid retaining require calibration.
fasteners. Open the control box and secure the
control box lid in a level position. How to Calibrate the Joystick
3 Visually locate the circuit board mounted to the
(before serial number GS6803-42382)
inside of the platform control box lid. Note: If the joystick is out of calibration, fault code
4 Tag and disconnect the wire connections from 30 will be present on the diagnostic display and the
the red Emergency Stop button. error indicator light will be illuminated at the
platform controls.
5 Tag and disconnect the wire harness
connectors from the platform controls circuit 1 Turn the key switch to platform control and pull
board. out the red Emergency Stop button to the ON
position at both the ground and platform
Electrocution hazard. Contact with controls.
electrically charged circuits could
result in death or serious injury. 2 Remove the platform control box lid retaining
Remove all rings, watches and fasteners. Open the control box lid.
other jewelry. Electrocution hazard. Contact with
Component damage hazard. electrically charged circuits could
Electrostatic discharge (ESD) can result in death or serious injury.
damage printed circuit board Remove all rings, watches and
components. Maintain firm contact other jewelry.
with a metal part of the machine
that is grounded at all times when
handling printed circuit boards OR
use a grounded wrist strap.
6 Remove the platform controls circuit board
retaining fasteners.
7 Remove the platform controls circuit board from
the platform control box lid.
3 Locate the potentiometer on the base of the 5 Loosen the set screw on the potentiometer
joystick. shaft just enough to allow the shaft to rotate.
6 With the joystick in the center or neutral
position, adjust the potentiometer shaft until
2.05V DC is displayed on the voltmeter. Tighten
the set screw.
7 Move the joystick full stroke in both directions
several times. Return the joystick to the center
position.
Result: The voltmeter should read 2.05V DC.
Result: If the voltmeter does not read
2.05V DC, repeat steps 5 through 8.
8 Turn the key switch to the off position.
9 Wait a few seconds and then turn the key
switch to platform control.
a joystick controller JC1 Result: The error indicator light on the top of the
b potentiometer shaft slot platform control box should not be illuminated
c potentiometer shaft set screw and code 30 should not be present on the
d platform controls circuit board U3
diagnostic display.
e potentiometer
f brown wire Result: If the error indicator light is illuminated
g purple wire
or if code 30 is present on the diagnostic
4 Using a volt meter set to read DC voltage, place display, repeat this procedure beginning with
the voltmeter negative lead on the purple wire. step 5.
Place the volt meter positive lead on the brown
10 Turn the key switch to the off position.
wire.
11 Close the lid and install the fasteners.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
20 AMP
Speed Stop
procedure. Stop
a
GS-2668 RT before serial number 26563 is
disabled when the platform is 20 feet / 6.1 m or b
higher while the platform is extended. The GS-
2668 RT after serial number 26562 is able to drive STOP
a
Models with outriggers: Press and hold the
horn button and the outrigger enable button,
then turn the key switch to platform controls.
Result: The diagnostic display window at the STOP
Speed Stop
STOP
a
platform controls.
Models with outriggers: Press and hold the
horn button and the outrigger enable button,
then turn the key switch to platform controls. STOP
Models before serial number GS6803-42382 can Note: If replacing the circuit board, use dielectric
be adjusted to a different configuration by changing grease on the DIP switch and all plug-in
the combination of the DIP switch settings, located connectors.
on the circuit board inside the platform control box.
1 Push in the red Emergency Stop button to the
DIP switches have two positions - on or off. When
off position at both the ground and platform
reading the DIP switch code in the DIP Switch
controls. Turn the key switch to the off position.
Codes Chart on the next page, the on and off are
represented by the numbers 1 (on) and 0 (off). 2 Remove the fasteners securing the lid of the
platform controls and open the platform control
How to Determine the DIP Switch box.
Configuration
1 Turn the key switch to ground control and pull Machine Option Definitions
out the red Emergency Stop buttons to the on
Descent Delay: This option halts descent at
position at both the ground and platform
approximately 12 feet / 3.6 m. All controls must be
controls.
released for 4 to 6 seconds before descent is re-
2 Move and hold the platform up/down toggle enabled. Required for Europe.
switch in the up direction and activate the Lift/Drive Cut Out: Lift and drive functions are
function enable toggle switch from the ground disabled when the down limit switch is activated
controls. and the machine is on a slope exceeding the rating
Result: The diagnostic display window located on the serial plate. Activated for all machines.
on the ground control panel, will display a Motion Alarm: The motion alarm will sound when
configuration number without the dot activating a function.
illuminated. This configuration number indicates Motion Beacons: The flashing beacons operate
the current configuration of the machine. only when activating a function.
Note: Configuration code that is less than 100 will Overload: This cuts out all functions when the
be shown as a constant display. Configuration platform overload pressure switch is tripped. The
code that is greater than 99 will be shown as a red Emergency Stop button must be cycled before
flashing display. any function can be resumed. Required for
Europe.
Sim Operation: When enabled, this allows some
machine functions to be activated simultaneously.
Required to be disabled for European models.
Beacons: When installed on the machine, the
flashing beacons operate continuously when the
key switch is turned to ground or platform controls
and both red Emergency Stop buttons are pulled
out to the on position.
3 Rotate the platform control box in the position 7 To confirm the settings, pull out the red
shown to correctly identify the configuration of Emergency Stop button to the on position at
the DIP switch settings. both the ground and platform controls and turn
the key switch to ground control. Do not start
the engine.
a
8 Move and hold the platform up/down toggle
f
switch in the up direction and activate the
function enable toggle switch from the ground
controls.
Result: The diagnostic display window located
e
on the ground control panel, will display a
configuration number without the dot
b illuminated. This configuration number indicates
the current configuration of the machine.
Note: Configuration code that is less than 100 will
be shown as a constant display. Configuration
code that is greater than 99 will be shown as a
flashing display.
c
SYSTEM
a
20 AMP
HOUR METER
ON DIP b
ON (1) d
Stop
Function
Enable
OFF (0)
1 2 3 4 5 6 7 8
No Simultaneous
Overload Sensor
Motion Beacon
Descent Delay
Gasoline/LPG
Motion Alarm
A • in the column indicate that the machine Diagnostic DIP
Operation
configuration includes this option. Display Switch
Code Code
Diesel
Lift/Drive Cut Out
No Simultaneous
Overload Sensor
Motion Beacon
Descent Delay
Gasoline/LPG
Motion Alarm
Operation
Display Switch
Code Code
50 10000000 • •
Diesel
52 01110001 • • •
53 10000001 • • •
55 01110010 • • •
01 01011010 • •
56 10000010 • •
02 00111010 • 58 10011111 • • •
04 01010001 • • 59 01111111 • • •
05 10100110 • • 61 01110111 • • •
07 01011011 • • 62 01111000 • • •
08 00111011 • • 64 10011000 • • • •
10 01010000 • • • 65 10011001 • • • •
11 10100111 • • • 67 01110011 • • • •
13 01010100 • • 68 10001011 • • • •
14 00110000 • • 70 10001101 • • • •
16 00100100 • • • 71 01111100 • • • •
17 10100100 • • • •
73 10011011 • • •
19 01011000 • • • 74 10000111 • • • •
20 00111000 • • • 76 01110100 • • • •
22 00101100 • • • • 77 10010011 • • • •
23 10101100 • • • • 79 01110110 • • • •
25 01010011 • • 80 00011010 • • • •
26 00110011 • • 82 10000100 • • • • •
28 00100101 • • • 83 10001100 • • • • •
29 10100101 • • • •
85 01110101 • • • •
31 01010111 • • • 86 10000110 • • • • •
32 00110111 • • • 88 10000101 • • • • •
34 00101001 • • • •
89 10011110 • • • •
35 10101001 • • • •
91 10001000 • • • •
37 01011100 • • • • 92 00011100 • • • • •
38 00111100 • • • • 94 01111011 • • • • • •
40 00101101 • • • • •
95 10011100 • • • • •
41 10101101 • • • •
43 01011111 • • • •
44 00111111 • • • •
46 00101111 • • • • •
47 10101111 • • • • •
No Simultaneous
Overload Sensor
No Simultaneous
Overload Sensor
Motion Beacon
Descent Delay
Motion Beacon
Gasoline/LPG
Descent Delay
Motion Alarm
Gasoline/LPG
Diagnostic DIP
Motion Alarm
Diagnostic DIP
Operation
Display Switch
Operation
Display Switch
Code Code
Diesel
Code Code
Diesel
97 00010000 • • 145 00111110 • • •
98 00010001 • • 146 01000000 • • •
100 00010011 • • • 148 01000010 • • • •
101 00010100 • • • 149 01000011 • • • •
103 00010110 • • • 151 01000101 • • • •
104 00010111 • • • 152 01000110 • • • •
106 00011001 • • • • 154 01001000 • • • •
107 01111010 • • • • 155 01001001 • • • •
109 00101000 • • • 157 01001011 • • • •
110 00011101 • • • 158 01001100 • • • •
112 00011111 • • • • 160 01001110 • • • • •
113 00000000 • • • • 161 01001111 • • • • •
115 00000010 • • • • 163 01010101 • • • • •
116 00000011 • • • • 164 01010110 • • • • •
118 00000101 • • • • • 166 01011101 • • • • •
119 00000110 • • • • • 167 01011110 • • • • •
121 00001000 • • • 169 01100001 • • • • •
122 00001001 • • • 170 01100010 • • • • •
124 00001011 • • • • 172 01100110 • • • • •
125 00001100 • • • • 173 01100111 • • • • •
127 00001110 • • • • 175 01101110 • • • • •
128 00001111 • • • • 176 10100000 • • • • •
130 00100001 • • • • 178 10100010 • • • • • •
131 00100010 • • • • 179 10100011 • • • • • •
133 00100110 • • • • • 181 10101010 • • • • • •
134 00100111 • • • • • 182 10101011 • • • • • •
136 00101011 • • • • • 184 10110000 • • • • • •
137 00101110 • • • • • 185 10110001 • • • • • •
139 00110010 • • • • • 187 10110011 • • • • • •
140 00110100 • • • • • 188 10110100 • • • • • •
142 00110110 • • • • • • 190 10110110 • • • • • • •
143 00111001 • • • • • • 191 10110111 • • • • • • •
17 Remove the retaining fasteners from the 4 Repeat steps 2 through 4 for the other side of
platform pivot pins at the non-steer end of the the platform.
machine. 5 Lift the platform extension lock handle.
18 Use a slide hammer to remove the pins. 6 Remove the two bolts that attach the platform
extension lock handle assembly to the platform
Crushing hazard. The platform will
extension railing.
fall when the pivot pins are
removed if not properly supported 7 Remove the two bolts that attach the extension
by the forklift. lock pin bracket to the railing. Lay the lock
handle assembly off to the side.
19 Carefully lift the platform off of the machine and
place it on a structure capable of supporting it. 8 Remove the platform extension limit switch
mounting fasteners and remove the limit switch.
Crushing hazard. The platform will Do not disconnect the wiring.
become unbalanced and fall when
removed from the machine if not 9 GS-2668 RT before serial number 26563 and
properly supported and secured to GS-3268 RT before serial number 41200:
the forklift. Remove the platform extension limit switch
mounting fasteners and remove the limit switch.
Note: Note the position of the wear pads before the Do not disconnect the wiring.
platform is removed so that when the platform is
installed they will be in the correct position. 10 Remove the platform controls from the platform
and lay them off to the side.
1 12
13
14
3 15
4 16
17
5
6 18
19
20
8 21
22
9
23
10
11
GS-2668
Steer End Non-steer End
1 Number 5 pivot pin (steer end) 13 Number 4 inner arm
2 Number 4 center pivot pin 14 Number 4 outer arm
3 Number 4 pivot pin (steer end) 15 Number 4 pivot pin (non-steer end)
4 Number 3 outer arm 16 Number 3 inner arm
5 Lift cylinder rod-end pivot pin 17 Number 3 center pivot pin
6 Number 3 pivot pin (steer end) 18 Number 3 pivot pin (non-steer end)
7 Number 2 center pivot pins (2 each) 19 Number 2 inner arm
8 Number 2 pivot pin (steer end) 20 Number 2 outer arm
9 Number 1 center pivot pin 21 Number 2 pivot pin (non-steer end)
10 Number 1 inner arm 22 Lift cylinder barrel-end pivot pin
11 Number 1 pivot pin(s) (steer end) 23 Number 1 outer arm
12 Number 5 pivot pin (non-steer end)
17 Remove the external snap rings from the 26 Remove the external snap rings from the
number 4 center pivot pin (index #2). number 3 center pivot pin (index #17) at the
ground controls side.
18 Use a soft metal drift to remove the number 4
center pivot pin (index #2). 27 Use a soft metal drift to tap the number 3 center
pivot pin (index #17) halfway out at the ground
19 Remove the external snap rings from the
controls side.
number 4 pivot pin (index #15) at the non-steer
end of the machine. 28 Remove the external snap rings from the
number 3 pivot pin (index #18) at the non-steer
20 Use a soft metal drift to remove the number 4
end.
pivot pin (index #15) from the non-steer end.
Remove the number 4 outer arm (index #14) 29 Use a soft metal drift to tap the number 3 pivot
from the machine. pin (index #18) halfway out at the non-steer end
of the machine. Remove the number 3 outer
Crushing hazard. The number 4
arm (index #4) at the ground controls side from
outer arm (index #14) could
the machine.
become unbalanced and fall if not
properly supported when removed Crushing hazard. The number 3
from the machine. outer arm (index #4) at the ground
controls side could become
21 Attach a lifting strap from an overhead crane to
unbalanced and fall if not properly
the number 4 inner arm (index #13).
supported when removed from the
22 Remove the external snap rings from the machine.
number 4 pivot pin (index #3).
30 Attach a lifting strap from an overhead crane to
23 Use a soft metal drift to remove the number 4 the number 3 outer arm (index #4) at the engine
pivot pin (index #3). Remove the number 4 side.
inner arm (index #13) from the machine.
31 Remove the external snap rings from the
Crushing hazard. The number 4 number 3 center pivot pin (index #17) at the
inner arm (index #13) could engine side.
become unbalanced and fall if not
32 Use a soft metal drift to tap the number 3 center
properly supported when removed
pivot pin (index #17) at the engine side in the
from the machine.
other direction.
24 Attach a lifting strap from an overhead crane to
33 Use a soft metal drift to tap the number 3 pivot
the number 3 outer arm (index #4) at the
pin (index #18) at the non-steer end in the other
ground controls side.
direction. Remove the number 3 outer arm
25 Support the number 3 inner arm (index #16) (index #4) from the engine side of the machine.
with a second overhead crane at the non-steer
Crushing hazard. The number 3
end.
outer arm (index #4) at the engine
side could become unbalanced
and fall if not properly supported
when removed from the machine.
34 Remove the cables from the lower cable tray. 43 Attach a lifting strap from an overhead crane to
Lay the cables off to the side of the machine. the number 2 outer arm (index #20) at the
ground controls side.
35 Remove the mounting fasteners from the lower
cable tray mounting bracket on the number 2 44 Support the number 2 inner arm (index #19)
center pivot pin (index #7) at the engine side of with a second overhead crane at the non-steer
the machine. end.
36 Remove the mounting fasteners from the lower 45 Remove the external snap rings from the
cable tray supports at both ends of the lower number 2 center pivot pin (index #7) at the
cable tray. ground controls side.
37 Remove the lower cable tray from the machine. 46 Use a soft metal drift to remove the number 2
center pivot pin (index #7) at the ground
Component damage hazard.
controls side.
Cables can be damaged if they
are kinked or pinched. 47 Remove the external snap rings from the
number 2 pivot pin (index #21) at the non steer
38 Attach a lifting strap from an overhead crane to
end.
the lug on the rod end of the lift cylinder.
48 Use a soft metal drift to tap the number 2 pivot
39 Remove the pin retaining fasteners from the
pin (index #21) halfway out at the non-steer end
cylinder rod-end pivot pin (index #5). Use a soft
of the machine. Remove the number 2 outer
metal drift to remove the pin.
arm (index #20) at the ground controls side
Crushing hazard. The cylinder from the machine.
could fall if not properly supported
Crushing hazard. The number 2
when the pin is removed.
outer arm (index #20) at the
40 Lower the cylinder onto the number 1 center ground controls side could
pivot pin (index #9). become unbalanced and fall if not
properly supported when removed
41 Remove the external snap rings from the from the machine.
number 3 pivot pin (index #6) at the steer end.
49 Attach a lifting strap from an overhead crane to
42 Use a soft metal drift to remove the number 3 the number 2 outer arm (index #20) at the
pivot pin (index #6) at the steer end. Remove engine side.
the number 3 inner arm (index #16) from the
machine. 50 Remove the external snap rings from the
number 2 center pivot pin (index #7) at the
Crushing hazard. The number 3 engine side.
inner arm (index #16) could
become unbalanced and fall if not 51 Use a soft metal drift to remove the number 2
properly supported when removed center pivot pin (index #7) at the engine side.
from the machine.
52 Use a soft metal drift to tap the number 2 pivot 57 Tag and disconnect the wiring from the solenoid
pin (index #21) at the non steer end in the other valve on the lift cylinder.
direction. Remove the number 2 outer arm
58 Remove the cables from the number 1 inner
(index #20) from the engine side of the
arm (index #10). Lay the cables off to the side
machine.
of the machine.
Crushing hazard. The number 2
Component damage hazard.
outer arm (index #20) at the
Cables can be damaged if they
engine side could become
are kinked or pinched.
unbalanced and fall if not properly
supported when removed from the 59 Remove the LPG tank.
machine.
60 Remove the LPG tank bracket mounting
53 Support the number 1 outer arm (index #23) fasteners. Remove the LPG tank bracket from
with a second overhead crane at the steer end. the machine.
54 Remove the external snap rings from the 61 Raise the scissor assembly slightly and return
number 2 pivot pin (index #8) at the steer end. the safety arm to the stowed position. Lower
the scissor assembly.
55 Use a soft metal drift to remove the number 2
pivot pin (index #8) at the steer end. Remove Crushing hazard. The scissor
the number 2 inner arm (index #19) from the assembly could become
machine. unbalanced and fall if not properly
supported when the safety arm is
Crushing hazard. The number 2
returned to the stowed position.
inner arm (index #19) could
become unbalanced and fall if not 62 Support and secure the entry ladder to an
properly supported when removed appropriate lifting device. Remove the entry
from the machine. ladder mounting fasteners. Remove the entry
ladder from the machine.
56 Tag, disconnect and plug the hydraulic hose on
the lift cylinder. Cap the fitting on the cylinder. Crushing hazard. The entry ladder
could become unbalanced and fall
Bodily injury hazard. Spraying
if not properly supported and
hydraulic oil can penetrate and
secured to the lifting device.
burn skin. Loosen hydraulic
connections very slowly to allow 63 Secure both ends of the scissor arms together
the oil pressure to dissipate with a strap or other suitable device.
gradually. Do not allow oil to squirt
or spray.
64 Attach each end of a lifting strap to each end of 71 Remove the pin retaining fasteners from the
the scissor assembly. cylinder barrel-end pivot pin (index #22). Use a
soft metal drift to remove the pin. Remove the
65 Attach an overhead crane to the center of the
cylinder from the scissor assembly.
strap.
Crushing hazard. The cylinder
66 Remove the pin retaining fasteners from the
could become unbalanced and fall
number 1 pivot pin(s) (index #11). Use a soft
if not properly supported when
metal drift to remove the pin(s).
removed from the assembly.
Crushing hazard. The scissor
72 Attach a lifting strap from an overhead crane to
assembly could fall if not properly
the number 1 outer arm (index #23).
supported by the overhead crane.
73 Support the number 1 inner arm (index #10)
67 Lift the scissor assembly slightly and slide the
with a second overhead crane.
scissor assembly towards the non-steer end of
the machine to allow the wear pads to slide out 74 Remove the external snap rings from the
of the channel. number 1 center pivot pin (index #9).
68 Remove the scissor assembly from the 75 Use a soft metal drift to remove the number 1
machine and place it on a structure capable of center pivot pin (index #9).
supporting it.
Crushing hazard. The scissor
Crushing hazard. The scissor assembly could become
assembly could become unbalanced and fall if not properly
unbalanced and fall if not properly supported when the center pivot
supported and secured to the pin is removed.
overhead crane.
76 Remove the number 1 outer arm (index #23)
Note: During removal, the lifting strap connected to from the assembly.
the overhead crane will need to be carefully
Crushing hazard. The number 1
adjusted for proper balancing.
inner arm (index #10) could
69 Remove the straps securing the scissor arms become unbalanced and fall if not
together. properly supported when removed
from the machine.
70 Attach a lifting strap from an overhead crane to
the lug on the rod end of the lift cylinder. Raise
the rod end of the cylinder to a vertical position.
1 16
2 17
3 18
4 19
20
5
21
6
22
7
8 23
9 24
10 25
26
11
27
12 28
13 29
14 30
15
GS-3268
Steer End Non-steer End
1 Number 6 pivot pin (steer end) 16 Number 6 pivot pin (non-steer end)
2 Number 5 center pivot pin 17 Number 5 inner arm
3 Upper lift cylinder rod-end pivot pin 18 Number 5 outer arm
4 Number 5 pivot pin (steer end) 19 Number 5 pivot pin (non-steer end)
5 Number 4 center pivot pins (2 each) 20 Number 4 inner arm
6 Number 4 pivot pin (steer end) 21 Number 4 outer arm
7 Number 3 outer arm 22 Number 4 pivot pin (non-steer end)
8 Number 3 center pivot pin 23 Upper lift cylinder barrel-end pivot pin
9 Lower lift cylinder rod-end pivot pin 24 Number 3 inner arm
10 Number 3 pivot pin (steer end) 25 Number 3 pivot pin (non-steer end)
11 Number 2 center pivot pins (2 each) 26 Number 2 inner arm
12 Number 2 pivot pin (steer end) 27 Number 2 outer arm
13 Number 1 center pivot pin 28 Number 2 pivot pin (non-steer end)
14 Number 1 inner arm 29 Lower lift cylinder barrel-end pivot pin
15 Number 1 pivot pin(s) (steer end) 30 Number 1 outer arm
12 Lower the cylinder onto the number 3 center 24 Raise the platform approximately 10 feet / 3 m.
pivot pin (index #8).
25 Lift the safety arm, move it to the center of the
13 Attach a lifting strap from an overhead crane to scissor arm and rotate down to a vertical
the number 5 inner arm (index #17). position. Lower the scissor assembly onto the
safety arm.
14 Remove the external snap rings from the
number 5 pivot pin (index #4). Crushing hazard. Keep hands
clear of the safety arm when
15 Use a soft metal drift to remove the number 5
lowering the platform.
pivot pin (index #4). Remove the number 5
inner arm (index #17) from the machine. 26 Turn the key switch to the off position and push
in the red Emergency Stop buttons to the off
Crushing hazard. The number 5
position at both the ground and platform
inner arm (index #17) could
controls.
become unbalanced and fall if not
properly supported when removed 27 Attach a lifting strap from an overhead crane to
from the machine. the number 4 outer arm (index #21) at the
ground controls side.
16 Remove the mounting fasteners from the upper
cable tray mounting bracket on the number 4 28 Support the number 4 inner arm (index #20)
center pivot pin (index #5) at the engine side of with a second overhead crane at the non-steer
the machine. end.
17 Remove the mounting fasteners from the upper 29 Remove the external snap rings from the
cable tray supports at both ends of the upper number 4 center pivot pin (index #5) at the
cable tray. ground controls side.
18 Remove the upper cable tray. 30 Use a soft metal drift to remove the number 4
center pivot pin (index #5) at the ground
19 Tag and disconnect the wiring from the solenoid
controls side.
valve on the lift cylinder.
31 Remove the external snap rings from the
20 Remove the safety arm from the number 4 inner
number 4 pivot pin (index #22) at the non-steer
arm (index #20).
end.
21 Install the safety arm on the number 2 inner arm
32 Use a soft metal drift to tap the number 4 pivot
(index #26) at the steer end of the machine.
pin (index #22) halfway out at the non-steer end
22 Connect the platform controls to the quick of the machine. Remove the number 4 outer
disconnect plug to allow the machine to arm (index #21) at the ground controls side
operate. from the machine.
23 Turn the key switch to ground control and pull Crushing hazard. The number 4
out the red Emergency Stop buttons to the on outer arm (index #21) at the
position at both the ground and platform ground controls side could
controls. Start the engine. become unbalanced and fall if not
properly supported when removed
from the machine.
33 Attach a lifting strap from an overhead crane to 40 Remove the pin retaining fasteners from the
the number 4 outer arm (index #21) at the upper cylinder barrel-end pivot pin (index #23).
engine side. Use a soft metal drift to remove the pin.
Remove the cylinder from the machine.
34 Remove the external snap rings from the
number 4 center pivot pin (index #5) at the Crushing hazard. The cylinder
engine side. could become unbalanced and fall
when removed from the machine if
35 Use a soft metal drift to remove the number 4
not properly supported.
center pivot pin (index #5) at the engine side.
Component damage hazard. Be
36 Use a soft metal drift to tap the number 4 pivot
careful not to damage the valve or
pin (index #22) in the other direction. Remove
fittings on the cylinder while
the number 4 outer arm (index #21) from the
removing it from the machine.
engine side of the machine.
41 Attach a lifting strap from an overhead crane to
Crushing hazard. The number 4
the number 3 outer arm (index #7) at the
outer arm at the engine side
ground controls side.
(index #21) could become
unbalanced and fall if not properly 42 Support the number 3 inner arm (index #24)
supported when removed from the with a second overhead crane at the non-steer
machine. end.
37 Remove the external snap rings from the 43 Remove the external snap rings from the
number 4 pivot pin (index #6) at the steer end number 3 center pivot pin (index #8) at the
of the machine. ground controls side.
38 Use a soft metal drift to remove the number 4 44 Use a soft metal drift to tap the number 3 center
pivot pin (index #6) at the steer end. Remove pivot pin (index #8) halfway out at the ground
the number 4 inner arm (index #20) from the controls side.
machine.
45 Remove the external snap rings from the
Crushing hazard. The number 4 number 3 pivot pin (index #25) at the non steer
inner arm (index #20) could end.
become unbalanced and fall if not
46 Use a soft metal drift to tap the number 3 pivot
properly supported when removed
pin (index #25) halfway out at the non-steer end
from the machine.
of the machine. Remove the number 3 outer
39 Attach a lifting strap from an overhead crane to arm (index #7) at the ground controls side from
the lug on the rod end of the upper lift cylinder. the machine.
Raise the rod end of the cylinder to a vertical
Crushing hazard. The number 3
position.
outer arm (index #7) at the ground
controls side could become
unbalanced and fall if not properly
supported when removed from the
machine.
47 Attach a lifting strap from an overhead crane to 57 Remove the pin retaining fasteners from the
the number 3 outer arm (index #7) at the engine lower cylinder rod-end pivot pin (index #9). Use
side. a soft metal drift to remove the pin.
48 Remove the external snap rings from the Crushing hazard. The cylinder
number 3 center pivot pin (index #8) at the could fall if not properly supported
engine side. when the pin is removed.
49 Use a soft metal drift to tap the number 3 center 58 Lower the cylinder onto the number 1 center
pivot pin (index #8) at the engine side in the pivot pin (index #13).
other direction.
59 Remove the external snap rings from the
50 Use a soft metal drift to tap the number 3 pivot number 3 pivot pin (index #10) at the steer end.
pin (index #25) at the non-steer end in the other
60 Use a soft metal drift to remove the number 3
direction. Remove the number 3 outer arm
pivot pin (index #10) at the steer end. Remove
(index #7) from the engine side of the machine.
the number 3 inner arm (index #24) from the
Crushing hazard. The number 3 machine.
outer arm (index #7) at the engine
Crushing hazard. The number 3
side could become unbalanced
inner arm (index #24) could
and fall if not properly supported
become unbalanced and fall if not
when removed from the machine.
properly supported when removed
51 Remove the cables from the number 3 inner from the machine.
arm (index #24). Lay the cables off to the side
61 Attach a lifting strap from an overhead crane to
of the machine.
the number 2 outer arm (index #27) at the
52 Remove the cables from the lower cable tray. ground controls side.
Lay the cables off to the side of the machine.
62 Support the number 2 inner arm (index #26)
53 Remove the mounting fasteners from the lower with a second overhead crane at the non-steer
cable tray mounting bracket on the number 2 end.
center pivot pin (index #11) at the engine side
63 Remove the external snap rings from the
of the machine.
number 2 center pivot pin (index #11) at the
54 Remove the mounting fasteners from the lower ground controls side.
cable tray supports at both ends of the lower
64 Use a soft metal drift to remove the number 2
cable tray.
center pivot pin (index #11) at the ground
55 Remove the lower cable tray from the machine. controls side.
Component damage hazard. 65 Remove the external snap rings from the
Cables can be damaged if they number 2 pivot pin (index #28) at the non steer
are kinked or pinched. end.
56 Attach a lifting strap from an overhead crane to
the lug on the rod end of the lower lift cylinder.
66 Use a soft metal drift to tap the number 2 pivot 73 Use a soft metal drift to remove the number 2
pin (index #28) halfway out at the non-steer end pivot pin (index #12) at the steer end. Remove
of the machine. Remove the number 2 outer the number 2 inner arm (index #26) from the
arm (index #27) at the ground controls side machine.
from the machine.
Crushing hazard. The number 2
Crushing hazard. The number 2 inner arm (index #26) could
outer arm (index #27) at the become unbalanced and fall if not
ground controls side could properly supported when it is
become unbalanced and fall if not removed from the machine.
properly supported when removed
74 Support and secure the entry ladder to an
from the machine.
appropriate lifting device. Then remove the
67 Attach a lifting strap from an overhead crane to entry ladder mounting fasteners. Remove the
the number 2 outer arm (index #27) at the entry ladder from the machine.
engine side.
Crushing hazard. The entry ladder
68 Remove the external snap rings from the could become unbalanced and fall
number 2 center pivot pin (index #11) at the if not properly supported and
engine side. secured to the lifting device.
69 Use a soft metal drift to remove the number 2 75 Disconnect and plug the hydraulic hose on the
center pivot pin (index #11) at the engine side. lift cylinder. Cap the fitting on the cylinder.
70 Use a soft metal drift to tap the number 2 pivot Bodily injury hazard. Spraying
pin (index #28) at the non-steer end in the other hydraulic oil can penetrate and
direction. Remove the number 2 outer arm burn skin. Loosen hydraulic
(index #27) from the engine side of the connections very slowly to allow
machine. the oil pressure to dissipate
gradually. Do not allow oil to squirt
Crushing hazard. The number 2 or spray.
outer arm (index #27) at the
engine side could become 76 Tag and disconnect the wiring from the solenoid
unbalanced and fall if not properly valve on the lift cylinder.
supported when removed from the
77 Remove the cables from the number 1 inner
machine.
arm (index #14). Lay the cables off to the side
71 Support the number 1 outer arm (index #30) of the machine.
with a second overhead crane at the steer end.
78 Remove the LPG tank.
72 Remove the external snap rings from the
79 Remove the LPG tank bracket mounting
number 2 pivot pin (index #12) at the steer end.
fasteners. Remove the LPG tank bracket from
the machine.
80 Raise the scissor assembly slightly and return 87 Remove the straps securing the scissor arms
the safety arm to the stowed position. Lower together.
the scissor assembly. Remove the straps.
88 Attach a lifting strap from an overhead crane to
Crushing hazard. The scissor the lug on the rod end of the lower lift cylinder.
assembly could become Raise the rod end of the cylinder to a vertical
unbalanced and fall if not properly position.
supported when the safety arm is
89 Remove the pin retaining fasteners from the
returned to the stowed position.
lower cylinder barrel-end pivot pin (index #29).
81 Secure both ends of the scissor arms together Use a soft metal drift to remove the pin.
with a strap or suitable device. Remove the cylinder from the scissor
assembly.
82 Attach each end of a lifting strap of ample
capacity to each end of the scissor assembly. Crushing hazard. The cylinder
could become unbalanced and fall
83 Attach an overhead crane to the center of the
if not properly supported when
strap.
removed from the assembly.
84 Remove the pin retaining fasteners from the
90 Attach a lifting strap from an overhead crane to
number 1 pivot pin(s) (index #15). Use a soft
the number 1 outer arm (index #30).
metal drift to remove the pin(s).
91 Support the number 1 inner arm (index #14)
Crushing hazard. The scissor
with a second overhead crane.
assembly could fall if not properly
supported by the overhead crane. 92 Remove the external snap rings from the
number 1 center pivot pin (index #13).
85 Lift the scissor assembly slightly and slide the
scissor assembly towards the non-steer end of 93 Use a soft metal drift to remove the number 1
the machine to allow the wear pads to slide out center pivot pin (index #13).
of the channel.
Crushing hazard. The scissor
86 Remove the scissor assembly from the assembly could become
machine and place it on a structure capable of unbalanced and fall if not properly
supporting it. supported when removed from the
machine.
Crushing hazard. The scissor
assembly could become 94 Remove the number 1 outer arm (index #30)
unbalanced and fall if not properly from the assembly.
supported and secured to the
Crushing hazard. The number 1
overhead crane.
outer arm (index #30) could
Note: During removal, the lifting strap connected to become unbalanced and fall if not
the overhead crane will need to be carefully properly supported when removed
adjusted for proper balancing. from the machine.
3-3 8 Turn the key switch to the off position and push
in the red Emergency Stop buttons to the off
Wear Pads position at both the ground and platform
controls.
How to Replace the Scissor Arm 9 Secure both ends of the scissor arms together
Wear Pads with a strap or other suitable device.
1 Remove the platform. See 2-1, How to Remove 10 Attach a strap from an overhead crane to the
the Platform. non-steer end of the scissor arms.
2 Remove the mounting fasteners from the 11 Raise the scissor arms slightly at the non-steer
stationary wear pads on the platform. end with the overhead crane just enough to
take the pressure off of the non-steer end slide
Note: Pay attention to the position of the wear pads
blocks.
before they are removed so when the new ones
are installed they will be in the correct position. 12 Remove the pin retaining fasteners from the
slide block pivot pin.
3 Connect the platform controls to the quick
disconnect plug to allow the machine to 13 Place a rod through the pin and twist to remove
operate. the pin.
4 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls. Start the engine.
5 Raise the platform approximately 10 feet / 3 m.
6 Lift the safety arm, move it to the center of the
scissor arm and rotate down to a vertical
position.
7 Lower the scissor arms onto the safety arm. 14 Remove the slide block and remove the wear
pad mounting fasteners.
Crushing hazard. Keep hands
clear of the safety arm when 15 Install the new wear pad.
lowering the scissor arms. 16 Repeat steps 12 through 15 for the other wear
pad slide block.
17 Install the wear pad slide blocks into the drive
chassis and install the slide block pivot pins and
pin retaining fasteners.
12 Carefully pull the lift cylinder out the non-steer 4 Tag and disconnect the wiring from the solenoid
end of the machine through the scissor arms. valve at the barrel end of the lift cylinder.
Crushing hazard. The lift cylinder 5 Tag, disconnect and plug the hydraulic hose
could become unbalanced and fall from the lift cylinder. Cap the fitting on the
if not properly supported when cylinder.
removed from the machine. Bodily injury hazard. Spraying
Component damage hazard. Be hydraulic oil can penetrate and
careful not to damage the valve or burn skin. Loosen hydraulic
fittings on the cylinder while connections very slowly to allow
removing it from the machine. the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
REV D
Kubota D905 Engine
4-1 4-3
Timing Adjustment Engine RPM
Complete information to perform this procedure is How to Adjust the RPM
available in the Kubota D905 Workshop Manual
(Kubota part number 97897-02432). 1 Start the engine from the ground controls.
2 Hold the start toggle switch to the start position
Kubota D905 Workshop Manual and check the engine RPM on the diagnostic
Genie part number 31742 display. Refer to Section 2, Specifications.
Proceed to step 4 if the low idle is correct.
3 To correct the low idle speed, loosen the lock
nut, then turn the low idle adjustment screw
4-2 clockwise to increase the rpm or
Glow Plugs counterclockwise to decrease the rpm. Tighten
the lock nut and recheck the rpm.
How to Check the Glow Plugs a b
5 Connect the red positive (+) lead from a volt 5 Hold the start toggle switch to the start position
meter to the number three glow plug. Connect and check the engine RPM on the diagnostic
the black negative (-) lead to ground. display. Refer to Section 2, Specifications.
6 Hold the glow plug switch in the on position. 6 To correct the high idle speed, loosen the lock
nut on the solenoid, then turn the solenoid boot
Result: The volt meter should read 12V DC or counterclockwise to increase the rpm or
more. clockwise to decrease the rpm. Tighten the lock
nut and recheck the rpm.
a pump
How to Repair the Kubota b pump shaft
c pump coupler
D905 Engine d flex plate
e flywheel
Repair procedures and additonal engine f 1/32 inch / 0.8 mm gap
information are available in the
Kubota D905 Operator's Manual
(Kubota part number 16622-8916-5) OR the
Kubota D905 Workshop Manual
(Kubota part number 97897-00870).
4-5 a b
How to Replace the Coolant 2 Tag and disconnect the wiring from the switch.
Remove the switch from the engine.
Temperature and Oil Pressure
Switches Bodily injury hazard. Contact with
hot engine fluids or components
1 Open the engine side cover and pull up on the may cause severe burns.
lock pin on the engine pivot tray located under
3 Install the new switch and tighten. Torque
the radiator. Swing the engine pivot tray out and
to 8-18 ft-lbs / 11-24 Nm.
away from the machine to access both
switches. Note: Always use pipe thread sealant when
installing a new switch.
5-1 5-3
Timing Adjustment - Choke Adjustment -
Gasoline/LPG Models Gasoline/LPG Models
Note: The ignition timing cannot be adjusted. The The choke is solenoid-operated and functions only
timing adjustment screw is factory sealed with a in the gasoline mode. The choke will not operate in
tamper resistant cap installed by the manufacturer. LPG mode.
If service or repair is needed, contact your local
Kubota dealer.
5-4
Flex Plate
5-2
Carburetor Adjustment - See 4-4, Flex Plate.
Gasoline/LPG Models
Note: The carburetor cannot be adjusted. The
carburetor mixture screws are factory sealed with 5-5
tamper resistant caps installed by the Coolant Temperature and Oil
manufacturer. If service or repair is needed,
contact your local Kubota dealer.
Pressure Switches
See 4-5, Coolant Temperature and Oil Pressure
Switches.
5-6 a b c d
Engine RPM
Note: Perform this procedure in gasoline mode 4 Move the engine idle control switch to high idle
with the engine at normal operating temperature. (rabbit symbol) from the ground controls.
1 Start the engine from the ground controls. 5 Hold the start toggle switch to the start position
and check the engine RPM on the diagnostic
2 Hold the start toggle switch to the start position display. Refer to Section 2, Specifications.
and check the engine RPM on the diagnostic
display. Refer to Section 2, Specifications. 6 To correct the high idle speed, loosen the yoke
Proceed to step 4 if the low idle is correct. lock nut on the high idle solenoid, then turn the
high idle adjustment nut and solenoid boot
3 To correct the low idle speed, turn the low idle counterclockwise to increase the rpm or
adjustment screw on the carburetor clockwise clockwise to decrease the rpm. Tighten the
to increase rpm or counterclockwise to yoke lock nut and recheck the rpm.
decrease rpm.
Note: Be sure the solenoid fully retracts when
activating high idle.
6-1 6-2
Engine RPM Timing Adjustment
a solenoid
b yoke locknut
c yoke
d low idle lock nut
e low idle adjustment screw
g
7 To adjust, loosen the upper lock nut on the
cable mounting bracket. Turn the lower lock nut AE
clockwise to decrease the distance or
a manual lowering cable sheath
counterclockwise to increase the distance. b upper lock nut
c cable mounting bracket
d lower lock nut
e cable mounting nut
f end of the lowering cable
g manual lowering valve
(hydraulic schematic item AE)
Models with software revision B1 or lower: 6 Use the yellow platform down arrow to scroll to
max high torque drive.
1 Pull out the red Emergency Stop button to the
Result: MAX HIGH TORQUE DRIVE is showing in the
on position at the platform controls.
diagnostic display window.
2 Push in the red Emergency Stop button to the
7 Press the lift function enable button.
off position at the ground controls.
8 Press the yellow platform down button to
3 Turn the key switch to ground control.
decrease the drive speed or press the blue
platform up button to increase the drive speed.
Refer to Section 2, Specifications.
9 Press the lift function enable button.
10 Push in the red Emergency Stop button to the
off position at the ground controls.
How to b
a
Adjust the Raised Drive Speed
c
Tip-over hazard. Do not adjust the
lift and/or drive speed higher than
specified in this procedure. Setting d
drive speed greater than
specifications could cause the a diagnostic display
machine to tip over resulting in b blue platform up button
death or serious injury. c lift function enable button
d yellow platform down button
Note: On machines with software revision B1 or
5 Press the lift function enable button.
lower, raised drive speeds in forward and reverse
are simultaneously adjusted, resulting in both 6 Use the yellow platform down arrow to scroll to
directions of travel operating at the same speed. raised drive speed.
On machines with software revision C0 or higher,
the raised forward drive speed and the raised Result: MAX RAISED DRIVE SPEED is showing in the
reverse drive speed may be adjusted independent diagnostic display window.
of one another. See 7-2, How to Determine the 7 Press the lift function enable button.
Revision Level.
8 Press the yellow platform down button to
Models with software revision B1 or lower: decrease the raised drive speed or press the
blue platform up button to increase the raised
1 Pull out the red Emergency Stop button to the
drive speed. Refer to Section 2, Specifications.
on position at the platform controls.
9 Press the lift function enable button.
2 Push in the red Emergency Stop button to the
off position at the ground controls. 10 Push in the red Emergency Stop button to the
off position at the ground controls.
3 Turn the key switch to ground control.
11 Check the raised drive speed of the machine.
4 Press and hold both the blue platform up and
Refer to the Maintenance procedure B-11, Test
yellow platform down buttons. Pull out the red
the Drive Speed - Raised Position.
Emergency Stop button to the on position at the
ground controls.
Result: TUNE SPEEDS is showing in the diagnostic
display window. The ECM is now in
programming mode.
a diagnostic display
b blue platform up button
c lift function enable button
d yellow platform down button
4 Use the yellow platform down arrow to scroll to 9 Press the lift function enable button to activate
select options. or deactivate the motion beacon option.
Result: SELECT OPTIONS is showing in the Note: For this option to function correctly, the
diagnostic display window. The ECM is now in machine must be equipped with flashing beacons.
programming mode.
10 Models with platform overload (option): Use
5 Press the lift function enable button. the yellow platform down arrow to scroll to
overload.
Result: DESCENT DELAY is showing in the
diagnostic display window. Press the lift Result: OVERLOAD ON is showing in the diagnostic
function enable button to activate or deactivate display window.
the descent delay option.
Result: OVERLOAD OFF is showing in the
6 Models with software revisions F0, E0, D0 diagnostic display window. Press the lift
and lower: Use the yellow platform down arrow function enable button to activate the overload
to scroll to lift/drive cutout. option.
Result: LFT/DRV CUTOUT ON is showing in the 11 Use the yellow platform down arrow to scroll to
diagnostic display window. sim operation.
Result: LFT/DRV CUTOUT OFF is showing in the Result: SIM OPERATION ON is showing in the
diagnostic display window. Press the lift diagnostic display window.
function enable button to activate the lift/drive
cutout option. Result: SIM OPERATION OFF is showing in the
diagnostic display window. Press the lift
Note: The lift/drive cutout option should be function enable button to activate the sim
activated or in the ON position. operation option.
7 Use the yellow platform down arrow to scroll to Note: For all models except CE, the sim operation
motion alarm. option should be activated or in the ON position.
Result: MOTION ALARM is showing in the Models with software revisions E0, D0 or lower,
diagnostic display window. proceed to step 12.
Models with software revisions F0 and higher,
8 Press the lift function enable button to activate
proceed to step 15.
or deactivate the motion alarm option OR use
the yellow platform down arrow to scroll to
motion beacon.
Result: MOTION BEACON is showing in the
diagnostic display window.
12 Use the yellow platform down arrow to scroll to 16 Use the yellow platform down arrow to scroll to
beacons option. generator option.
Result: BEACONS AUTO is showing in the Result: GENERATOR OFF is showing in the
diagnostic display window. Press the lift diagnostic display window. Press the lift
function enable button to activate or deactivate function enable button to activate or deactivate
the beacons option. the generator option.
Note: For this option to function, the machine must Note: For this option to function correctly, the
be equipped with flashing beacons and the machine must be equipped with the required
software set to BEACONS AUTO or BEACONS ON. generator components.
13 Use the yellow platform down arrow to scroll to 17 Use the yellow platform down arrow to scroll to
generator option. outriggers option.
Result: GENERATOR AUTO is showing in the Result: OUTRIGGERS OFF is showing in the
diagnostic display window. Press the lift diagnostic display window. Press the lift
function enable button to activate or deactivate function enable button to activate or deactivate
the generator option. the outrigger option.
Note: For this option to function correctly, the Note: For this option to function correctly, the
machine must be equipped with the required machine must be equipped with the required
generator components and the software set to outrigger components.
GENERATOR AUTO or GENERATOR ON.
ANSI and CSA models with
14 Use the yellow platform down arrow to scroll to all software revisions:
outriggers option.
18 Use the yellow platform down arrow to scroll to
Result: OUTRIGGERS AUTO is showing in the return to the main menu.
diagnostic display window. Press the lift
function enable button to activate or deactivate Result: RETURN TO MAIN MENU is showing in the
the outrigger option. Proceed to step 18. diagnostic display window.
Note: For this option to function correctly, the 19 Press the lift function enable button.
machine must be equipped with the required Result: SELECT OPTIONS is showing in the
outrigger components and the software set to diagnostic display window.
OUTRIGGERS AUTO or OUTRIGGERS ON.
20 Push in the red Emergency Stop button to the
15 Use the yellow platform down arrow to scroll to off position at the ground controls.
beacons option.
Result: BEACONS OFF is showing in the diagnostic
display window. Press the lift function enable
button to activate or deactivate the beacons
option.
Note: For this option to function, the machine must
be equipped with flashing beacons.
CE models with all software revisions: 5 Press the lift function enable button.
1 Turn the key switch to ground controls and pull Result: DESCENT DELAY ON is showing in the
out the red Emergency Stop buttons to the on diagnostic display window.
position at both platform and ground controls.
Result: DESCENT DELAY OFF is showing in the
Result: The revision level of the ECM will diagnostic display window. Press the lift
appear in the LED display window. Note the function enable button to activate the descent
result. delay option.
2 Push in the red Emergency Stop button to the Note: For CE models, the descent delay option
off position at the ground controls. should be activated or in the ON position.
3 Press and hold both the blue platform up and 6 Models with software revisions F0, E0, D0
yellow platform down buttons. Pull out the red and lower: Use the yellow platform down arrow
Emergency Stop button to the on position at the to scroll to lift/drive cutout.
ground controls. Result: LFT/DRV CUTOUT ON is showing in the
Result: TUNE SPEEDS is showing in the diagnostic diagnostic display window.
display window. Result: LFT/DRV CUTOUT OFF is showing in the
diagnostic display window. Press the lift
a b function enable button to activate the lift/drive
cutout option.
c
Note: The lift/drive cutout option should be
activated or in the ON position.
d
7 Use the yellow platform down arrow to scroll to
a diagnostic display motion alarm.
b blue platform up button
c lift function enable button
Result: MOTION ALARM is showing in the
d yellow platform down button diagnostic display window.
4 Use the yellow platform down arrow to scroll to 8 Press the lift function enable button to activate
select options. or deactivate the motion alarm option OR use
the yellow platform down arrow to scroll to
Result: SELECT OPTIONS is showing in the motion beacon.
diagnostic display window. The ECM is now in
programming mode. Result: MOTION BEACON is showing in the
diagnostic display window.
9 Press the lift function enable button to activate 12 Use the yellow platform down arrow to scroll to
or deactivate the motion beacon option. beacons option.
Note: For this option to function correctly, the Result: BEACONS AUTO is showing in the
machine must be equipped with flashing beacons. diagnostic display window. Press the lift
function enable button to activate or deactivate
10 Use the yellow platform down arrow to scroll to the beacons option.
overload.
Note: For this option to function, the machine must
Result: OVERLOAD ON is showing in the diagnostic be equipped with flashing beacons and the
display window. software set to BEACONS AUTO or BEACONS ON.
Result: OVERLOAD OFF is showing in the
13 Use the yellow platform down arrow to scroll to
diagnostic display window. Press the lift
generator option.
function enable button to activate the overload
option. Result: GENERATOR AUTO is showing in the
diagnostic display window. Press the lift
Note: For CE models, the overload option should
function enable button to activate or deactivate
be activated or in the ON position.
the generator option.
11 Use the yellow platform down arrow to scroll to Note: For this option to function correctly, the
sim operation. machine must be equipped with the required
Result: SIM OPERATION OFF is showing in the generator components and the software set to
diagnostic display window. GENERATOR AUTO or GENERATOR ON.
Result: SIM OPERATION ON is showing in the 14 Use the yellow platform down arrow to scroll to
diagnostic display window. Press the lift outriggers option.
function enable button to deactivate the sim
Result: OUTRIGGERS AUTO is showing in the
operation option.
diagnostic display window. Press the lift
Note: For CE models, the sim operation option function enable button to activate or deactivate
should be deactivated or in the OFF position. the outrigger option. Proceed to step 18.
Models with software revisions E0, D0 or lower, Note: For this option to function correctly, the
proceed to step 12. machine must be equipped with the required
Models with software revisions F0 and higher, outrigger components and the software set to
proceed to step 15. OUTRIGGERS AUTO or OUTRIGGERS ON.
15 Use the yellow platform down arrow to scroll to CE models with all software revisions:
beacons option.
18 Use the yellow platform down arrow to scroll to
Result: BEACONS OFF is showing in the diagnostic return to the main menu.
display window. Press the lift function enable
button to activate or deactivate the beacons Result: RETURN TO MAIN MENU is showing in the
option. diagnostic display window.
Note: For this option to function, the machine must 19 Press the lift function enable button.
be equipped with flashing beacons. Result: SELECT OPTIONS is showing in the
diagnostic display window.
16 Use the yellow platform down arrow to scroll to
generator option. 20 Push in the red Emergency Stop button to the
Result: GENERATOR OFF is showing in the off position at the ground controls.
diagnostic display window. Press the lift
function enable button to activate or deactivate
the generator option.
Note: For this option to function correctly, the
machine must be equipped with the required
generator components.
17 Use the yellow platform down arrow to scroll to
outriggers option.
Result: OUTRIGGERS OFF is showing in the
diagnostic display window. Press the lift
function enable button to activate or deactivate
the outrigger option.
Note: For this option to function correctly, the
machine must be equipped with the required
outrigger components.
MODELS
WITHOUT
a
OUTRIGGERS
d
Y
b X c
BEFORE
SERIAL NUMBER
41200
17 Connect the wire harness to the level sensor. 31 Before serial number 41137: Raise the
platform at least 12 feet / 3.6 m.
18 Pull out the red Emergency Stop button to the
on position at the platform controls. Result - ANSI and CSA models: The tilt alarm
will sound at 180 beeps per minute.
19 Tighten the level sensor adjusting fasteners
until the bubble in the top of the level sensor is Result - CE and Australian models: The drive
centered in the circles. function and the lift function will not operate and
the tilt alarm will sound at 180 beeps per
Note: Be sure there are threads showing through
minute.
the top of the adjusting fasteners.
Result: If the tilt sensor alarm does not sound,
Result: The tilt sensor alarm should not sound. adjust the tilt level sensor until the alarm just
20 After serial number 41199: Raise the platform begins to sound OR the down limit switch may
and rotate the safety arm to the stowed need to be adjusted.
position. After serial number 41136: Raise the platform
21 Lower the platform to the stowed position. at least 12 feet / 3.6 m.
22 Raise the machine slightly. Result - The drive function and the lift function
will not operate and the tilt alarm will sound at
23 Remove the blocks from under both wheels. 180 beeps per minute.
24 Lower the machine and remove the jack. Result: If the tilt sensor alarm does not sound,
25 Remove the blocks from the wheels at the adjust the tilt level sensor until the alarm just
non-steer end of the machine. begins to sound OR the down limit switch may
need to be adjusted.
26 Block the wheels at the steer end of the
machine. 32 Lower the platform to the stowed position.
27 Center a lifting jack under the drive chassis at 33 Raise the machine slightly.
the non-steer end of the machine. 34 Remove the blocks from under both wheels.
28 Raise the machine approximately 35 Lower the machine and remove the jack.
12 inches / 0.3 m.
36 Remove the blocks from the wheels at the steer
29 Place a 6.64 x 10 x 10 inch / 16.87 x 25 x 25 cm end of the machine.
thick steel block under both wheels at the
non-steer end of the machine. 37 Center a lifting jack under the drive chassis at
the ground controls side of the machine.
30 Lower the machine onto the blocks.
38 Raise the machine approximately
4 inches / 10 cm.
39 Models with RT tires: Place a 42 Turn the level sensor adjusting nuts just until
1.85 x 10 x 10 inch / 4.7 x 25 x 25 cm thick the level sensor alarm does not sound.
steel block under both wheels at the ground
43 Lower the platform to the stowed position.
controls side of the machine.
Models with non-marking tires: Place a 44 Raise the machine slightly.
1.94 x 10 x 10 inch / 4.93 x 25 x 25 cm thick
steel block under both wheels at the ground 45 Remove the blocks from under both wheels.
controls side of the machine. 46 Lower the machine and remove the jack.
Models with industrial tires: Place a
1.95 x 10 x 10 inch / 4.95 x 25 x 25 cm thick 47 Center a lifting jack under the drive chassis at
steel block under both wheels at the ground the engine side of the machine.
controls side of the machine. 48 Raise the machine approximately
40 Lower the machine onto the blocks. 4 inches / 10 cm.
41 Before serial number 41137: Raise the 49 Models with RT tires: Place a
platform at least 12 feet / 3.6 m. 2.15 x 10 x 10 inch / 5.46 x 25 x 25 cm thick
steel block under both wheels at the ground
Result: The tilt alarm does not sound and all controls side of the machine.
functions will operate. Proceed to step 43. All other models: Place a
Result - ANSI and CSA models: The tilt alarm 2.25 x 10 x 10 inch / 5.72 x 25 x 25 cm thick
sounds at 180 beeps per minute. Proceed to steel block under both wheels at the ground
step 42. controls side of the machine.
Result - CE and Australian models: The drive 50 Lower the machine onto the blocks.
function and the lift function will not operate and
the tilt alarm sounds at 180 beeps per minute.
Proceed to step 42.
After serial number 41136: Raise the platform
at least 12 feet / 3.6 m.
Result: The tilt alarm does not sound and all
functions will operate. Proceed to step 43.
Result - The drive function and the lift function
will not operate and the tilt alarm sounds at 180
beeps per minute. Proceed to step 42.
51 Before serial number 41137: Raise the 52 Lower the platform to the stowed position.
platform at least 12 feet / 3.6 m.
53 Push in the red Emergency Stop button to the
Result - ANSI and CSA models: The tilt alarm off position at both the ground and platform
will sound at 180 beeps per minute. controls.
Result - CE and Australian models: The drive 54 Turn the key switch to the off position.
function and the lift function will not operate and
55 Raise the machine slightly.
the tilt alarm will sound at 180 beeps per
minute. 56 Remove the blocks from under both wheels.
Result: If the tilt sensor alarm does not sound, 57 Lower the machine and remove the jack.
adjust the tilt level sensor until the alarm just
begins to sound OR the down limit switch may 58 Before serial number 41200: Close the ground
need to be adjusted. control panel. Install and securely tighten the
retaining fasteners. Do not over tighten.
After serial number 41136: Raise the platform
at least 12 feet / 3.6 m. After serial number 41199: Install the cover
onto the level sensor enclosure. Install and
Result - The drive function and the lift function securely tighten the retaining fasteners. Do not
will not operate and the tilt alarm will sound at over tighten.
180 beeps per minute.
Result: If the tilt sensor alarm does not sound,
adjust the tilt level sensor until the alarm just
begins to sound OR the down limit switch may
need to be adjusted.
2 Raise the platform approximately 10 feet / 3 m. 6 Tag and disconnect the wire harness from the
level sensor.
3 Lift the safety arm, move to the center of the
scissor arm and rotate to a vertical position. 7 Remove the fasteners securing the level sensor
to the chassis. Remove the level sensor from
the machine.
b
Tip-over hazard. The tilt level
sensor must be installed with the
"Y" on the level sensor base
closest to the steer end of the
machine. Failure to install the tilt MODELS
level sensor as instructed will WITHOUT
cause the machine to tip over OUTRIGGERS
resulting in death or serious injury.
9 Connect the wire harness to the level sensor.
10 Turn the key switch to platform control and pull
out the red Emergency Stop buttons to the on
position at both the ground and platform
controls.
11 Tighten the level sensor adjusting fasteners
until the bubble in the top of the level sensor is
centered in the circles.
Level sensor - models without outriggers
Note: Be sure there are threads showing through
the top of the adjusting fasteners. a chassis
b level sensor
Result: The tilt sensor alarm should not sound. c "X" indicator
d "Y" indicator
12 Raise the platform and rotate the safety arm to
16 Models with RT tires: Place a
the stowed position.
1.85 x 10 x 10 inch / 4.7 x 25 x 25 cm thick
13 Lower the platform to the stowed position. steel block under both wheels at the ground
controls side of the machine.
14 Center a lifting jack under the drive chassis at
Models with non-marking tires: Place a
the ground controls side of the machine.
1.94 x 10 x 10 inch / 4.93 x 25 x 25 cm thick
15 Raise the machine approximately steel block under both wheels at the ground
4 inches / 10 cm. controls side of the machine.
17 Lower the machine onto the blocks.
18 Raise the platform at least 12 feet / 3.6 m. 28 Raise the platform at least 12 feet / 3.6 m.
Result: The tilt alarm does not sound and all Result - The drive function and the lift function
functions will operate. Proceed to step 20. will not operate and the tilt alarm will sound at
180 beeps per minute.
Result - The drive function and the lift function
will not operate and the tilt alarm will sound at Result: If the tilt sensor alarm does not sound,
180 beeps per minute. Proceed to step 19. adjust the tilt level sensor until the alarm just
begins to sound OR the down limit switch may
19 Turn the level sensor adjusting nuts just until
need to be adjusted.
the level sensor alarm does not sound.
29 Lower the platform to the stowed position.
20 Lower the platform to the stowed position.
30 Push in the red Emergency Stop button to the
21 Raise the machine slightly.
off position at both the ground and platform
22 Remove the blocks from under both wheels. controls.
23 Lower the machine and remove the jack. 31 Turn the key switch to the off position.
24 Center a lifting jack under the drive chassis at 32 Raise the machine slightly.
the engine side of the machine.
33 Remove the blocks from under both wheels.
25 Raise the machine approximately
34 Lower the machine and remove the jack.
4 inches / 10 cm.
35 Install the cover onto the level sensor
26 Models with RT tires: Place a
enclosure. Install and securely tighten the
2.15 x 10 x 10 inch / 5.46 x 25 x 25 cm thick
retaining fasteners. Do not over tighten.
steel block under both wheels at the ground
controls side of the machine.
Models with non-marking tires: Place a
2.25 x 10 x 10 inch / 5.72 x 25 x 25 cm thick
steel block under both wheels at the ground
controls side of the machine.
27 Lower the machine onto the blocks.
AFTER
SERIAL NUMBER
41199
15 Adjust the "Y" axis (side-to-side) to 2.5V DC. 19 Disconnect the positive and negative leads.
Tap the top of the level sensor lightly with
20 Apply Sentry Seal to the adjusting nuts.
fingers after each turn of an adjusting nut.
21 Push in the red Emergency Stop button to the
Tip-over hazard. Do not adjust the
off position at the platform controls.
potentiometers on the bottom of
the level sensor or calibrate the 22 Before serial number GS6803-42382: Press
level sensor other than specified in and hold the outrigger enable button and press
this procedure. Failure to calibrate and hold the auto level button and pull out the
the tilt level sensor as instructed red Emergency Stop button to the on position at
will cause the machine to tip over the platform controls. Continue to hold the
resulting in death or serious injury. outrigger enable button and the auto level
button for approximately 3 seconds or until a
Note: Be sure there are threads showing through
beep is heard. Release the buttons.
the top of each adjusting nut.
After serial number GS6803-42381: Press
16 Disconnect the positive lead. and hold the auto level button and press and
hold the left front outrigger button. Pull out the
Adjust the front-to-back axis: red Emergency Stop button to the on position at
17 Without disconnecting the wire harness from the platform controls. Continue to hold the auto
the level sensor, connect the positive lead of level button and left front outrigger button for
the multimeter to the blue wire at the level approximately 3 seconds or until a beep is
sensor. heard. Release the buttons.
18 Adjust the "X" axis (front-to-back) to 2.43V DC. 23 Push in the red Emergency Stop button to the
Tap the top of the level sensor lightly with off position at the platform controls.
fingers after each turn of an adjusting nut.
Tip-over hazard. Do not adjust the
potentiometers on the bottom of
the level sensor or calibrate the
level sensor other than specified in
this procedure. Failure to calibrate
the tilt level sensor as instructed
will cause the machine to tip over
resulting in death or serious injury.
Note: Be sure there are threads showing through
the top of each adjusting nut.
Confirm the side-to-side level sensor setting: 32 Lower the machine and remove the jack.
24 Center a lifting jack under the drive chassis at 33 Center a lifting jack under the drive chassis at
the ground control side of the machine. the tank side of the machine.
27 Lower the machine onto the blocks. 36 Lower the machine onto the blocks.
28 Pull out the red Emergency Stop button to the 37 Raise the platform at least 12 feet / 3.6 m.
on position at platform controls. Start the
Result: The platform stops raising and the tilt
engine.
alarm will sound at 180 beeps per minute.
29 Raise the platform at least 12 feet / 3.6 m.
Result: The platform does not stop raising and
Result: The platform stops raising and the tilt the tilt alarm does not sound. The level sensor
alarm will sound at 180 beeps per minute. must be replaced. Repeat this procedure
beginning with step 2.
Result: The platform does not stop raising and
the tilt alarm does not sound. The level sensor Note: For reference only, the output of the level
must be replaced. Repeat this procedure sensor should be approximately 3.3V DC. To
beginning with step 2. confirm, connect the positive lead of a multimeter
to the yellow wire at the level sensor, and the
Note: For reference only, the output of the level negative lead to the black wire.
sensor should be approximately 1.7V DC. To
confirm, connect the positive lead of a multimeter 38 Lower the platform to the stowed position.
to the yellow wire at the level sensor, and the
39 Raise the machine slightly.
negative lead to the black wire.
40 Remove the blocks from under both wheels.
30 Raise the machine slightly.
41 Lower the machine and remove the jack.
31 Remove the blocks from under both wheels.
Confirm the front-to-back level sensor setting: 53 Place a 4.08 x 10 x 10 inch / 10.36 x 25 x 25 cm
thick steel block under both wheels at the
42 Center a lifting jack under the drive chassis at non-steer end of the machine.
the steer end of the machine.
54 Lower the machine onto the blocks.
43 Raise the machine approximately
6 inches / 15 cm. 55 Raise the platform at least 12 feet / 3.6 m.
44 Place a 4.08 x 10 x 10 inch / 10.36 x 25 x 25 cm Result: The platform stops raising and the tilt
thick steel block under both wheels at the steer alarm will sound at 180 beeps per minute.
end of the machine.
Result: The platform does not stop raising and
45 Lower the machine onto the blocks. the tilt alarm does not sound. The level sensor
must be replaced. Repeat this procedure
46 Raise the platform at least 12 feet / 3.6 m. beginning with step 2.
Result: The platform stops raising and the tilt Note: For reference only, the output of the level
alarm will sound at 180 beeps per minute. sensor should be approximately 3.4V DC. To
Result: The platform does not stop raising and confirm, connect the positive lead of a multimeter
the tilt alarm does not sound. The level sensor to the blue wire at the level sensor, and the
must be replaced. Repeat this procedure negative lead to the black wire.
beginning with step 2.
56 Lower the platform to the stowed position.
Note: For reference only, the output of the level
57 Raise the machine slightly.
sensor should be approximately 1.5V DC. To
confirm, connect the positive lead of a multimeter 58 Remove the blocks from under both wheels.
to the blue wire at the level sensor, and the
59 Lower the machine and remove the jack.
negative lead to the black wire.
60 Turn the key switch to the off position.
47 Lower the platform to the stowed position.
48 Raise the machine slightly.
49 Remove the blocks from under both wheels.
50 Lower the machine and remove the jack.
51 Center a lifting jack under the drive chassis at
the non-steer end of the machine.
52 Raise the machine approximately
6 inches / 15 cm.
Manifolds REV D
9-1
Function Manifold Components
The function manifold is located inside the hydraulic tray.
Index Schematic
No. Description Item Function Torque
1 DO3 valve, 3 position 4 way ................ A ......... Controls flow to the steer end
ground controls side drive motor
and the non-steer end engine side
drive motor in forward and reverse ....... 30-35 in-lbs / 3-4 Nm
2 DO3 valve, 3 position 4 way ................ B ......... Controls flow to the steer end
engine side drive motor and
the non-steer end ground
controls side drive motor in
forward and reverse .............................. 30-35 in-lbs / 3-4 Nm
3 Check valve ......................................... C ......... Drive speed select circuit .................. 25-30 ft-lbs / 34-41 Nm
4 Check valve ......................................... D ......... Prevents engine from running
backwards when on an incline
and reversing direction of travel ........ 25-30 ft-lbs / 34-41 Nm
5 Check valve ......................................... E ......... Steer circuit ....................................... 25-30 ft-lbs / 34-41 Nm
6 Check valve ......................................... F ......... Proportional circuit ............................ 25-30 ft-lbs / 34-41 Nm
7 Relief valve, 3500 psi / 241.3 bar ........ G ......... Relief valve for number
one section of pump ......................... 15-25 ft-lbs / 20-34 Nm
8 Check valve ......................................... H ......... Proportional circuit ................................ 30-35 in-lbs / 3-4 Nm
9 Diagnostic nipple - Test port #1 .......... I ........... Testing
10 Diagnostic nipple - Test port #2 .......... J .......... Testing
11 Relief valve,
GS-2668 RT, 3600 psi / 248.2 bar
GS-3268 RT, 2800 psi / 193 bar ......... K ......... Platform up ........................................ 15-25 ft-lbs / 34-41 Nm
12 Check valve ........................................ L .......... Drive circuit anti-cavitation ................ 20-25 ft-lbs / 27-34 Nm
13 Shuttle valve ........................................ M ......... Brake circuit ...................................... 20-25 ft-lbs / 27-34 Nm
REV D MANIFOLDS
Y5A
A
B
2
Y5 Y6A
Y6
29
AB AC
28
3
AA
27
Z C 4
26
E 5
F
6
D
Y G
25 Y1 7
X Y1B
H
24 8
W Y1A
23
V
22
U Y2
21
I
9
S
Y3
Y8 K
Y9 Y4 Q J
10
P
T R
O
N
L
20 19 18 17 16 15 14 13 12 11
MANIFOLDS REV D
REV D MANIFOLDS
Y5A
A
B
2
Y5 Y6A
Y6
29
AB AC
28
3
AA
27
Z C 4
26
E 5
F
6
D
Y G
25 Y1 7
X Y1B
H
24 8
W Y1A
23
V
22
U Y2
21
I
9
S
Y3
Y8 K
Y9 Y4 Q J
10
P
T R
O
N
L
20 19 18 17 16 15 14 13 12 11
MANIFOLDS REV D
A
9-2 B
Valve Adjustments - Y5
Y5A
Function Manifold Y6
Y6A
AA
Valves Y1 D
E
X F
The function manifold contains two system relief Y1B
5 Move the joystick full stroke in the forward a P1 system relief valve
b test port #1
direction. Note the pressure readings on both c test port #2
pressure gauges. Refer to Section 2, d P2 system relief valve
Specifications.
7 Adjust the internal hex socket. Turn it clockwise
6 Turn the engine off. Use a wrench to hold the to increase the pressure or counterclockwise to
P2 system relief valve (item O) or P1 system decrease the pressure. Install the relief valve
relief valve (item G) and remove the cap . cap.
Tip-over hazard. Failure to adjust
the relief valve as instructed will
cause the machine to tip over
resulting in death or serious injury.
Do not adjust the relief valve
higher than specified.
8 Repeat steps 4 through 5 to confirm the relief
valve pressures.
REV D MANIFOLDS
A
How to Adjust the Steer Relief B
Valve Y5
Y5A
Y6
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure Y6A
AA
gauge to test port #2 (item J) on the function
C
manifold. Y
Z
Y1 D
controls. W
Y1A H
3 Start the engine from the platform controls.
V
4 Press and hold the function enable toggle
switch and hold the steer thumb rocker switch U
MANIFOLDS REV D
A
How to Adjust the B
Y6
Note: Be sure that the hydraulic oil level is within Y6A
AA
the top 2 inches / 5 cm of the sight gauge.
Z C
Y
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure Y1 D
gauge to test port #1 (item I) on the function
E
manifold. X F
Y1B
2 Place the maximum rated load in the platform. G
controls. Y2
S
4 Start the engine from the ground controls. T
Y9 I
a
5 Press and hold the function enable switch and
hold the platform up/down toggle switch in the R Y3
K
Y8 b
up direction. Allow the platform to raise Y4 Q
J
P
completely, then continue holding the switch O
N
while observing the pressure reading on the L
Section 2, Specifications.
a test port #1
6 Turn the engine off. Hold the lift relief valve with b lift relief valve
a wrench and remove the cap (item K).
7 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Failure to adjust
the relief valve as instructed will
cause the machine to tip over
resulting in death or serious injury.
Do not adjust the relief valve
higher than specified.
8 Repeat steps 4 through 5 to confirm the relief
valve pressure.
REV D MANIFOLDS
9-3
Outrigger Manifold Components
The outrigger manifold is located beneath the hose cover panel on top of the drive chassis
Index Schematic
No. Description Item Function Torque
1 Relief valve, 2000 psi / 137.8 bar ......... BA ......... Outrigger circuit ..................................... 20 ft-lbs / 27.1 Nm
2 Solenoid valve, 2 position 2 way .......... BB ......... Outrigger slow extend .............................. 25 ft-lbs / 34 Nm
3 Orifice - plug,
0.063 inch / 1.6 mm .............................. BC ......... Outrigger retract
4 Solenoid valve, 3 position 4 way .......... BD ......... Outrigger extend/retract ........................... 25 ft-lbs / 34 Nm
5 Counterbalance valve
(not used after serial number 40484) ... BE ......... Outrigger retract circuit .................. 30-35 ft-lbs / 41-47 Nm
1
BA
BE
5
BE
5
Y39
BD Y40
4
Y44
BC
3 2
BB
MANIFOLDS REV D
REV D MANIFOLDS
MANIFOLDS REV D
9-5
Generator Manifold Components
The generator manifold is located above the function manifold.
Index Schematic
No. Description Item Function Torque
1 Solenoid valve, 2 position 3 way ......... DA .......... Generator on/off .................................. 25 ft-lbs / 34 Nm
2 Flow regulator, 4.3 gpm / 16.3 L/min ... DB .......... Generator speed ................................. 20 ft-lbs / 27.1 Nm
3 Relief valve, 3000 psi / 206.8 bar ........ DC .......... Generator circuit .................................. 20 ft-lbs / 27.1 Nm
1
DA
2
DB
3
DC
REV D MANIFOLDS
MANIFOLDS REV D
While valves may operate when coil resistance is Solenoid valve, 2 position 4 way 7.5Ω
outside specification, maintaining coils within 12V DC with diode (schematic item P)
specification will help ensure proper valve function
over a wide range of operating temperatures. Solenoid valve, 3 position 4 way 7.5Ω
12V DC with diode (schematic item R)
Electrocution hazard. Contact with
electrically charged circuits could Proportional valve, 5Ω
result in death or serious injury. 12V DC (schematic item T)
Remove all rings, watches and
other jewelry. Solenoid valve, 2 position 2 way 9.5Ω
12V DC with diode (schematic items U, W, X and Y)
Note: If the machine has been in operation, allow
the coil to cool at least 3 hours before performing Solenoid valve, 2 position 2 way 9Ω
this test. 12V DC with diode (schematic item AI)
1 Tag and disconnect the wiring from the coil to
Solenoid valve, 2 position 2 way 7.5Ω
be tested. 12V DC (schematic item BB)
2 Test the coil resistance using a multimeter set
to resistance (Ω). Refer to the Valve Coil Solenoid valve, 3 position 4 way 7.5Ω
Resistance Specification table. 12V DC (schematic item BD)
Result: If the resistance is not within the Solenoid valve, 2 position 2 way 8.2Ω
adjusted specification, plus or minus 10%, 10V DC (schematic items CA, CB, CC and CD)
replace the coil.
Solenoid valve, 2 position 3 way 6Ω
12V DC (schematic item DA)
REV D MANIFOLDS
+
protect the electrical system, resulting in a tripped
10 W 9V
circuit breaker or component damage. RESISTOR BATTERY
+
electrically charged circuits could
result in death or serious injury.
-
Remove all rings, watches and a multimeter
other jewelry. b 9V DC battery
c 10: resistor
1 Test the coil for resistance. See 9-3, How to d coil
Test a Coil. Note: Dotted lines in illustration indicate a
reversed connection as specified in step 6
2 Connect a 10: resistor to the negative terminal
of a known good 9V DC battery. Connect the 4 Connect the negative lead to the other terminal
other end of the resistor to a terminal on the on the coil.
coil.
Note: If testing a single-terminal coil, connect the
Note: The battery should read 9V DC or more negative lead to the internal metallic ring at either
when measured across the terminals. end of the coil.
:
Resistor, 10:
5 Momentarily connect the positive lead from the
Genie part number 27287 multimeter to the positive terminal on the 9V DC
battery. Note the current reading.
6 At the battery or coil terminals, reverse the
3 Set a multimeter to read DC current. connections. Note the current reading.
Note: The multimeter, when set to read DC Result: Both current readings are greater than
current, should be capable of reading up to 800 0 mA and are different by a minimum of 20%.
mA. The coil is good.
Result: If one or both of the current readings are
0 mA, or if the two current readings do not differ
by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
replaced.
REV A
Non-steer Axle Components
12-1 5 Tag, disconnect and plug the hydraulic hoses
from the drive motor and brake. Cap the fittings
Drive Motor and Brake on the drive motor and brake.
Bodily injury hazard. Spraying
How to Remove a Drive Motor hydraulic oil can penetrate and
and Brake burn skin. Loosen hydraulic
connections very slowly to
Component damage hazard. allow the oil pressure to
Repairs to the motor should only dissipate gradually. Do not
be performed by an authorized allow oil to squirt or spray.
dealer.
6 Support and secure the drive motor and brake
Component damage hazard. The assembly to a lifting jack.
work area and surfaces where this
procedure will be performed must 7 Remove the drive motor and brake mounting
be clean and free of debris that fasteners.
could get into the hydraulic system 8 Remove the drive motor and brake assembly
and cause severe component from the machine.
damage. Dealer service is
recommended. Crushing hazard. The drive motor
and brake assembly may become
Note: When removing a hose assembly or fitting, unbalanced and fall if not properly
the O-ring on the fitting and/or hose must be supported and secured to the
replaced and then torqued to specification during lifting jack when removed from the
installation. Refer to Section Two, Hydraulic Hose machine.
and Fitting Torque Specifications
1 Block the steer wheels and center a lifting jack
under the drive chassis at the non-steer end of
the machine.
2 Loosen the wheel lug bolts. Do not remove
them.
3 Raise the machine approximately
2 inches / 5 cm and place blocks under the
drive chassis for support.
4 Remove the wheel lug bolts. Remove the tire
and wheel assembly.
REV B
Brake Release Hand Pump Components
14-1
Brake Release Hand Pump Components
Before serial number 41200: The brake release hand pump manifold is mounted underneath the battery
in the hydraulic tray.
After serial number 41199: The brake release hand pump manifold is mounted at the non-steer end of
the chassis on the ground controls side of the machine.
Index Schematic
No. Description Item Function Torque
1 Shuttle valve ..................................... AE ............. Brake release circuit ............................ 45-50 in-lbs / 5 Nm
2 Check valve, pilot operated .............. AF ............. Manual brake release circuit ............ 65-70 in-lbs / 7-8 Nm
3 Hand pump ....................................... AG ............ Manual brake release .............................. 30 ft-lbs / 41 Nm
4 Needle valve ..................................... AH ............ Manual brake release enable .............. 45-50 in-lbs / 5 Nm
AE
AH
4 2
AF Note: 'alpha' callouts refer
to corresponding notes on
the hydraulic schematic
AG 3
3
AG
4
AH
GS-2668 975 kg
On machines with platform overload systems,
proper calibration is essential to safe machine GS-3268 919 kg
operation. An improperly calibrated platform
overload system could result in the system failing
to sense an overloaded platform. The stability of 8 Turn the key switch to platform control and pull
the machine is compromised and it could tip over. out the red Emergency Stop button to the on
position at both the ground and platform
Note: Be sure the hydraulic oil level is between the controls. Start the engine.
full and add marks on the oil level indicator.
9 Raise the platform to approximately 4 m.
1 Models with outriggers: Deploy the outriggers
10 Rotate the safety arm away from the machine
and level the machine.
and let it hang down.
2 Apply a thin layer of dry film lubricant to the
11 Before serial number GS6805-44169:
area of the chassis where the scissor arm wear
Remove the cover from the pressure switch.
pads make contact.
After serial number GS6805-44168: Loosen
3 Disconnect the platform controls from the the retaining ring and remove the switch
machine at the platform. adjustment cover from the pressure switch.
4 Open the side cover at the ground controls side Note: The pressure switch is located on the lower
of the machine and locate the Electronic lift cylinder.
Control Module (ECM) wire harness to platform
controls wire harness connection above the
hydraulic tank.
5 Tag and disconnect the platform controls wire
harness from the ECM wire harness.
12 Before serial number GS6805-44169: Using a 15 Raise the platform until the position indicator
wrench, slowly turn the nut of the platform corresponds to the maximum load position of
overload pressure switch one-quarter turn into the capacity indicator decal.
the hydraulic line.
Tip-over hazard. Raising the
After serial number GS6805-44168: Using a
platform with maximum load
small slotted screwdriver, turn the adjustment
above the maximum load position,
screw of the platform overload pressure switch
as shown on the capacity indicator
one-quarter turn into the hydraulic line.
decal on the side of the platform,
13 Push in the red Emergency Stop button to the could result in the machine tipping
off position at the ground controls. over, resulting in death or serious
injury. Do not raise the platform
14 Pull out the red Emergency Stop button to the
above the maximum load position
on position at the ground controls. Wait 3
of the capacity indicator decal.
seconds and start the engine.
Note: To perform this step, the lift relief valve will
Result: The alarm doesn't sound and the engine need to be adjusted.
will start and run. Proceed to step 15.
Note: Before raising the platform, applying a piece
Result: The engine will not start and an alarm is of tape onto the underside of the platform, at a
sounding. Repeat this procedure beginning with
point which corresponds to the maximum load
step 12.
position of the capacity indicator decal, may help
Note: The red Emergency Stop button must be complete this part of the procedure.
cycled after each quarter turn of the nut to allow
the platform overload system to reset. Result: The engine continues to run. Proceed to
step 16.
Note: Wait a minimum of 3 seconds between each
quarter turn of the nut to allow the platform Result: The engine has stopped and an alarm is
sounding. Proceed to step 17.
overload system to reset.
Set the pressure switch: 20 Return the safety arm to the stowed position.
Lower the platform to the stowed position.
16 Using a wrench, turn the nut of the platform
overload pressure switch out of the hydraulic Note: After returning the safety arm to the stowed
line until the overload alarm sounds and the position, use the auxiliary down function to lower
engine stops running. the platform.
Note: Turning the nut out of the hydraulic line will Set the maximum height limit switch:
activate the alarm; turning the nut into the hydraulic
line will deactivate the alarm. 21 Using a suitable lifting device, place a test
weight in the center of the platform floor.
17 Slowly turn the nut of the platform overload Secure the weight to the platform. Refer to the
pressure switch one-quarter turn into the chart below.
hydraulic line.
18 Push in the red Emergency Stop button to the GS-2668 RT 567 kg
off position at the ground controls.
GS-3268 RT 454 kg
19 Pull out the red Emergency Stop button to the
on position at the ground controls. Wait 3
seconds and start the engine. 22 Raise the platform to approximately 4 m.
Result: The alarm doesn't sound and the engine 23 Rotate the safety arm away from the machine
will start and run. Proceed to step 20. and let it hang down.
Result: The engine will not start and an alarm is 24 Remove the maximum height limit switch
sounding. Repeat this procedure beginning with fasteners. Remove the maximum height limit
step 17. switch and set it to the side so that the limit
switch will not be activated.
Note: The red Emergency Stop button must be
cycled after each quarter turn of the nut to allow 25 Raise the platform until it is approximately
the platform overload system to reset. 65 cm less than full height.
Note: Wait a minimum of 3 seconds between each
quarter turn of the nut to allow the platform
overload system to reset.
26 Raise the platform in 5 cm increments until the 27 Install and adjust the maximum height limit
overload alarm sounds and the engine stops switch until it activates just before the point
running. Proceed to step 27. reached in step 26. Securely tighten the
fasteners. Do not over tighten.
Result: The alarm does not sound and the
engine continues to run when the platform 28 Use the auxiliary down function to lower the
reaches full height. Repeat this procedure platform approximately 15 cm.
beginning with step 7.
29 Start the engine and fully raise the platform.
a b c Result: The engine continues to run. Proceed to
step 30.
Result: An alarm sounds and the engine stops
running. Repeat this procedure beginning with
step 24.
30 Lower the platform to approximately 4 m.
31 Return the safety arm to the stowed position.
Disable the descent delay function:
32 Push in the red Emergency Stop button to the
off position at the ground controls.
GS-2668 33 Turn the key switch to ground control.
GS-3268
34 Press and hold both the blue platform up and 39 Pull out the red Emergency Stop button to the
yellow platform down buttons. Pull out the red on position at the ground controls.
Emergency Stop button to the on position at the
Note: For more information on programming, refer
ground controls.
to Section 4, Repair.
Result: TUNE SPEEDS is showing in the diagnostic
display window. Calibrate the load sense delay limit switch:
40 Turn the key switch to platform control. Start the
b engine.
a
41 Lower the platform until the load sense delay
c limit switch activates and the platform stops
lowering. Release the joystick.
d
Result: The alarm does not sound and the
engine continues to run. Proceed to step 49.
a diagnostic display
b blue platform up button Result: The alarm sounds and the engines
c lift function enable button
d yellow platform down button stops running. The load sense delay limit switch
needs to be calibrated. Proceed to step 42.
35 Use the yellow platform down arrow to scroll to
SELECT OPTIONS.
42 Raise the platform to approximately 4 m.
Result: SELECT OPTIONS is showing in the 43 Rotate the safety arm away from the machine
diagnostic display window. The ECM is now in and let it hang down.
programming mode. 44 Loosen the fasteners securing the load sense
36 Press the lift function enable button. delay limit switch just enough to allow
movement of the limit switch.
Result: DESCENT DELAY ON is showing in the
diagnostic display window. 45 Move the roller head of the load sense delay
limit switch 1 mm upwards. Tighten the
37 Press the lift function enable button to fasteners. Do not over tighten.
deactivate the descent delay option.
46 Return the safety arm to the stowed position.
Result: DESCENT DELAY OFF is showing in the
diagnostic display window. 47 Raise the platform approximately 1 m.
38 Push in the red Emergency Stop button to the 48 Repeat this procedure beginning with step 41.
off position at the ground controls.
Enable the descent delay function: Calibrate the down limit switch:
49 Push in the red Emergency Stop button to the 57 Turn the key switch to platform control. Start the
off position at the ground controls. engine.
50 Turn the key switch to ground control. 58 Raise the platform approximately 1 m.
51 Press and hold both the blue platform up and 59 Lower the platform until the down limit switch
yellow platform down buttons. Pull out the red activates and the platform stops lowering.
Emergency Stop button to the on position at the Quickly release the controls and then
ground controls. immediately attempt to lower the platform to
the stowed position.
Result: TUNE SPEEDS is showing in the diagnostic
display window. Result: The platform stops for 4 to six seconds.
52 Use the yellow platform down arrow to scroll to Release the joystick and proceed to step 67.
select options. Result: The platform stops and then will
Result: SELECT OPTIONS is showing in the immediately begin to lower again. The down
diagnostic display window. The ECM is now in limit switch needs to be calibrated. Proceed to
programming mode. step 60.
53 Press the lift function enable button. 60 Raise the platform to approximately 4 m.
Result: DESCENT DELAY OFF is showing in the 61 Rotate the safety arm away from the machine
diagnostic display window. and let it hang down.
54 Press the lift function enable button to activate 62 Loosen the fasteners securing the down limit
the descent delay option. switch just enough to allow movement of the
limit switch.
Result: DESCENT DELAY ON is showing in the
diagnostic display window. 63 Move the roller head of the down limit switch
1 mm upwards. Tighten the fasteners. Do not
55 Push in the red Emergency Stop button to the over tighten.
off position at the ground controls.
64 Raise the platform approximately 1 m.
56 Pull out the red Emergency Stop button to the
on position at the ground controls. 65 Return the safety arm to the stowed position.
66 Repeat this procedure beginning with step 59.
67 Lower the platform to the stowed position and 72 Raise the platform to approximately 4 m.
remove the weight from the platform.
73 Rotate the safety arm away from the machine
Result: The platform lowers to the stowed and let it hang down.
position. Proceed to step 72. 74 Install the cover onto the platform overload
Result: The platform stops lowering. The down pressure switch or switch box and securely
limit switch needs to be calibrated. Proceed to tighten the cover retaining fasteners. Do not
step 68. over tighten.
68 Raise the platform to approximately 4 m. 75 Apply Sentry Seal to one of the cover retaining
fasteners where it contacts the platform
69 Rotate the safety arm away from the machine overload pressure switch box.
and let it hang down..
76 Return the safety arm to the stowed position.
70 Loosen the fasteners securing the down limit
switch just enough to allow movement of the 77 Lower the platform to the stowed position.
limit switch. 78 Calibrate the lift relief valve. See 9-2, How to
71 Move the roller head of the down limit switch Adjust the Lift Relief Valve.
1 mm downwards. Tighten the fasteners. Do
not over tighten.
AT MAXIMUM HEIGHT WITH RATED LOAD IN TURN OFF RED EMERGENCY STOP
PLATFORM, THE PRESSURE SWITCH SYSTEM NEEDS TO BE RESET BUTTON, WAIT THREE SECONDS AND TURN
ALARM CONTINUES TO SOUND BACK ON
MAXIMUM HEIGHT LIMIT SWITCH OUT OF LOWER THE UP LIMIT SWITCH SLIGHTLY
ADJUSTMENT -OR- FAULTY -OR- REPLACE CONTACTS
TOO MUCH WEIGHT IN PLATFORM PUT CORRECT RATED LOAD IN PLATFORM
TURN THE PRESSURE SWITCH NUT 1/4
PRESSURE SWITCH OUT OF ADJUSTMENT
TURN INTO THE HYDRAULIC LINE
BATTERIES ARE NOT FULLY CHARGED CHARGE BATTERIES
OVERLOAD SYSTEM NOT ADJUSTED
REPEAT CALIBRATION PROCEDURE
PROPERLY
SLIDER CHANNEL NOT LUBRICATED LUBRICATE SLIDER CHANNELS
AT DOWN LIMIT WITH RATED LOAD IN TURN OFF RED EMERGENCY STOP
PLATFORM, THE PRESSURE SWITCH SYSTEM NEEDS TO BE RESET BUTTON, WAIT THREE SECONDS AND TURN
ALARM CONTINUES TO SOUND BACK ON
DOWN LIMIT SWITCH OUT OF ADJUSTMENT RAISE THE DOWN LIMIT SWITCH
TOO MUCH WEIGHT IN PLATFORM PUT CORRECT RATED LOAD IN PLATFORM
TURN THE PRESSURE SWITCH NUT 1/4
OVERLOAD SYSTEM NOT ADJUSTED
TURN INTO THE HYDRAULIC LINE -OR-
PROPERLY
REPEAT CALIBRATION PROCEDURE
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:
Be aware of the following hazards and follow
Troubleshooting and repair procedures shall be generally accepted safe workshop practices.
completed by a person trained and qualified on
Crushing hazard. When testing
the repair of this machine.
or replacing any hydraulic
Immediately tag and remove from service a component, always support
damaged or malfunctioning machine. the structure and secure it
from movement.
Repair any machine damage or malfunction
before operating the machine. Electrocution hazard. Contact
with electrically charged circuits
Unless otherwise specified, perform each could result in death or serious
repair procedure with the machine in the injury. Remove all rings, watches
following configuration: and other jewelry.
· Machine parked on a firm, level surface
Bodily injury hazard. Spraying
· Platform in the stowed position hydraulic oil can penetrate and
· Key switch in the off position with the key burn skin. Loosen hydraulic
removed connections very slowly to allow
the oil pressure to dissipate
· The red Emergency Stop button in the off
gradually. Do not allow oil to
position at both ground and platform controls
squirt or spray.
· Wheels chocked
· All external AC power supply disconnected
from the machine
FAULT CODES
REV B
Fault Code Chart
(before serial number GS6803-42382)
–– Normal operation.
Consult Genie
ECM does not allow Machine does not Defective ECM or
01, 02 or 03 machine to function. operate. platform controls.
Industries Service
Department
Ground controls
engine start toggle Check for stuck
Engine will not start.
ECM does not allow switch fault, or is toggle switch OR test
10 machine to function.
Machine will not
activated when the or replace the toggle
operate.
keyswitch is turned switch.
on.
Ground controls
engine choke or glow Check for stuck
Engine will not start.
ECM does not allow plug toggle switch toggle switch OR test
11 machine to function.
Machine will not
fault, or is activated or replace the toggle
operate.
when the keyswitch switch.
is turned on.
Ground controls
platform up/down Check for stuck
Engine will not start.
ECM does not allow toggle switch fault, or toggle switch OR test
12 machine to function.
Machine will not
is activated when the or replace the toggle
operate.
keyswitch is turned switch.
on.
Platform controls Check or replace
Engine will not start. engine choke or glow platform control panel
ECM does not allow Machine will not plug button fault, or is switch board or
20 machine to function. operate from activated when the replace the platform
platform. keyswitch is turned controls main circuit
on. board.
Check or replace
Platform controls
Engine will not start. platform control panel
engine start button
ECM does not allow Machine will not switch board or
21 machine to function. operate from
fault, or is activated
replace the platform
when the keyswitch
platform. controls main circuit
is turned on.
board.
Platform controls
Check for stuck
Engine will not start. steer left rocker
steer microswitch
ECM does not allow Machine will not switch fault, or is
22 machine to function. operate from activated when the
OR test or replace
the steer
platform. keyswitch is turned
microswitch.
on.
Platform controls
Check for stuck
Engine will not start. steer right rocker
steer microswitch
ECM does not allow Machine will not switch fault, or is
23 machine to function. operate from activated when the
OR test or replace
the steer
platform. keyswitch is turned
microswitch.
on.
Platform controls
Engine will not start. platform up/down Check for stuck
ECM does not allow Machine will not toggle switch fault, or toggle switch OR test
26 machine to function. operate from is activated when the or replace the toggle
platform. keyswitch is turned switch.
on.
Platform controls Check for stuck
platform up/down fast function enable
Engine will not start.
speed function button OR test or
ECM does not allow Machine will not
27 machine to function. operate from
enable button fault, or replace the platform
is activated when the up/down fast speed
platform.
key switch is turned function enable
on. button.
Platform controls Check for stuck
platform up/down function enable
Engine will not start.
slow speed function button OR test or
ECM does not allow Machine will not
28 machine to function. operate from
enable button fault, or replace the platform
is activated when the up/down slow speed
platform.
keyswitch is turned function enable
on. button.
Check for stuck
function enable
Platform controls switch OR check for
Engine will not start. function enable function enable
ECM does not allow Machine will not switch fault, or is switch being tied
29 machine to function. operate from activated when the down OR test or
platform. key switch is turned replace the platform
on. up/down slow speed
function enable
button.
Platform controls
Engine will not start. Check to make sure
joystick fault, or is
ECM does not allow Machine will not the joystick is in the
30 machine to function. operate from
activated when the
center or neutral
keyswitch is turned
platform. position.
on.
REV A
Fault Code Chart
(from serial number GS6803-42382 to GS6805-44770)
Fault Code LED Condition Result Solution
SYSTEM READY Green Normal operation
35 Red
Left rear outrigger enable
button fault at platform Outriggers disabled.
Troubleshoot button OR replace printed
LEFT REAR circuit board at platform controls.
OUTRIG SW FLT controls.
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics
problem
still exists
Up limit switch
J4 J3
Electronic Control Module
J1 J2 Level
sensor
Horn
Function manifold
Flashing beacon
Ground controls
18 pin connector
6
J4 J3
6
6
B 1
6
C 1
A 1
12
C 1 6 12
B 1 6 12
J1 J2
A 1 6 12
12
B 1
12
C 1
12
A 1
36 pin connector
Platform controls
Engine
To outriggers
Down limit
Flashing beacons switch
J1 J2 Level
sensor
Generator
Ground controls
and ECM
Function manifold
J1 Connector J2 Connector
(36 pin) (36 pin)
A1 Right turn - Y3 (output) A1 Up limit switch LS5 (input)
A2 Left turn - Y4 (output) A2 Down limit switchLS6 (input)
A3 Platform up - Y8 (output) A3 Aux down power (input)
A4 Brake - Y2 (output) A4 Aux down relay CR23-86 (output)
A5 Drive forward 1 - Y6 (output) A5 Key switch KS1-3 (input)
A6 Drive reverse 1 - Y5 (output) A6 Level sensor S7 (white) (input)
A7 Drive forward 2 - Y6A (output) A7 Plug
A8 Drive reverse 2 - Y5A (output) A8 Plug
A9 Platform down - Y7 (output) A9 Plug
A10 Drive coil - Y1 (output) A10 Platform controls (ground) (input)
A11 Drive coil - Y1A (output) A11 Platform controls data high (+) (input)
A12 Drive coil - Y1B (output) A12 Platform controls data low (-) (input)
C 1 6 12
B 1 6 12 Electronic Control Module
C 1
A 1
B 1
12
12
12
A 1 6 12
J1 J2
36 pin connector
12
B 1
12
C 1
12
A 1
P2 P2
EMERGENCY STOP EMERGENCY STOP
BUTTON BUTTON
BK RD BK RD
NC 1
NC 1
2
2
RD RD
JC4 JC4
JOYSTICK JOYSTICK
BN BN
CONTROLLER CONTROLLER
WH/BL
WH/BK
WH/RD
WH/RD
WH
WH/YL
PP
BN
U3 U3
OR PLATFORM PLATFORM
WH/BK
CONTROLS CONTROLS
WH CIRCUIT CIRCUIT
WH/BL BOARD BOARD
PP
OR OR
PP
D7 SW25 D7 SW25
VOLTAGE DIP SWITCH VOLTAGE DIP SWITCH
ON DIP ON DIP
REGULATOR REGULATOR
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
YL
BL
WH
RD RD WH
WH
GN BK BK
BL
BL
WH
BK BK
BL WH
BK
YL YL
BK BK
RD
RD RD
BK
H1
ALARM BK
NC 1
RD
P2
EMERGENCY
STOP
OR
BL
JC1 WH
JOYSTICK
CONTROLLER
1 5
J5
GY
4
J3
BK
U3
RD 1 PLATFORM
CONTROLS
CIRCUIT
BK BOARD
PP
YL
WH/BL
1 14
GY
BL
J2
OR
RD
WH
BN
6
BK
YL
TS20 BL
OR RD
1
TS21 J1
PLATFORM
KS1
P1
M4
GROUND
Solenoid valve with Motor or pump
Emergency Stop GROUND spike supression Flashing beacon
button
Key switch diode
30 86
Wire connection
87 85
Solenoid valve Spark plugs
Control relay no diode Horn or alarm
A A
Glow plug(s) C C
No connection Button B B
D D
(circuits crossing) Solenoid valve with E E
redundant coils
Quick disconnect
Diode M3
Pressure switch
(+)
Capacitor (+)
G6 G6
( )
-
Hour meter
Ignition coil
Potentiometer
-
( )
Limit switch
G
12V DC
Battery
Resistor
Distributor Level sensor
Work lights
(models without outriggers)
Electrical Schematic
Gasoline/LPG Models (before serial number 21161) REV C
Part 1 of 2
P1
EMERGENCY
CB2 STOP
PLATFORM
KS1
1A
GROUND
85 86
CR43
GROUND POWER TO
87 ECM
30
85 86
CR25 C2
(+) CR1 87 ENGINE RUN 33000 uf
BN23 ENGINE 30
START
AUXILIARY 86 30
R7 2000
85 86
PLATFORM
DOWN B4
( )
- 12V DC 87
CR8
TS52
TS56
TS54
TS3
(GS-3268RT ONLY) 85 87 IGNITION
30
85 86
CR15
START
HIGH IDLE
LPG SELECT
CHOKE
87 STARTING
30
AID
CB1 85 86
20A
87
CR4
30 HIGH IDLE
J4-C3
J2-A5
J4-A3
J4-B4
J4-C4
J1-C11,C12
J4-B5
J4-A5
J4-A2
J4-A4
J4-A1
R
D1 F
U5
J1-C1\C4
J2-B12
J4-C2
G6
J1-A9
J2-B7
J4-B6
J2-B8
J4-B2
J4-C1
J4-B1
J1-B1
L30
U19
Q7 CR5 L27
30 86
U26 SW1 SW2 L41 Q1 Q2
G
H1
M3 87 85
Q3
N.O. N.C.
H2
L42 M4
B1
12V DC FB1
B1 M3 D1 U19 U26 U20 G6 Q7 Q3 L30 H2 Y7 Y7A FB1 H1 SW1 SW2 L41 L42 L27 Y29 Q1 M4 Q2
TEMPERATURE SWITCH
COOLANT
HOURMETER
CHOKE
(OPTION)
AUTOMOTIVE-STYLE HORN
ALTERNATOR
BATTERY 12V DC
IGNITION COIL
DISTRIBUTOR
SPARK PLUG(S)
GENERATOR (OPTION)
TILT ALARM
GENERATOR ON LED
LPG SELECT
FUEL PUMP
PLATFORM DOWN
(GS-3268 ONLY)
PLATFORM DOWN
TEMPERATURE LED
COOLANT
FLASHING BEACON (OPTION)
GASOLINE SELECT
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES0116F
Electrical Schematic
REV C Gasoline/LPG Models (before serial number 21161)
Part 2 of 2
P2
EMERGENCY
QD4 QD3 STOP
BK
C C C C BK POWER TO PLATFORM
RD
A A A A RD POWER TO GROUND
B B B B WH GROUND PIO3 PIO2
D D
D D BL DATA LINK (HIGH) PIO4
E E
G8 E E YL DATA LINK (LOW) PIO5
DIAGNOSTIC
DISPLAY 12V DC
SW25 U3 D7 5V DC
1
TS67 2
PP
FUNCTION 3
RD WH 4 JC1
ENABLE
5 BN R15 JOYSTICK
LS6 LS5 LS1 N.C. 6 5K
POTENTIOMETER
CONTROLLER
PLATFORM PLATFORM EXTENSION 7 OR
DOWN UP DECK 8
WH/BK WH/YL
LEVEL
SENSOR SW5 SW6 STEER
LEFT/ RIGHT
N.C. N.C. N.C. CIRCUIT WH/BL FUNCTION ENABLE
GROUND FROM PLATFORM
LEFT
RIGHT
BOARD PIN18
TS66 WH/RD
PIN15
UP
DOWN
S7 WH
PLATFORM
PIN14
DATA LINK (+) BK
LEVEL
SENSOR
BK PLATFORM CONTROLS
BN
MEMBRANE DECAL
POUT2 POWER LED L19
POUT7 LPG LED L22
J2-A1
J3-A1
J2-C1/C10
J2-A2
J3-A3
J3-A2
J3-B4
J3-A4
J1-C7,C8
J3-A5
J2-A6
J2-B10
J1-A12
J1-A11
J1-A7
J1-B3
J1-A3
J1-A4
J1-A6
J1-A8
J1-A5
J1-A2
J1-A1
WH
PIN1 LIFT ENABLE HIGH BN12
Y3 Y4 Y8 Y2 Y6 Y5 Y6A Y5A Y1 Y1A Y1B Y9 BL
PIN2 LIFT ENABLE LOW BN13
STEER LEFT
DRIVE PARALLEL
DRIVE PARALLEL
DRIVE PARALLEL
PLATFORM UP
BRAKE RELEASE
FLOW CONTROL
PROPORTIONAL
DRIVE FORWARD (1)
RD
PIN3 UP
PLATFORM UP/DOWN TS20
YL
PIN4 DOWN
RD
POUT1 +
H1
BK ALARM
PIN11 -
PLATFORM CONTROLS
- NOTE -
MACHINE SHOWN IN THE STOWED
ES0116F POSITION WITH THE POWER OFF
Electrical Schematic
Gasoline/LPG Models (from serial number 21161 to 21837) REV C
Part 1 of 2
P1
EMERGENCY
CB2 STOP
PLATFORM
KS1
1A
GROUND
85 86
CR43
GROUND POWER TO
87 ECM
30
85 86
CR25
(+) CR1 87 ENGINE RUN
BN23 ENGINE 30
START
AUXILIARY 86 30
85 86
PLATFORM
DOWN B4
( )
- 12V DC 87
CR8
TS52
TS56
TS54
TS3
(GS-3268RT ONLY) 85 87 IGNITION
30
85 86
CR15
START
HIGH IDLE
LPG SELECT
CHOKE
87 STARTING
30
AID
CB1 85 86
20A
87
CR4
30 HIGH IDLE
J4-C3
J2-A5
J4-A3
J4-B4
J4-C4
J1-C11,C12
J4-B5
J4-A5
J4-A2
J4-A4
J4-A1
R
D1 F
U5
J1-C1\C4
J2-B12
J4-C2
G6
J1-A9
J2-B7
J4-B6
J2-B8
J4-B2
J4-C1
J4-B1
J1-B1
L30
U19
Q7 CR5 L27
30 86
U26 SW1 SW2 L41 Q1 Q2
G
H1
M3 87 85
Q3
N.O. N.C.
H2
L42 M4
B1
12V DC FB1
B1 M3 D1 U19 U26 U20 G6 Q7 Q3 L30 H2 Y7 Y7A FB1 H1 SW1 SW2 L41 L42 L27 Y29 Q1 M4 Q2
TEMPERATURE SWITCH
COOLANT
HOURMETER
CHOKE
(OPTION)
AUTOMOTIVE-STYLE HORN
ALTERNATOR
BATTERY 12V DC
IGNITION COIL
DISTRIBUTOR
SPARK PLUG(S)
GENERATOR (OPTION)
TILT ALARM
GENERATOR ON LED
LPG SELECT
FUEL PUMP
PLATFORM DOWN
(GS-3268 ONLY)
PLATFORM DOWN
TEMPERATURE LED
COOLANT
FLASHING BEACON (OPTION)
GASOLINE SELECT
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES0116G
Electrical Schematic
REV C Gasoline/LPG Models (from serial number 21161 to 21837)
Part 2 of 2
P2
EMERGENCY
QD4 QD3 STOP
BK
C C C C BK POWER TO PLATFORM
RD
A A A A RD POWER TO GROUND
B B B B WH GROUND PIO3 PIO2
D D
D D BL DATA LINK (HIGH) PIO4
E E
G8 E E YL DATA LINK (LOW) PIO5
DIAGNOSTIC
DISPLAY 12V DC
SW25 U3 D7 5V DC
1
TS67 2
PP
FUNCTION 3
RD WH 4 JC1
ENABLE
5 BN R15 JOYSTICK
LS6 LS5 LS1 N.C. 6 5K
POTENTIOMETER
CONTROLLER
PLATFORM PLATFORM EXTENSION 7 OR
DOWN UP DECK 8
WH/BK WH/YL
LEVEL
SENSOR SW5 SW6 STEER
LEFT/ RIGHT
N.C. N.C. N.C. CIRCUIT WH/BL FUNCTION ENABLE
GROUND FROM PLATFORM
LEFT
RIGHT
BOARD PIN18
TS66 WH/RD
PIN15
UP
DOWN
S7 WH
PLATFORM
PIN14
DATA LINK (+) BK
LEVEL
SENSOR
BK PLATFORM CONTROLS
BN
MEMBRANE DECAL
POUT2 POWER LED L19
POUT7 LPG LED L22
J2-A1
J3-A1
J2-C1/C10
J2-A2
J3-A3
J3-A2
J3-B4
J3-A4
J1-C7,C8
J3-A5
J2-A6
J2-B10
J1-A12
J1-A11
J1-A7
J1-B3
J1-A3
J1-A4
J1-A6
J1-A8
J1-A5
J1-A2
J1-A1
WH
PIN1 LIFT ENABLE HIGH BN12
Y3 Y4 Y8 Y2 Y6 Y5 Y6A Y5A Y1 Y1A Y1B Y9 BL
PIN2 LIFT ENABLE LOW BN13
STEER LEFT
DRIVE PARALLEL
DRIVE PARALLEL
DRIVE PARALLEL
PLATFORM UP
BRAKE RELEASE
FLOW CONTROL
PROPORTIONAL
DRIVE FORWARD (1)
RD
PIN3 UP
PLATFORM UP/DOWN TS20
YL
PIN4 DOWN
RD
POUT1 +
H1
BK ALARM
PIN11 -
PLATFORM CONTROLS
- NOTE -
MACHINE SHOWN IN THE STOWED
ES0116G POSITION WITH THE POWER OFF
Electrical Schematic
Gasoline/LPG Models (from serial number 21838 to 38464) REV C
Part 1 of 3
GROUND
85 86
CR43
GROUND POWER TO
87 ECM
30
85 86
CR25
(+) CR1 87 ENGINE RUN
BN23 ENGINE 30
START
AUXILIARY 86 30
85 86
PLATFORM
DOWN B4
( )
- 12V DC 87
CR8
TS52
TS56
TS54
TS3
(GS-3268RT ONLY) 85 87 IGNITION
30
85 86
CR15
START
HIGH IDLE
LPG SELECT
CHOKE
87 STARTING
30
AID
CB1 85 86
20A
87
CR4
30 HIGH IDLE
J4-C3
J2-A5
J4-A3
J4-B4
J4-C4
J1-C11,C12
J4-B5
J4-A5
J4-A2
J4-A4
J4-A1
R
D1 F
U5
J1-C1\C4
J2-B12
J4-C2
G6
J1-A9
J2-B7
J4-B6
J2-B8
J4-B2
J4-C1
J4-B1
J1-B1
L30
U19
Q7 CR5 L27
30 86
U26 L41 Q1 Q2
G
H1
M3 87 85
Q3
H2 SW1 SW2
L42 M4
B1 N.O. N.C.
12V DC FB1
B1 M3 D1 U19 U26 U20 G6 Q7 Q3 L30 H2 Y7 Y7A FB1 H1 SW1 SW2 L41 L42L27 Y29 Q1 M4 Q2
TEMPERATURE SWITCH
COOLANT
HOURMETER
CHOKE
(OPTION)
AUTOMOTIVE-STYLE HORN
ALTERNATOR
BATTERY 12V DC
IGNITION COIL
DISTRIBUTOR
SPARK PLUG(S)
GENERATOR (OPTION)
TILT ALARM
GENERATOR ON LED
LPG SELECT
FUEL PUMP
PLATFORM DOWN
(GS-3268 ONLY)
PLATFORM DOWN
TEMPERATURE LED
COOLANT
FLASHING BEACON (OPTION)
GASOLINE SELECT
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES0116N
Electrical Schematic
REV C Gasoline/LPG Models (from serial number 21838 to 38464)
Part 2 of 3
QD4
C C
A A
B B
D D
E E
TS67
FUNCTION RD WH
ENABLE
LS6 LS5 LS1 PS3 N.C.
PLATFORM PLATFORM EXTENSION PLATFORM
DOWN UP DECK OVERLOAD
LS12 LS13 LS14 LS15
LEFT RIGHT LEFT RIGHT
FRONT FRONT REAR REAR LEVEL
OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER SENSOR
N.C. N.C. N.C. N.O. CIRCUIT
DOWN
S7
PLATFORM
J3-A1
J2-C1/C10
J2-A2
J3-A3
J3-A2
J2-A7
J2-A8
J2-A10
J3-A6
J3-B5
J3-B4
J3-A4
J1-C7,C8
J3-A5
J2-A6
J2-B10
U5
ELECTRONIC CONTROL MODULE
J2-B10
J1-A10
J1-A12
J1-A11
J1-B6
J1-B7
J2-B3
J1-A7
J1-B8
J1-B3
J1-B5
J1-A3
J1-A4
J1-A6
J1-A8
J1-B2
J3-B2
J1-A5
J1-A2
J3-B1
J2-B1
J1-A1
RD
BL
YL
S8
2-AXIS
LEVEL
SENSOR
BK
Y3 Y4 Y8 Y2 Y6 Y5 Y6A Y5A Y1 Y1A Y1B Y9 Y35 Y36 Y33 Y34 Y40 Y39 Y44 S9
STEER LEFT
DRIVE FORWARD
DRIVE PARALLEL
DRIVE PARALLEL
DRIVE PARALLEL
PLATFORM UP
BRAKE RELEASE
DRIVE REVERSE
STEER RIGHT
DRIVE REVERSE
FLOW CONTROL
PROPORTIONAL
OUTRIGGER
RIGHT FRONT
DRIVE FORWARD
OUTRIGGER
RIGHT REAR
SLOW
OUTRIGGER EXTEND
OUTRIGGER
LEFT REAR
OUTRIGGER EXTEND
OUTRIGGER RETRACT
OUTRIGGER
LEFT FRONT
SENSOR
AUTO LEVELING
- NOTE -
MACHINE SHOWN IN THE STOWED
ES0116N POSITION WITH THE POWER OFF
Electrical Schematic
Gasoline/LPG Models (from serial number 21838 to 38464) REV C
Part 3 of 3
P2 P2
EMERGENCY EMERGENCY
QD3 STOP QD3 STOP
BK BK
C C BK POWER TO PLATFORM C C BK POWER TO PLATFORM
RD RD
A A RD POWER TO GROUND A A RD POWER TO GROUND
SW25 U3 D7 5V DC
SW25 U3 D7 5V DC
1 1
2 2
3 OR 3 OR
4 JC1 4 JC1
5 BN R15 JOYSTICK 5 BN R15 JOYSTICK
6 5K CONTROLLER 6 5K CONTROLLER
7 PP POTENTIOMETER 7 PP POTENTIOMETER
8 8
WH/BK WH/YL WH/BK WH/YL
RIGHT
LEFT
RIGHT
PIN18 PIN18
WH/RD WH/RD
PIN15 PIN15
WH WH
PIN14 PIN14
Electrical Schematic
Gasoline/LPG Models (from serial number 38465 to 41199) REV C
Part 1 of 3
P1
EMERGENCY
CB2 STOP
PLATFORM
KS1
7A
GROUND
85 86
CR43
GROUND POWER TO
87 ECM
30
85 86
CR25
(+) CR1 87 ENGINE RUN
BN23 ENGINE 30
START
AUXILIARY 86 30
85 86
PLATFORM
DOWN B4
( )
- 12V DC 87
CR8
TS52
TS56
TS54
TS3
(GS-3268RT ONLY) 85 87 IGNITION
30
85 86
CR15
START
HIGH IDLE
LPG SELECT
CHOKE
87 STARTING
30
AID
CB1 85 86
20A
87
CR4
30 HIGH IDLE
J4-C3
J2-A5
J4-A3
J4-B4
J4-C4
J1-C11,C12
J4-B5
J4-A5
J4-A2
J4-A4
J4-A1
R
D1 F
U5
J1-C1\C4
J2-B12
J4-C2
G6
J1-A9
J2-B7
J4-B6
J2-B8
J4-B2
J4-C1
J4-B1
J1-B1
L30
U19
Q7 CR5 L27
30 86
U26 L41 Q1 Q2
G
H1
M3 87 85
Q3
H2 SW1 SW2
L42 M4
B1 N.O. N.C.
12V DC FB1
B1 M3 D1 U19 U26 U20 G6 Q7 Q3 L30 H2 Y7 Y10 Y7A Y10A FB1 H1 SW1 SW2 L41 L42 L27 Y29 Q1 M4 Q2
TEMPERATURE SWITCH
COOLANT
HOURMETER
CHOKE
(OPTION)
AUTOMOTIVE-STYLE HORN
ALTERNATOR
BATTERY 12V DC
IGNITION COIL
DISTRIBUTOR
SPARK PLUG(S)
GENERATOR (OPTION)
TILT ALARM
GENERATOR ON LED
LPG SELECT
FUEL PUMP
PLATFORM DOWN
TEMPERATURE LED
COOLANT
FLASHING BEACON (OPTION)
GASOLINE SELECT
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES0116S
Electrical Schematic
REV C Gasoline/LPG Models (from serial number 38465 to 41199)
Part 2 of 3
QD4
C C
A A
B B
D D
E E
TS67
FUNCTION RD WH
ENABLE
LS6 LS5 LS1 PS3 N.C.
PLATFORM PLATFORM EXTENSION PLATFORM
DOWN UP DECK OVERLOAD
LS12 LS13 LS14 LS15
LEFT RIGHT LEFT RIGHT
FRONT FRONT REAR REAR LEVEL
OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER SENSOR
N.C. N.C. N.C. N.O. CIRCUIT
DOWN
S7
PLATFORM
J3-A1
J2-C1/C10
J2-A2
J3-A3
J3-A2
J2-A7
J2-A8
J2-A10
J3-A6
J3-B5
J3-B4
J3-A4
J1-C7,C8
J3-A5
J2-A6
J2-B10
U5
ELECTRONIC CONTROL MODULE
J2-B10
J1-A10
J1-A12
J1-A11
J1-B6
J1-B7
J2-B3
J1-A7
J1-B8
J1-B3
J1-B5
J1-A3
J1-A4
J1-A6
J1-A8
J1-B2
J3-B2
J1-A5
J1-A2
J3-B1
J2-B1
J1-A1
RD
BL
YL
S8
2-AXIS
LEVEL
SENSOR
BK
Y3 Y4 Y8 Y2 Y6 Y5 Y6A Y5A Y1 Y1A Y1B Y9 Y35 Y36 Y33 Y34 Y40 Y39 Y44 S9
STEER LEFT
DRIVE FORWARD
DRIVE PARALLEL
DRIVE PARALLEL
DRIVE PARALLEL
PLATFORM UP
BRAKE RELEASE
DRIVE REVERSE
STEER RIGHT
DRIVE REVERSE
FLOW CONTROL
PROPORTIONAL
OUTRIGGER
RIGHT FRONT
DRIVE FORWARD
OUTRIGGER
RIGHT REAR
SLOW
OUTRIGGER EXTEND
OUTRIGGER
LEFT REAR
OUTRIGGER EXTEND
OUTRIGGER RETRACT
OUTRIGGER
LEFT FRONT
SENSOR
AUTO LEVELING
- NOTE -
MACHINE SHOWN IN THE STOWED
ES0116S POSITION WITH THE POWER OFF
Electrical Schematic
Gasoline/LPG Models (from serial number 38465 to 41199) REV C
Part 3 of 3
P2 P2
EMERGENCY EMERGENCY
QD3 STOP QD3 STOP
BK BK
C C BK POWER TO PLATFORM C C BK POWER TO PLATFORM
RD RD
A A RD POWER TO GROUND A A RD POWER TO GROUND
SW25 U3 D7 5V DC
SW25 U3 D7 5V DC
1 1
2 2
3 OR 3 OR
4 JC1 4 JC1
5 BN R15 JOYSTICK 5 BN R15 JOYSTICK
6 5K CONTROLLER 6 5K CONTROLLER
7 PP POTENTIOMETER 7 PP POTENTIOMETER
8 8
WH/BK WH/YL WH/BK WH/YL
RIGHT
LEFT
RIGHT
PIN18 PIN18
WH/RD WH/RD
PIN15 PIN15
WH WH
PIN14 PIN14
Electrical Schematic
Gasoline/LPG Models (from serial number 41200 to 41823) REV D
Part 1 of 3
PLATFORM
KS1
GROUND
85 86
CR43
GROUND POWER TO
87 ECM
30
(+)
85 86
CR25
CR1 87
30 ENGINE RUN
ENGINE
START
( ) B4
- 12V DC 86 30
85 86
87
CR8 BN14 BN68
85 87 30 IGNITION LPG START
SELECT
85 86
87
CR15
30 GLOW
CB1 PLUG
20A
85 86
R
D1 F 87
CR4
3 30 HIGH IDLE
J4-C3
J2-A5
J4-B4
J4-C4
J1-C11,C12 J2-B12
J4-B5
J4-A5
J4-A1
J4-A2
1
G6
2 L30 J1-C1\C4
U5
ELECTRONIC CONTROL MODULE
HYDRAULIC
J2-B11
J2-B7
J4-B6
J2-B8
J1-A9
J4-B2
J1-B1
J4-B1
OIL COOLER
(OPTION)
(+) B1 F9A
12V DC 20A SW4 CR5 86
30
U19
N.O. Q7 L27
U26 30 86 87 85
SW1 SW2 L41
CR17
G
H1
Q3 H2
M3
87 85
N.O. N.C.
L42
( ) M1 FB1
-
B1 M3 D1 U19 U26 U20 M1 SW4 G6 Q7 Q3 L30 H2 Y7 Y10 Y7A Y10A H1 FB1 SW1 SW2 L41 L42 L27 Y29
TEMPERATURE SWITCH
COOLANT
HOURMETER
(OPTION)
AUTOMOTIVE-STYLE HORN
ALTERNATOR
BATTERY 12V DC
IGNITION COIL
DISTRIBUTOR
SPARK PLUG(S)
GENERATOR (OPTION)
COOLING FAN (OPTION)
HYDRAULIC OIL
TILT ALARM
GENERATOR ON LED
TEMPERATURE SWITCH
HYDRAULIC OIL
TEMPERATURE LED
COOLANT
PLATFORM DOWN
AUXILIARY PLATFORM
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES0116U
Electrical Schematic
REV D Gasoline/LPG Models (from serial number 41200 to 41823)
Part 2 of 3
P1
EMERGENCY
STOP QD4
C C
A A
B B
D D
E E
G8
OUTRIGGERS DIAGNOSTIC
DISPLAY
(OPTION) (OPTION)
BN44 FUNCTION RD WH
ENABLE
J2-C1/C10
J4-A3
J4-A4
J2-A1
J2-A2
J3-A2
J3-A3
J2-A7
J2-A8
J2-A10
J3-A6
J3-B5
J3-B4
J3-A4
J1-C7,C8
J3-A5
J2-A6
J2-B10
U5
ELECTRONIC CONTROL MODULE
J2-B10
J1-A10
J1-A12
J1-A11
J4-C2
J1-B6
J1-B7
J2-B3
J1-A7
J1-B8
J1-B3
J1-B5
J1-A3
J1-A4
J1-A6
J3-B2
J1-A8
J1-B2
J1-A5
J1-A2
J4-C1
J3-B1
J2-B1
J1-A1
RD
BL
YL
S8
2-AXIS
LEVEL
SENSOR
Q1 Q2
M4
BK
Y3 Y4 Y8 Y2 Y6 Y5 Y6A Y5A Y1 Y1A Y1B Y9 Y35 Y36 Y33 Y34 Y40 Y39 Y44 S9 Q1 M4 Q2
LPG SELECT
FUEL PUMP
STEER LEFT
DRIVE FORWARD
DRIVE PARALLEL
DRIVE PARALLEL
DRIVE PARALLEL
PLATFORM UP
BRAKE RELEASE
DRIVE REVERSE
STEER RIGHT
DRIVE REVERSE
FLOW CONTROL
PROPORTIONAL
OUTRIGGER
RIGHT FRONT
DRIVE FORWARD
OUTRIGGER
RIGHT REAR
SLOW
OUTRIGGER EXTEND
OUTRIGGER
LEFT REAR
OUTRIGGER EXTEND
OUTRIGGER RETRACT
OUTRIGGER
LEFT FRONT
SENSOR
AUTO LEVELING
GASOLINE SELECT
- NOTE -
MACHINE SHOWN IN THE STOWED
ES0116U POSITION WITH THE POWER OFF
Electrical Schematic
Gasoline/LPG Models (from serial number 41200 to 41823) REV D
Part 3 of 3
P2 P2
EMERGENCY EMERGENCY
QD3 STOP QD3 STOP
BK BK
C C BK POWER TO PLATFORM C C BK POWER TO PLATFORM
RD RD
A A RD POWER TO GROUND A A RD POWER TO GROUND
SW25 U3 D7 5V DC
SW25 U3 D7 5V DC
1 1
2 2
3 OR 3 OR
4 JC1 4 JC1
5 BN R15 JOYSTICK 5 BN R15 JOYSTICK
6 5K CONTROLLER 6 5K CONTROLLER
7 PP POTENTIOMETER 7 PP POTENTIOMETER
8 8
WH/BK WH/YL WH/BK WH/YL
RIGHT
LEFT
RIGHT
PIN18 PIN18
WH/RD WH/RD
PIN15 PIN15
WH WH
PIN14 PIN14
Electrical Schematic
Gasoline/LPG Models (from serial number 41824 to GS6803-42381) REV C
Part 1 of 3
PLATFORM 2
B
B1 GROUND
4
85 86
CR43
GROUND 3 POWER TO
87 ECM
30
KS1
KEY SWITCH
85 86
CR25
CR1 87
30 ENGINE RUN
ENGINE
START
86 30
85 86
87
CR8 BN14 BN68
85 87 30 IGNITION LPG START
SELECT
87a
85 86
87
CR15
30 STARTING AID
CB1
20A
85 86
R
D1 F 87
CR4
30 HIGH IDLE
J4-C3
J2-A5
J4-B4
J4-C4
J1-C11,C12 J2-B12
J4-B5
J4-A5
J4-A1
J4-A2
G6
L30 J1-C1\C4
U5
ELECTRONIC CONTROL MODULE
HYDRAULIC
J2-B11
J2-B7
J4-B6
J2-B8
J1-A9
J4-B2
J1-B1
J4-B1
OIL COOLER
(OPTION)
(+) B1 F9A
12V DC 20A SW4 CR5 86
30
U19
N.O. Q7 L27
U26 30 86 87 85
SW1 SW2 L41
CR17
G
H1
Q3 H2
M3
87 85
N.O. N.C.
L42
( ) M1 FB1
-
B1 M3 D1 U19 U26 U20 M1 SW4 G6 Q7 Q3 L30 H2 Y7 Y10 Y7A Y10A H1 FB1 SW1 SW2 L41 L42 L27 Y29
TEMPERATURE SWITCH
COOLANT
HOURMETER
(OPTION)
AUTOMOTIVE-STYLE HORN
ALTERNATOR
BATTERY 12V DC
IGNITION COIL
DISTRIBUTOR
SPARK PLUG(S)
GENERATOR (OPTION)
COOLING FAN (OPTION)
HYDRAULIC OIL
TILT ALARM
GENERATOR ON LED
TEMPERATURE SWITCH
HYDRAULIC OIL
TEMPERATURE LED
COOLANT
PLATFORM DOWN
AUXILIARY PLATFORM
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES0116V
Electrical Schematic
REV C Gasoline/LPG Models (from serial number 41824 to GS6803-42381)
Part 2 of 3
P1
EMERGENCY
STOP QD4
C C
A A
B B
D D
E E
G8
OUTRIGGERS DIAGNOSTIC
DISPLAY
(OPTION) (OPTION)
BN44 FUNCTION RD WH
ENABLE
J2-C1/C10
J4-A3
J4-A4
J2-A1
J2-A2
J3-A2
J3-A3
J2-A7
J2-A8
J2-A10
J3-A6
J3-B5
J3-B4
J3-A4
J1-C7,C8
J3-A5
J2-A6
J2-B10
U5
ELECTRONIC CONTROL MODULE
J2-B10
J1-A10
J1-A12
J1-A11
J4-C2
J1-B6
J1-B7
J2-B3
J1-A7
J1-B8
J1-B3
J1-B5
J1-A3
J1-A4
J1-A6
J3-B2
J1-A8
J1-B2
J1-A5
J1-A2
J4-C1
J3-B1
J2-B1
J1-A1
RD
BL
YL
S8
2-AXIS
LEVEL
SENSOR
Q1 Q2
M4
BK
Y3 Y4 Y8 Y2 Y6 Y5 Y6A Y5A Y1 Y1A Y1B Y9 Y35 Y36 Y33 Y34 Y40 Y39 Y44 S9 Q1 M4 Q2
LPG SELECT
FUEL PUMP
STEER LEFT
DRIVE FORWARD
DRIVE PARALLEL
DRIVE PARALLEL
DRIVE PARALLEL
PLATFORM UP
BRAKE RELEASE
DRIVE REVERSE
STEER RIGHT
DRIVE REVERSE
FLOW CONTROL
PROPORTIONAL
OUTRIGGER
RIGHT FRONT
DRIVE FORWARD
OUTRIGGER
RIGHT REAR
SLOW
OUTRIGGER EXTEND
OUTRIGGER
LEFT REAR
OUTRIGGER EXTEND
OUTRIGGER RETRACT
OUTRIGGER
LEFT FRONT
SENSOR
AUTO LEVELING
GASOLINE SELECT
- NOTE -
MACHINE SHOWN IN THE STOWED
ES0116V POSITION WITH THE POWER OFF
Electrical Schematic
Gasoline/LPG Models (from serial number 41824 to GS6803-42381) REV C
Part 3 of 3
P2 P2
EMERGENCY EMERGENCY
QD3 STOP QD3 STOP
BK BK
C C BK POWER TO PLATFORM C C BK POWER TO PLATFORM
RD RD
A A RD POWER TO GROUND A A RD POWER TO GROUND
SW25 U3 D7 5V DC
SW25 U3 D7 5V DC
1 1
2 2
3 OR 3 OR
4 JC1 4 JC1
5 BN R15 JOYSTICK 5 BN R15 JOYSTICK
6 5K CONTROLLER 6 5K CONTROLLER
7 PP POTENTIOMETER 7 PP POTENTIOMETER
8 8
WH/BK WH/YL WH/BK WH/YL
RIGHT
LEFT
RIGHT
PIN18 PIN18
WH/RD WH/RD
PIN15 PIN15
WH WH
PIN14 PIN14
Electrical Schematic
ANSI Models with Gasoline/LPG Power REV A
(from serial number GS6803-42382 to GS6805-43594)
Part 1 of 3
KS1 KEY SWITCH P1
B1 EMERGENCY STOP
2
PLATFORM
CONTROL
B 4
GROUND
CONTROL
AB1
CB2 20A
AB7 AB3 AB3 AB3
AB28
J2-A4
J2-B7
J2-B8
J2-B11
J1-C2
J2-C12
J2-A2
J2-C1/C3
J2-A5
J2-A3
U5
ECM
BAT L30
WORK LIGHTS
EXCT STA
D1 J1-C7
BN23 BN91
J2-C4 AUXILIARY DOWN AUXILIARY DOWN
J1-A3
J1-A9
J2-B9 ENABLE
U19
(+)
CR15 CR4
B1 ( )
- STARTING HIGH IDLE
STARTER
AID
+
86 30 7 86 30 8
U26
C5
G
M3 85 87 87A 85 87 87A
4700 uF
Y7A Y10A
-
Q7 Q3
CHOKE HIGH IDLE
H2 SOLENOID SOLENOID
Y8 Y7 Y10
H2 AUTOMOTIVE-STYLE HORN
K1 STARTER RELAY
B1 12 VOLT BATTERY
M3 STARTER MOTOR
U26 DISTRIBUTOR
D1 ALTERNATOR
G6 ENGINE HOURMETER
U32 GLOW PLUG (OPTION)
Y8 PLATFORM UP
Y7 PLATFORM DOWN
(GS-3268 ONLY)
Y7A PLATFORM DOWN
(GS-3268 ONLY)
Y10A AUX PLATFORM DOWN
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7161A
Electrical Schematic
REV A ANSI Models with Gasoline/LPG Power
(from serial number GS6803-42382 to GS6805-43594)
Part 2 of 3
RD
WH
F9A SW4
N.O.
20A
CR17 30 86
N.C.
LEVEL SENSOR
87 85 CIRCUIT BOARD
HYDRAULIC
OIL COOLER
(OPTION) M1 S7 LEVEL
SENSOR
MODELS WITHOUT
BATTERY (-) OUTRIGGERS
AB23
BK AB29
AB1
J2-B2
J2-A6
J2-B10
U5
ELECTRONIC CONTROL MODULE
J2-B12
J1-A10
J1-A12
J2-C11
J1-C11
J1-B12
J1-A11
J1-C8
J1-C9
J1-A2
J1-A5
J1-A4
J1-A7
J1-A1
J1-A6
J1-B3
J1-A8
J2-C7
J1-B1
Y4 Y1 Y1B Y6 Y6A Y9 Q2 Q1
M4
H5 ALARM
Y4 STEER LEFT
Y1 DRIVE PARALLEL
Y2 BRAKE RELEASE
Y9
Q2 GASOLINE SELECT
M4 FUEL PUMP
Q1 LPG SELECT
ECM GROUND
S7 LEVEL SENSOR
FLOW CONTROL
PROPORTIONAL
- NOTE -
MACHINE SHOWN IN THE STOWED
ES7161A POSITION WITH THE POWER OFF
Electrical Schematic
ANSI Models with Gasoline/LPG Power REV A
(from serial number GS6803-42382 to GS6805-43594)
Part 3 of 3
QD4 QD3 P2
BK EMERGENCY
WH/RD 4 4 4 4 BK POWER TO PLATFORM STOP
RD
RD/WH 3 3 3 3 RD POWER TO GROUND
BL 1 1 1 1 WH GROUND WH J5 PIN1
BK 2 2 DATA LINK (HIGH) BL
2 2 BL J5 PIN4
OR 5 5 5 5 OR OR
DATA LINK (LOW) J5 PIN5
OUTRIGGERS
(OPTION) J5 PIN2
12V DC
AB3 AB3 AB2 AB2 U3 D7
PLATFORM CONTROLS VOLTAGE 5V DC
PRINTED CIRCUIT BOARD REGULATOR
S8
2 AXIS GY
TILT LEVEL J2 PIN1
SENSOR
HALL EFFECT
J2 PIN2
YL
JC1
GROUND
GENERATOR
POWER
WH JOYSTICK
PITCH
J2 PIN12
ROLL
BL
YL
BK
J2 PIN4
DATA LINK (-)
DATA LINK (+)
GND FROM PLAT
LEFT
RIGHT
N.O. N.O. N.O. N.O. OR STEER
J2 PIN5
BK LEFT/ RIGHT
AB23 AB24 J2 PIN6
RD
J2 PIN7
AB27 AB26 AB17 AB16 AB25 AB1 J2 PIN8
WH/BL
J2 PIN14
J1-C5
J1-C3
J1-C6
J1-C4
J2-B10
J2-B1
J2-B3
J2-B2
J2-A10
J2-A11
J2-A12
POUT1
MODULE
J1-B7
J1-B6
J1-B8
J1-B5
J1-B9
YL
J1 PIN4
PLATFORM UP/DOWN TS20
BL -OR-
J1 PIN3
PLATFORM & OUTRIGGER
RD UP/DOWN
J1 PIN1 TS21
BK
J1 PIN5
J3 PIN1
RD +
- NOTE - J3 PIN2
BK
H1
ALARM PLATFORM
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7161A
CONTROLS
Electrical Schematic
ANSI Models with Gasoline/LPG Power REV A
(from serial number GS6805-43595 to GS6805-44770)
Part 1 of 3
F9 5A FUSE P1EMERGENCY STOP
KS1 KEY SWITCH
2
B1
PLATFORM
CONTROL
4
B
3
GROUND
CONTROL
AB1
CB2 20A
AB7 AB3 AB3 AB3
AB28
J2-A4
J2-B7
J2-B8
J2-B11
J1-C2
J2-C12
J2-A2
J2-C1/C3
J2-A5
J2-A3
U5
ECM
BAT L30
WORK LIGHTS
EXCT STA
D1 J1-C7
BN23 BN91
J2-C4 AUXILIARY DOWN AUXILIARY DOWN
J1-A3
J1-A9
J2-B9 ENABLE
U19
(+)
CR15 CR4
B1 ( )
- STARTING HIGH IDLE
STARTER
AID
+
86 30 7 86 30 8
U26
C5
G
M3 85 87 87A 85 87 87A
4700 uF
Y7A Y10A
-
Q7 Q3
CHOKE HIGH IDLE
H2 SOLENOID SOLENOID
Y8 Y7 Y10
H2 AUTOMOTIVE-STYLE HORN
K1 STARTER RELAY
B1 12 VOLT BATTERY
M3 STARTER MOTOR
U26 DISTRIBUTOR
D1 ALTERNATOR
G6 ENGINE HOURMETER
U32 GLOW PLUG (OPTION)
Y8 PLATFORM UP
Y7 PLATFORM DOWN
(GS-3268 ONLY)
Y7A PLATFORM DOWN
(GS-3268 ONLY)
Y10A AUX PLATFORM DOWN
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7161D
Electrical Schematic
REV A ANSI Models with Gasoline/LPG Power
(from serial number GS6805-43595 to GS6805-44770)
Part 2 of 3
RD
WH
F9A SW4
N.O.
20A
CR17 30 86
N.C.
LEVEL SENSOR
87 85 CIRCUIT BOARD
HYDRAULIC
OIL COOLER
(OPTION) M1 S7 LEVEL
SENSOR
MODELS WITHOUT
BATTERY (-) OUTRIGGERS
AB23
BK AB29
AB1
J2-B2
J2-A6
J2-B10
U5
ELECTRONIC CONTROL MODULE
J2-B12
J1-A10
J1-A12
J2-C11
J1-C11
J1-B12
J1-A11
J1-C8
J1-C9
J1-A2
J1-A5
J1-A4
J1-A7
J1-A1
J1-A6
J1-B3
J1-A8
J2-C7
J1-B1
Y4 Y1 Y1B Y6 Y6A Y9 Q2 Q1
M4
H5 ALARM
Y4 STEER LEFT
Y1 DRIVE PARALLEL
Y2 BRAKE RELEASE
Y9
Q2 GASOLINE SELECT
M4 FUEL PUMP
Q1 LPG SELECT
ECM GROUND
S7 LEVEL SENSOR
FLOW CONTROL
PROPORTIONAL
- NOTE -
MACHINE SHOWN IN THE STOWED
ES7161D POSITION WITH THE POWER OFF
Electrical Schematic
ANSI Models with Gasoline/LPG Power REV A
(from serial number GS6805-43595 to GS6805-44770)
Part 3 of 3
QD4 QD3 P2
BK EMERGENCY
WH/RD 4 4 4 4 BK POWER TO PLATFORM STOP
RD
RD/WH 3 3 3 3 RD POWER TO GROUND
BL 1 1 1 1 WH GROUND WH J5 PIN1
BK 2 2 DATA LINK (HIGH) BL
2 2 BL J5 PIN4
OR 5 5 5 5 OR OR
DATA LINK (LOW) J5 PIN5
OUTRIGGERS
(OPTION) J5 PIN2
12V DC
AB3 AB3 AB2 AB2 U3 D7
PLATFORM CONTROLS VOLTAGE 5V DC
PRINTED CIRCUIT BOARD REGULATOR
S8
2 AXIS GY
TILT LEVEL J2 PIN1
SENSOR
HALL EFFECT
J2 PIN2
YL
JC1
GROUND
GENERATOR
POWER
WH JOYSTICK
PITCH
J2 PIN12
ROLL
BL
YL
BK
J2 PIN4
DATA LINK (-)
DATA LINK (+)
GND FROM PLAT
LEFT
RIGHT
N.O. N.O. N.O. N.O. OR STEER
J2 PIN5
BK LEFT/ RIGHT
AB23 AB24 J2 PIN6
RD
J2 PIN7
AB27 AB26 AB17 AB16 AB25 AB1 J2 PIN8
WH/BL
J2 PIN14
J1-C5
J1-C3
J1-C6
J1-C4
J2-B10
J2-B1
J2-B3
J2-B2
J2-A10
J2-A11
J2-A12
POUT1
MODULE
J1-B7
J1-B6
J1-B8
J1-B5
J1-B9
YL
J1 PIN4
PLATFORM UP/DOWN TS20
BL -OR-
J1 PIN3
PLATFORM & OUTRIGGER
RD UP/DOWN
J1 PIN1 TS21
BK
J1 PIN5
J3 PIN1
RD +
- NOTE - J3 PIN2
BK
H1
ALARM PLATFORM
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7161D
CONTROLS
Electrical Schematic
CE Models with Gasoline/LPG Power REV B
(from serial number GS6803-42382 to GS6805-43594)
Part 1 of 3
KS1 KEY SWITCH P1
B1 EMERGENCY STOP
2
PLATFORM
CONTROL
B 4
GROUND
CONTROL
AB1
CB2 20A
AB3 AB4
AB28
PS2
PLATFORM
OVERLOAD
PRESSURE
SWITCH
AB20
AB21
J2-A4
J2-B7
J2-B8
J2-B11
J1-C2
J2-C12
J2-A2
J2-C1/C3
J2-A5
J2-A3
U5
ECM
BAT
EXCT STA
D1 J1-C7
BN23 BN91
J2-C4 AUXILIARY DOWN AUXILIARY DOWN
J1-A3
J1-A9
AB1
ENABLE
U19 J2-B9
(+) CR15
STARTING L30 AB12
AID CR4 WORK N.C.
N.C.
86 30 7 HIGH IDLE LIGHTS LS24 LS25
B1 -
( ) AB1
MAXIMUM LOAD SENSE
STARTER 85 87 87A 86 30 8 HEIGHT DELAY
+
U26 LIMIT SW LIMIT SW
9
86 30
85 87 87A
G
M3 CR77
DOWN
ENABLE
85 87 87A
Y7A Y10A
C5
4700 uF
-
Q7
H2 CHOKE Q3
SOLENOID HIGH IDLE Y8 Y7 Y10
SOLENOID
H2 AUTOMOTIVE-STYLE HORN
K1 STARTER RELAY
B1 12 VOLT BATTERY
M3 STARTER MOTOR
U26 DISTRIBUTOR
G6 ENGINE HOURMETER
U32 GLOW PLUG (OPTION)
Y8 PLATFORM UP
Y7 PLATFORM DOWN
(GS-3268 ONLY)
Y7A PLATFORM DOWN
(GS-3268 ONLY)
Y10A AUX PLATFORM DOWN
- NOTE -
MACHINE SHOWN IN THE STOWED
ES7161A
POSITION WITH THE POWER OFF ES7183A
Electrical Schematic
REV B CE Models with Gasoline/LPG Power
(from serial number GS6803-42382 to GS6805-43594)
Part 2 of 3
RD
WH
F9A SW4
N.O.
20A
CR17 30 86
N.C.
LEVEL SENSOR
87 85 CIRCUIT BOARD
HYDRAULIC
OIL COOLER
(OPTION) M1 S7 LEVEL
SENSOR
MODELS WITHOUT
BATTERY (-) OUTRIGGERS
AB23
BK AB29
AB1
J2-B2
J2-A6
J2-B10
U5
ELECTRONIC CONTROL MODULE
J2-B12
J1-A10
J1-A12
J2-C11
J1-C11
J1-B12
J1-A11
J1-C8
J1-C9
J1-A2
J1-A5
J1-A4
J1-A7
J1-A1
J1-A6
J1-B3
J1-A8
J2-C7
J1-B1
Y4 Y1 Y1B Y6 Y6A Y9 Q2 Q1
M4
H5 ALARM
Y4 STEER LEFT
Y1 DRIVE PARALLEL
Y2 BRAKE RELEASE
Y9
Q2 GASOLINE SELECT
M4 FUEL PUMP
Q1 LPG SELECT
ECM GROUND
S7 LEVEL SENSOR
FLOW CONTROL
PROPORTIONAL
- NOTE -
MACHINE SHOWN IN THE STOWED
ES7161A POSITION WITH THE POWER OFF
Electrical Schematic
CE Models with Gasoline/LPG Power REV B
(from serial number GS6803-42382 to GS6805-43594)
Part 3 of 3
QD4 QD3 P2
BK EMERGENCY
WH/RD 4 4 4 4 BK POWER TO PLATFORM STOP
RD
RD/WH 3 3 3 3 RD POWER TO GROUND
BL 1 1 1 1 WH GROUND WH J5 PIN1
BK 2 2 DATA LINK (HIGH) BL
2 2 BL J5 PIN4
OR 5 5 5 5 OR OR
DATA LINK (LOW) J5 PIN5
OUTRIGGERS
(OPTION) J5 PIN2
12V DC
AB3 AB3 AB2 AB2 U3 D7
PLATFORM CONTROLS VOLTAGE 5V DC
PRINTED CIRCUIT BOARD REGULATOR
S8
2 AXIS GY
TILT LEVEL J2 PIN1
SENSOR
HALL EFFECT
J2 PIN2
YL
JC1
GROUND
GENERATOR
POWER
WH JOYSTICK
PITCH
J2 PIN12
ROLL
BL
YL
BK
J2 PIN4
DATA LINK (-)
DATA LINK (+)
GND FROM PLAT
LEFT
RIGHT
N.O. N.O. N.O. N.O. OR STEER
J2 PIN5
BK LEFT/ RIGHT
AB23 AB24 J2 PIN6
RD
J2 PIN7
AB27 AB26 AB17 AB16 AB25 AB1 J2 PIN8
WH/BL
J2 PIN14
J1-C5
J1-C3
J1-C6
J1-C4
J2-B10
J2-B1
J2-B3
J2-B2
J2-A10
J2-A11
J2-A12
POUT1
MODULE
J1-B7
J1-B6
J1-B8
J1-B5
J1-B9
YL
J1 PIN4
PLATFORM UP/DOWN TS20
BL -OR-
J1 PIN3
PLATFORM & OUTRIGGER
RD UP/DOWN
J1 PIN1 TS21
BK
J1 PIN5
J3 PIN1
RD +
- NOTE - J3 PIN2
BK
H1
ALARM PLATFORM
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7161A
CONTROLS
Electrical Schematic
CE Models with Gasoline/LPG Power REV B
(from serial number GS6805-43595 to GS6805-44168)
Part 1 of 3
F9 5A FUSE P1EMERGENCY STOP
KS1 KEY SWITCH
2
B1
PLATFORM
CONTROL
4
B
3
GROUND
CONTROL
AB1
CB2 20A
AB3 AB4
AB28
PS2
PLATFORM
OVERLOAD
PRESSURE
SWITCH
AB20
AB21
J2-A4
J2-B7
J2-B8
J2-B11
J1-C2
J2-C12
J2-A2
J2-C1/C3
J2-A5
J2-A3
U5
ECM
BAT
EXCT STA
D1 J1-C7
BN23 BN91
J2-C4 AUXILIARY DOWN AUXILIARY DOWN
J1-A3
J1-A9
AB1
ENABLE
U19 J2-B9
(+) CR15
STARTING L30 AB12
AID CR4 WORK N.C.
N.C.
86 30 7 HIGH IDLE LIGHTS LS24 LS25
B1 -
( ) AB1
MAXIMUM LOAD SENSE
STARTER 85 87 87A 86 30 8 HEIGHT DELAY
+
U26 LIMIT SW LIMIT SW
9
86 30
85 87 87A
G
M3 CR77
DOWN
ENABLE
85 87 87A
Y7A Y10A
C5
4700 uF
-
Q7
H2 CHOKE Q3
SOLENOID HIGH IDLE Y8 Y7 Y10
SOLENOID
H2 AUTOMOTIVE-STYLE HORN
K1 STARTER RELAY
B1 12 VOLT BATTERY
M3 STARTER MOTOR
U26 DISTRIBUTOR
G6 ENGINE HOURMETER
U32 GLOW PLUG (OPTION)
Y8 PLATFORM UP
Y7 PLATFORM DOWN
(GS-3268 ONLY)
Y7A PLATFORM DOWN
(GS-3268 ONLY)
Y10A AUX PLATFORM DOWN
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7183B
Electrical Schematic
REV B CE Models with Gasoline/LPG Power
(from serial number GS6805-43595 to GS6805-44168)
Part 2 of 3
RD
WH
F9A SW4
N.O.
20A
CR17 30 86
N.C.
LEVEL SENSOR
87 85 CIRCUIT BOARD
HYDRAULIC
OIL COOLER
(OPTION) M1 S7 LEVEL
SENSOR
MODELS WITHOUT
BATTERY (-) OUTRIGGERS
AB23
BK AB29
AB1
J2-B2
J2-A6
J2-B10
U5
ELECTRONIC CONTROL MODULE
J2-B12
J1-A10
J1-A12
J2-C11
J1-C11
J1-B12
J1-A11
J1-C8
J1-C9
J1-A2
J1-A5
J1-A4
J1-A7
J1-A1
J1-A6
J1-B3
J1-A8
J2-C7
J1-B1
Y4 Y1 Y1B Y6 Y6A Y9 Q2 Q1
M4
H5 ALARM
Y4 STEER LEFT
Y1 DRIVE PARALLEL
Y2 BRAKE RELEASE
Y9
Q2 GASOLINE SELECT
M4 FUEL PUMP
Q1 LPG SELECT
ECM GROUND
S7 LEVEL SENSOR
FLOW CONTROL
PROPORTIONAL
- NOTE -
MACHINE SHOWN IN THE STOWED
ES7183B POSITION WITH THE POWER OFF
Electrical Schematic
CE Models with Gasoline/LPG Power REV B
(from serial number GS6805-43595 to GS6805-44168)
Part 3 of 3
QD4 QD3 P2
BK EMERGENCY
WH/RD 4 4 4 4 BK POWER TO PLATFORM STOP
RD
RD/WH 3 3 3 3 RD POWER TO GROUND
BL 1 1 1 1 WH GROUND WH J5 PIN1
BK 2 2 DATA LINK (HIGH) BL
2 2 BL J5 PIN4
OR 5 5 5 5 OR OR
DATA LINK (LOW) J5 PIN5
OUTRIGGERS
(OPTION) J5 PIN2
12V DC
AB3 AB3 AB2 AB2 U3 D7
PLATFORM CONTROLS VOLTAGE 5V DC
PRINTED CIRCUIT BOARD REGULATOR
S8
2 AXIS GY
TILT LEVEL J2 PIN1
SENSOR
HALL EFFECT
J2 PIN2
YL
JC1
GROUND
GENERATOR
POWER
WH JOYSTICK
PITCH
J2 PIN12
ROLL
BL
YL
BK
J2 PIN4
DATA LINK (-)
DATA LINK (+)
GND FROM PLAT
LEFT
RIGHT
N.O. N.O. N.O. N.O. OR STEER
J2 PIN5
BK LEFT/ RIGHT
AB23 AB24 J2 PIN6
RD
J2 PIN7
AB27 AB26 AB17 AB16 AB25 AB1 J2 PIN8
WH/BL
J2 PIN14
J1-C5
J1-C3
J1-C6
J1-C4
J2-B10
J2-B1
J2-B3
J2-B2
J2-A10
J2-A11
J2-A12
POUT1
MODULE
J1-B7
J1-B6
J1-B8
J1-B5
J1-B9
YL
J1 PIN4
PLATFORM UP/DOWN TS20
BL -OR-
J1 PIN3
PLATFORM & OUTRIGGER
RD UP/DOWN
J1 PIN1 TS21
BK
J1 PIN5
J3 PIN1
RD +
- NOTE - J3 PIN2
BK
H1
ALARM PLATFORM
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7183B
CONTROLS
Electrical Schematic
CE Models with Gasoline/LPG Power REV A
(from serial number GS6805-44169 to GS6805-44770)
Part 1 of 3
F9 5A FUSE P1EMERGENCY STOP
KS1 KEY SWITCH
2
B1
PLATFORM
CONTROL
4
PS2A PLATFORM OVERLOAD PRESSURE SWITCH
B R25
3 5 OHM
GROUND
CONTROL
AB20
AB1
CB2 20A
AB4
AB28
AB21
J2-A4
J2-B7
J2-B8
J2-B11
J1-C2
J2-C12
J2-A2
J2-C1/C3
J2-A5
J2-A3
U5
ECM
BAT
EXCT STA
D1 J1-C7
BN23 BN91
J2-C4 AUXILIARY DOWN AUXILIARY DOWN
J1-A3
J1-A9
AB1
ENABLE
U19 J2-B9
(+) CR15
STARTING L30 AB12
AID CR4 WORK N.C.
N.C.
86 30 7 HIGH IDLE LIGHTS LS24 LS25
B1 -
( ) AB1
MAXIMUM LOAD SENSE
STARTER 85 87 87A 86 30 8 HEIGHT DELAY
+
U26 LIMIT SW LIMIT SW
9
86 30
85 87 87A
G
M3 CR77
DOWN
ENABLE
85 87 87A
Y7A Y10A
C5
4700 uF
-
Q7
H2 CHOKE Q3
SOLENOID HIGH IDLE Y8 Y7 Y10
SOLENOID
H2 AUTOMOTIVE-STYLE HORN
K1 STARTER RELAY
B1 12 VOLT BATTERY
M3 STARTER MOTOR
U26 DISTRIBUTOR
G6 ENGINE HOURMETER
U32 GLOW PLUG (OPTION)
Y8 PLATFORM UP
Y7 PLATFORM DOWN
(GS-3268 ONLY)
Y7A PLATFORM DOWN
(GS-3268 ONLY)
Y10A AUX PLATFORM DOWN
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7183C
Electrical Schematic
REV A CE Models with Gasoline/LPG Power
(from serial number GS6805-44169 to GS6805-44770)
Part 2 of 3
RD
WH
F9A SW4
N.O.
20A
CR17 30 86
N.C.
LEVEL SENSOR
87 85 CIRCUIT BOARD
HYDRAULIC
OIL COOLER
(OPTION) M1 S7 LEVEL
SENSOR
MODELS WITHOUT
BATTERY (-) OUTRIGGERS
AB23
BK AB29
AB1
J2-B2
J2-A6
J2-B10
U5
ELECTRONIC CONTROL MODULE
J2-B12
J1-A10
J1-A12
J2-C11
J1-B12
J1-C11
J1-A11
J1-C8
J1-C9
J1-A2
J1-A5
J1-A4
J1-A7
J1-A1
J1-A6
J1-B3
J1-A8
J2-C7
J1-B1
Y4 Y1 Y1A Y2 Y6 Y6A Q1 Q2
M4
H5 ALARM
Y4 STEER LEFT
Y1 DRIVE PARALLEL
Y2 BRAKE RELEASE
Y9
Q1 LPG SELECT
Q2 GASOLINE SELECT
M4 FUEL PUMP
ECM GROUND
S7 LEVEL SENSOR
FLOW CONTROL
PROPORTIONAL
- NOTE -
MACHINE SHOWN IN THE STOWED
ES7183C POSITION WITH THE POWER OFF
Electrical Schematic
CE Models with Gasoline/LPG Power REV A
(from serial number GS6805-44169 to GS6805-44770)
Part 3 of 3
QD4 QD3 P2
BK EMERGENCY
WH/RD 4 4 4 4 BK POWER TO PLATFORM STOP
RD
RD/WH 3 3 3 3 RD POWER TO GROUND
BL 1 1 1 1 WH GROUND WH J5 PIN1
BK 2 2 DATA LINK (HIGH) BL
2 2 BL J5 PIN4
OR 5 5 5 5 OR OR
DATA LINK (LOW) J5 PIN5
OUTRIGGERS
(OPTION) J5 PIN2
12V DC
AB3 AB3 AB2 AB2 U3 D7
PLATFORM CONTROLS VOLTAGE 5V DC
PRINTED CIRCUIT BOARD REGULATOR
S8
2 AXIS GY
TILT LEVEL J2 PIN1
SENSOR
HALL EFFECT
J2 PIN2
YL
JC1
GROUND
GENERATOR
POWER
WH JOYSTICK
PITCH
J2 PIN12
ROLL
BL
YL
BK
J2 PIN4
DATA LINK (-)
DATA LINK (+)
GND FROM PLAT
LEFT
RIGHT
N.O. N.O. N.O. N.O. OR STEER
J2 PIN5
BK LEFT/ RIGHT
AB23 AB24 J2 PIN6
RD
J2 PIN7
AB27 AB26 AB17 AB16 AB25 AB1 J2 PIN8
WH/BL
J2 PIN14
J1-C5
J1-C3
J1-C6
J1-C4
J2-B10
J2-B1
J2-B3
J2-B2
J2-A10
J2-A11
J2-A12
POUT1
MODULE
J1-B7
J1-B6
J1-B8
J1-B5
J1-B9
YL
J1 PIN4
PLATFORM UP/DOWN TS20
BL -OR-
J1 PIN3
PLATFORM & OUTRIGGER
RD UP/DOWN
J1 PIN1 TS21
BK
J1 PIN5
J3 PIN1
RD +
- NOTE - J3 PIN2
BK
H1
ALARM PLATFORM
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7183C
CONTROLS
Electrical Schematic
Diesel Models (before serial number 21161) REV B
Part 1 of 2
P1
EMERGENCY
CB2 STOP
PLATFORM
KS1
1A
GROUND
85 86
CR43
GROUND POWER TO
87 ECM
30
85 86
CR25 C2
(+) CR1 87 ENGINE RUN 33000 uf
BN23 ENGINE 30
START
AUXILIARY 86 30
R7 2000
85 86
PLATFORM
DOWN B4
(GS-3268RT ONLY)
( )
- 12V DC 87
CR8
85 87 30 FUEL
TS52 TS56 TS54
85 86
CR15
START
HIGH IDLE
GLOW PLUG
87 GLOW
30
PLUG
CB1 85 86
20A
87
CR4
30 HIGH IDLE
J4-C3
J2-A5
J4-A3
J4-B4
J4-C4
J1-C11,C12
J4-B5
J4-A5
J4-A2
J4-A4
R
D1 F
U5
J1-C1\C4
J2-B12
G6
J1-A9
J2-B7
J4-B6
J2-B8
J4-B2
J4-B1
J1-B1
(+) B1
12V DC
30 86 L27
CR5
H1 SW1 SW2 L41
Q3
M3 87 85
N.O. N.C.
(HOLD)
(PULL)
U32 H2
L42
( ) FB1
-
Q8
B1 M3 D1 Q8 G6 U32 Q3 H2 Y7 Y7A H1 FB1 SW1 SW2 L41 L42 L27 Y29
TEMPERATURE SWITCH
COOLANT
HOURMETER
GLOW PLUG
(OPTION)
AUTOMOTIVE-STYLE HORN
ALTERNATOR
BATTERY 12V DC
GENERATOR (OPTION)
TILT ALARM
GENERATOR ON LED
FUEL SHUT OFF
PLATFORM DOWN
(GS-3268 ONLY)
PLATFORM DOWN
TEMPERATURE LED
COOLANT
FLASHING BEACON (OPTION)
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7140A
Electrical Schematic
REV B Diesel Models (before serial number 21161)
Part 2 of 2
P2
EMERGENCY
QD4 QD3 STOP
BK
C C C C BK POWER TO PLATFORM
RD
A A A A RD POWER TO GROUND
B B B B WH GROUND PIO3 PIO2
D D
D D BL DATA LINK (HIGH) PIO4
E E
G8 E E YL DATA LINK (LOW) PIO5
DIAGNOSTIC
DISPLAY 12V DC
SW25 U3 D7 5V DC
1
TS67 2
PP
FUNCTION 3
RD WH 4 JC1
ENABLE
5 BN R15 JOYSTICK
LS6 LS5 LS1 N.C. 6 5K
POTENTIOMETER
CONTROLLER
PLATFORM PLATFORM EXTENSION 7 OR
DOWN UP DECK 8
WH/BK WH/YL
LEVEL
SENSOR SW5 SW6 STEER
LEFT/ RIGHT
N.C. N.C. N.C. CIRCUIT WH/BL FUNCTION ENABLE
GROUND FROM PLATFORM
LEFT
RIGHT
BOARD PIN18
TS66 WH/RD
PIN15
UP
DOWN
S7 WH
PLATFORM
PIN14
DATA LINK (+) BK
LEVEL
SENSOR
BK PLATFORM CONTROLS
BN
MEMBRANE DECAL
POUT2 POWER LED L19
POUT3
J2-A1
J3-A1
J2-C1/C10
J2-A2
J3-A3
J3-A2
J3-B4
J3-A4
J1-C7,C8
J3-A5
J2-A6
J2-B10
J1-A12
J1-A11
J1-A7
J1-B3
J1-A3
J1-A4
J1-A6
J1-A8
J1-A5
J1-A2
J1-A1
WH
PIN1 LIFT ENABLE HIGH BN12
Y3 Y4 Y8 Y2 Y6 Y5 Y6A Y5A Y1 Y1A Y1B Y9 BL
PIN2 LIFT ENABLE LOW BN13
STEER LEFT
DRIVE FORWARD
DRIVE PARALLEL
DRIVE PARALLEL
DRIVE PARALLEL
PLATFORM UP
BRAKE RELEASE
DRIVE REVERSE
STEER RIGHT
DRIVE REVERSE
FLOW CONTROL
PROPORTIONAL
DRIVE FORWARD
RD
PIN3 UP
PLATFORM UP/DOWN TS20
YL
PIN4 DOWN
RD
POUT1 +
H1
BK ALARM
PIN11 -
PLATFORM CONTROLS
- NOTE -
MACHINE SHOWN IN THE STOWED
ES7140A POSITION WITH THE POWER OFF
Electrical Schematic
Diesel Models (from serial number 21161 to 21837) REV B
Part 1 of 2
P1
EMERGENCY
CB2 STOP
PLATFORM
KS1
1A
GROUND
85 86
CR43
GROUND POWER TO
87 ECM
30
85 86
CR25 C2
(+) CR1 87 ENGINE RUN 33000 uf
BN23 ENGINE 30
START
AUXILIARY 86 30
R7 2000
85 86
PLATFORM
DOWN B4
(GS-3268RT)
( )
- 12V DC 87
CR8
85 87 30 FUEL
TS52 TS56 TS54
85 86
CR15
START
HIGH IDLE
GLOW PLUG
87 GLOW
30
PLUG
CB1 85 86
20A
87
CR4
30 HIGH IDLE
J4-C3
J2-A5
J4-A3
J4-B4
J4-C4
J1-C11,C12
J4-B5
J4-A5
J4-A2
J4-A4
R
D1 F
U5
J1-C1\C4
J2-B12
G6
J1-A9
J2-B7
J4-B6
J2-B8
J4-B2
J4-B1
J1-B1
(+) B1
12V DC
30 86 L27
CR5
H1 SW1 SW2 L41
Q3
M3 87 85
N.O. N.C.
(HOLD)
(PULL)
U32 H2
L42
( ) FB1
-
Q8
B1 M3 D1 Q8 G6 U32 Q3 H2 Y7 Y7A H1 FB1 SW1 SW2 L41 L42 L27 Y29
TEMPERATURE SWITCH
COOLANT
HOURMETER
GLOW PLUG
(OPTION)
AUTOMOTIVE-STYLE HORN
ALTERNATOR
BATTERY 12V DC
GENERATOR (OPTION)
TILT ALARM
GENERATOR ON LED
FUEL SHUT OFF
PLATFORM DOWN
(GS-3268 ONLY)
PLATFORM DOWN
TEMPERATURE LED
COOLANT
FLASHING BEACON (OPTION)
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7140B
Electrical Schematic
REV B Diesel Models (from serial number 21161 to 21837)
Part 2 of 2
P2
EMERGENCY
QD4 QD3 STOP
BK
C C C C BK POWER TO PLATFORM
RD
A A A A RD POWER TO GROUND
B B B B WH GROUND PIO3 PIO2
D D
D D BL DATA LINK (HIGH) PIO4
E E
G8 E E YL DATA LINK (LOW) PIO5
DIAGNOSTIC
DISPLAY 12V DC
SW25 U3 D7 5V DC
1
TS67 2
PP
FUNCTION 3
RD WH 4 JC1
ENABLE
5 BN R15 JOYSTICK
LS6 LS5 LS1 N.C. 6 5K
POTENTIOMETER
CONTROLLER
PLATFORM PLATFORM EXTENSION 7 OR
DOWN UP DECK 8
WH/BK WH/YL
LEVEL
SENSOR SW5 SW6 STEER
LEFT/ RIGHT
N.C. N.C. N.C. CIRCUIT WH/BL FUNCTION ENABLE
GROUND FROM PLATFORM
LEFT
RIGHT
BOARD PIN18
TS66 WH/RD
PIN15
UP
DOWN
S7 WH
PLATFORM
PIN14
DATA LINK (+) BK
LEVEL
SENSOR
BK PLATFORM CONTROLS
BN
MEMBRANE DECAL
POUT2 POWER LED L19
POUT3
J2-A1
J3-A1
J2-C1/C10
J2-A2
J3-A3
J3-A2
J3-B4
J3-A4
J1-C7,C8
J3-A5
J2-A6
J2-B10
J1-A12
J1-A11
J1-A7
J1-B3
J1-A3
J1-A4
J1-A6
J1-A8
J1-A5
J1-A2
J1-A1
WH
PIN1 LIFT ENABLE HIGH BN12
Y3 Y4 Y8 Y2 Y6 Y5 Y6A Y5A Y1 Y1A Y1B Y9 BL
PIN2 LIFT ENABLE LOW BN13
STEER LEFT
DRIVE FORWARD
DRIVE PARALLEL
DRIVE PARALLEL
DRIVE PARALLEL
PLATFORM UP
BRAKE RELEASE
DRIVE REVERSE
STEER RIGHT
DRIVE REVERSE
FLOW CONTROL
PROPORTIONAL
DRIVE FORWARD
RD
PIN3 UP
PLATFORM UP/DOWN TS20
YL
PIN4 DOWN
RD
POUT1 +
H1
BK ALARM
PIN11 -
PLATFORM CONTROLS
- NOTE -
MACHINE SHOWN IN THE STOWED
ES7140B POSITION WITH THE POWER OFF
Electrical Schematic
Diesel Models (from serial number 21838 to 38464) REV B
Part 1 of 3
GROUND
85 86
CR43
GROUND POWER TO
87 ECM
30
85 86
CR25 C2
(+) CR1 87 ENGINE RUN 33000 uf
BN23 ENGINE 30
START
AUXILIARY 86 30
R7 2000
85 86
PLATFORM
DOWN B4
(GS-3268RT)
( )
- 12V DC 87
CR8
85 87 30 FUEL
TS52 TS56 TS54
85 86
CR15
START
HIGH IDLE
GLOW PLUG
87 GLOW
30
PLUG
CB1 85 86
20A
87
CR4
30 HIGH IDLE
J4-C3
J2-A5
J4-A3
J4-B4
J4-C4
J1-C11,C12 J2-B12
J4-B5
J4-A5
J4-A2
J4-A4
R
D1 F
J1-C1\C4
U5
ELECTRONIC CONTROL MODULE
J2-B11
G6
J2-B7
J4-B6
J2-B8
J4-B2
J1-A9
J4-B1
J1-B1
(+) B1
12V DC
30
CR5 86 L27
H1 SW1 SW2 L41
F9 Q3
30A 87 85
M3
N.O. N.C.
(HOLD)
(PULL)
U32 H2
L42
( ) FB1
-
Q8
B1 M3 D1 F9 Q8 G6 U32 Q3 H2 Y7 Y7A H1 FB1 SW1 SW2 L41 L42 L27 Y29
TEMPERATURE SWITCH
COOLANT
HOURMETER
GLOW PLUG
(OPTION)
AUTOMOTIVE-STYLE HORN
ALTERNATOR
BATTERY 12V DC
GENERATOR (OPTION)
TILT ALARM
GENERATOR ON LED
FUSE
TEMPERATURE LED
COOLANT
PLATFORM DOWN
F9 ADDED AFTER
SERIAL NUMBER 38365
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7140C
Electrical Schematic
REV B Diesel Models (from serial number 21838 to 38464)
Part 2 of 3
QD4
C C
A A
B B
D D
E E
TS67
FUNCTION RD WH
ENABLE
LS6 LS5 LS1 PS3 N.C.
PLATFORM PLATFORM EXTENSION PLATFORM
DOWN UP DECK OVERLOAD
LS12 LS13 LS14 LS15
LEFT RIGHT LEFT RIGHT
FRONT FRONT REAR REAR LEVEL
OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER SENSOR
N.C. N.C. N.C. N.O. CIRCUIT
DOWN
S7
PLATFORM
BN
J2-A1
J3-A1
J2-C1/C10
J2-A2
J3-A3
J3-A2
J2-A7
J2-A8
J2-A10
J3-A6
J3-B5
J3-B4
J3-A4
J1-C7,C8
J3-A5
J2-A6
J2-B10
U5
ELECTRONIC CONTROL MODULE
J2-B10
J1-A10
J1-A12
J1-A11
J1-B6
J1-B7
J2-B3
J1-A7
J1-B8
J1-B3
J1-B5
J1-A3
J1-A4
J1-A6
J1-A8
J1-B2
J3-B2
J1-A5
J1-A2
J3-B1
J2-B1
J1-A1
RD
BL
YL
S8
2-AXIS
LEVEL
SENSOR
BK
Y3 Y4 Y8 Y2 Y6 Y5 Y6A Y5A Y1 Y1A Y1B Y9 Y35 Y36 Y33 Y34 Y40 Y39 Y44 S9
STEER LEFT
DRIVE FORWARD
DRIVE PARALLEL
DRIVE PARALLEL
DRIVE PARALLEL
PLATFORM UP
BRAKE RELEASE
DRIVE REVERSE
STEER RIGHT
DRIVE REVERSE
FLOW CONTROL
PROPORTIONAL
OUTRIGGER
RIGHT FRONT
DRIVE FORWARD
OUTRIGGER
RIGHT REAR
SLOW
OUTRIGGER EXTEND
OUTRIGGER
LEFT REAR
OUTRIGGER EXTEND
OUTRIGGER RETRACT
OUTRIGGER
LEFT FRONT
SENSOR
AUTO LEVELING
- NOTE -
MACHINE SHOWN IN THE STOWED
ES7140C POSITION WITH THE POWER OFF
Electrical Schematic
Diesel Models (from serial number 21838 to 38464) REV B
Part 3 of 3
P2 P2
EMERGENCY EMERGENCY
QD3 STOP QD3 STOP
BK BK
C C BK POWER TO PLATFORM C C BK POWER TO PLATFORM
RD RD
A A RD POWER TO GROUND A A RD POWER TO GROUND
SW25 U3 D7 5V DC
SW25 U3 D7 5V DC
1 1
2 2
3 OR 3 OR
4 JC1 4 JC1
5 BN R15 JOYSTICK 5 BN R15 JOYSTICK
6 5K CONTROLLER 6 5K CONTROLLER
7 PP POTENTIOMETER 7 PP POTENTIOMETER
8 8
WH/BK WH/YL WH/BK WH/YL
RIGHT
LEFT
RIGHT
PIN18 PIN18
WH/RD WH/RD
PIN15 PIN15
WH WH
PIN14 PIN14
Electrical Schematic
Diesel Models (from serial number 38465 to 40173) REV B
Part 1 of 3
P1
EMERGENCY
CB2 STOP
PLATFORM
KS1
7A
GROUND
85 86
CR43
GROUND POWER TO
87 ECM
30
85 86
(+)
CR25 C2
87 ENGINE RUN 33000 uf
BN23 30
AUXILIARY 86 30
R7 2000
PLATFORM CR1 85 86
DOWN B4 ENGINE
(GS-3268RT)
( )
- 12V DC START 87
CR8
85 87 30 FUEL
TS52 TS56 TS54
85 86
CR15
START
HIGH IDLE
GLOW PLUG
87 GLOW
30
PLUG
CB1 85 86
20A
87
CR4
30 HIGH IDLE
J4-C3
J2-A5
J4-A3
J4-B4
J4-C4
J1-C11,C12 J2-B12
J4-B5
J4-A5
J4-A2
J4-A4
R
D1 F
J1-C1\C4
U5
ELECTRONIC CONTROL MODULE
J2-B11
G6
J2-B7
J4-B6
J2-B8
J4-B2
J1-A9
J4-B1
J1-B1
(+) B1
12V DC
30
CR5 86 L27
H1 SW1 SW2 L41
F9 Q3
30A 87 85
M3
N.O. N.C.
(HOLD)
(PULL)
U32 H2
L42
( ) FB1
-
Q8
B1 M3 D1 F9 Q8 G6 U32 Q3 H2 Y7 Y10 Y7A Y10A H1 FB1 SW1 SW2 L41 L42 L27 Y29
TEMPERATURE SWITCH
COOLANT
HOURMETER
GLOW PLUG
(OPTION)
AUTOMOTIVE-STYLE HORN
ALTERNATOR
BATTERY 12V DC
GENERATOR (OPTION)
TILT ALARM
GENERATOR ON LED
FUSE
TEMPERATURE LED
COOLANT
PLATFORM DOWN
AUXILIARY PLATFORM
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7140H
Electrical Schematic
REV B Diesel Models (from serial number 38465 to 40173)
Part 2 of 3
QD4
C C
A A
B B
D D
E E
G8
GS-3268 ONLY OUTRIGGERS DIAGNOSTIC
DISPLAY
(OPTION) (OPTION)
TS67
FUNCTION RD WH
ENABLE
LS6 LS5 LS1 PS3 N.C.
PLATFORM PLATFORM EXTENSION PLATFORM
DOWN UP DECK OVERLOAD
LS12 LS13 LS14 LS15
LEFT RIGHT LEFT RIGHT
FRONT FRONT REAR REAR LEVEL
OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER SENSOR
N.C. N.C. N.C. N.O. CIRCUIT
DOWN
S7
PLATFORM
BN
J2-A1
J2-C1/C10
J2-A2
J3-A1
J3-A2
J3-A3
J2-A7
J2-A8
J2-A10
J3-A6
J3-B5
J3-B4
J3-A4
J1-C7,C8
J3-A5
J2-A6
J2-B10
U5
ELECTRONIC CONTROL MODULE
J2-B10
J1-A10
J1-A12
J1-A11
J1-B6
J1-B7
J2-B3
J1-A7
J1-B8
J1-B3
J1-B5
J1-A3
J1-A4
J1-A6
J1-A8
J1-B2
J3-B2
J1-A5
J1-A2
J3-B1
J2-B1
J1-A1
RD
BL
YL
S8
2-AXIS
LEVEL
SENSOR
BK
Y3 Y4 Y8 Y2 Y6 Y5 Y6A Y5A Y1 Y1A Y1B Y9 Y35 Y36 Y33 Y34 Y40 Y39 Y44 S9
STEER LEFT
DRIVE FORWARD
DRIVE PARALLEL
DRIVE PARALLEL
DRIVE PARALLEL
PLATFORM UP
BRAKE RELEASE
DRIVE REVERSE
STEER RIGHT
DRIVE REVERSE
FLOW CONTROL
PROPORTIONAL
OUTRIGGER
RIGHT FRONT
DRIVE FORWARD
OUTRIGGER
RIGHT REAR
SLOW
OUTRIGGER EXTEND
OUTRIGGER
LEFT REAR
OUTRIGGER EXTEND
OUTRIGGER RETRACT
OUTRIGGER
LEFT FRONT
SENSOR
AUTO LEVELING
- NOTE -
MACHINE SHOWN IN THE STOWED
ES7140H POSITION WITH THE POWER OFF
Electrical Schematic
Diesel Models (from serial number 38465 to 40173) REV B
Part 3 of 3
P2 P2
EMERGENCY EMERGENCY
QD3 STOP QD3 STOP
BK BK
C C BK POWER TO PLATFORM C C BK POWER TO PLATFORM
RD RD
A A RD POWER TO GROUND A A RD POWER TO GROUND
SW25 U3 D7 5V DC
SW25 U3 D7 5V DC
1 1
2 2
3 OR 3 OR
4 JC1 4 JC1
5 BN R15 JOYSTICK 5 BN R15 JOYSTICK
6 5K CONTROLLER 6 5K CONTROLLER
7 PP POTENTIOMETER 7 PP POTENTIOMETER
8 8
WH/BK WH/YL WH/BK WH/YL
RIGHT
LEFT
RIGHT
PIN18 PIN18
WH/RD WH/RD
PIN15 PIN15
WH WH
PIN14 PIN14
Electrical Schematic
Diesel Models (from serial number 40174 to 40939) REV B
Part 1 of 3
P1
EMERGENCY
CB2 STOP
PLATFORM
KS1
7A
GROUND
85 86
CR43
GROUND POWER TO
87 ECM
30
85 86
(+)
CR25 C2
87 ENGINE RUN 33000 uf
BN23 30
AUXILIARY 86 30
R7 2000
PLATFORM CR1 85 86
DOWN B4 ENGINE
(GS-3268RT)
( )
- 12V DC START 87
CR8
85 87 30 FUEL
TS52 TS56 TS54
85 86
CR15
START
HIGH IDLE
GLOW PLUG
87 GLOW
30
PLUG
CB1 85 86
20A
87
CR4
30 HIGH IDLE
J4-C3
J2-A5
J4-A3
J4-B4
J4-C4
J1-C11,C12 J2-B12
J4-B5
J4-A5
J4-A2
J4-A4
R
D1 F
L30 J1-C1\C4
U5
ELECTRONIC CONTROL MODULE
J2-B11
G6
J2-B7
J4-B6
J2-B8
J4-B2
J1-A9
J4-B1
J1-B1
(+) B1
12V DC
30
CR5 86 L27
H1 SW1 SW2 L41
F9 Q3
30A 87 85
M3
N.O. N.C.
(HOLD)
(PULL)
U32 H2
L42
( ) FB1
-
Q8
B1 M3 D1 F9 Q8 G6 U32 Q3 L30 H2 Y7 Y10 Y7A Y10A H1 FB1 SW1 SW2 L41 L42 L27 Y29
TEMPERATURE SWITCH
COOLANT
HOURMETER
GLOW PLUG
(OPTION)
AUTOMOTIVE-STYLE HORN
ALTERNATOR
BATTERY 12V DC
GENERATOR (OPTION)
TILT ALARM
GENERATOR ON LED
FUSE
TEMPERATURE LED
COOLANT
PLATFORM DOWN
AUXILIARY PLATFORM
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7140
Electrical Schematic
REV B Diesel Models (from serial number 40174 to 40939)
Part 2 of 3
QD4
C C
A A
B B
D D
E E
G8
GS-3268 ONLY OUTRIGGERS DIAGNOSTIC
DISPLAY
(OPTION) (OPTION)
TS67
FUNCTION RD WH
ENABLE
LS6 LS5 LS1 PS3 N.C.
PLATFORM PLATFORM EXTENSION PLATFORM
DOWN UP DECK OVERLOAD
LS12 LS13 LS14 LS15
LEFT RIGHT LEFT RIGHT
FRONT FRONT REAR REAR LEVEL
OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER SENSOR
N.C. N.C. N.C. N.O. CIRCUIT
DOWN
S7
PLATFORM
BN
J2-A1
J2-C1/C10
J2-A2
J3-A1
J3-A2
J3-A3
J2-A7
J2-A8
J2-A10
J3-A6
J3-B5
J3-B4
J3-A4
J1-C7,C8
J3-A5
J2-A6
J2-B10
U5
ELECTRONIC CONTROL MODULE
J2-B10
J1-A10
J1-A12
J1-A11
J1-B6
J1-B7
J2-B3
J1-A7
J1-B8
J1-B3
J1-B5
J1-A3
J1-A4
J1-A6
J1-A8
J1-B2
J3-B2
J1-A5
J1-A2
J3-B1
J2-B1
J1-A1
RD
BL
YL
S8
2-AXIS
LEVEL
SENSOR
BK
Y3 Y4 Y8 Y2 Y6 Y5 Y6A Y5A Y1 Y1A Y1B Y9 Y35 Y36 Y33 Y34 Y40 Y39 Y44 S9
STEER LEFT
DRIVE FORWARD
DRIVE PARALLEL
DRIVE PARALLEL
DRIVE PARALLEL
PLATFORM UP
BRAKE RELEASE
DRIVE REVERSE
STEER RIGHT
DRIVE REVERSE
FLOW CONTROL
PROPORTIONAL
OUTRIGGER
RIGHT FRONT
DRIVE FORWARD
OUTRIGGER
RIGHT REAR
SLOW
OUTRIGGER EXTEND
OUTRIGGER
LEFT REAR
OUTRIGGER EXTEND
OUTRIGGER RETRACT
OUTRIGGER
LEFT FRONT
SENSOR
AUTO LEVELING
- NOTE -
MACHINE SHOWN IN THE STOWED
ES7140 POSITION WITH THE POWER OFF
Electrical Schematic
Diesel Models (from serial number 40174 to 40939) REV B
Part 3 of 3
P2 P2
EMERGENCY EMERGENCY
QD3 STOP QD3 STOP
BK BK
C C BK POWER TO PLATFORM C C BK POWER TO PLATFORM
RD RD
A A RD POWER TO GROUND A A RD POWER TO GROUND
SW25 U3 D7 5V DC
SW25 U3 D7 5V DC
1 1
2 2
3 OR 3 OR
4 JC1 4 JC1
5 BN R15 JOYSTICK 5 BN R15 JOYSTICK
6 5K CONTROLLER 6 5K CONTROLLER
7 PP POTENTIOMETER 7 PP POTENTIOMETER
8 8
WH/BK WH/YL WH/BK WH/YL
RIGHT
LEFT
RIGHT
PIN18 PIN18
WH/RD WH/RD
PIN15 PIN15
WH WH
PIN14 PIN14
Electrical Schematic
Diesel Models (from serial number 40940 to 41199) REV B
Part 1 of 3
P1
EMERGENCY
CB2 STOP
PLATFORM
KS1
7A
GROUND
85 86
CR43
GROUND POWER TO
87 ECM
30
85 86
(+)
CR25 C2
87 ENGINE RUN 33000 uf
BN23 30
AUXILIARY 86 30
R7 2000
PLATFORM CR1 85 86
DOWN B4 ENGINE
(GS-3268RT)
( )
- 12V DC START 87
CR8
85 87 30 FUEL
TS52 TS56 TS54
85 86
CR15
START
HIGH IDLE
GLOW PLUG
87 GLOW
30
PLUG
CB1 85 86
20A
87
CR4
30 HIGH IDLE
J4-C3
J2-A5
J4-A3
J4-B4
J4-C4
J1-C11,C12 J2-B12
J4-B5
J4-A5
J4-A2
J4-A4
R
D1 F
L30 J1-C1\C4
U5
ELECTRONIC CONTROL MODULE
J2-B11
G6
J2-B7
J4-B6
J2-B8
J4-B2
J1-A9
J4-B1
J1-B1
(+) B1
12V DC
30
CR5 86 L27
H1 SW1 SW2 L41
F9 Q3
30A 87 85
M3
N.O. N.C.
(HOLD)
(PULL)
U32 H2
L42
( ) FB1
-
Q8
B1 M3 D1 F9 Q8 G6 U32 Q3 L30 H2 Y7 Y10 Y7A Y10A H1 FB1 SW1 SW2 L41 L42 L27 Y29
TEMPERATURE SWITCH
COOLANT
HOURMETER
GLOW PLUG
(OPTION)
AUTOMOTIVE-STYLE HORN
ALTERNATOR
BATTERY 12V DC
GENERATOR (OPTION)
TILT ALARM
GENERATOR ON LED
FUSE
TEMPERATURE LED
COOLANT
PLATFORM DOWN
AUXILIARY PLATFORM
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7140N
Electrical Schematic
REV B Diesel Models (from serial number 40940 to 41199)
Part 2 of 3
QD4
C C
A A
B B
D D
E E
G8
GS-3268 ONLY OUTRIGGERS DIAGNOSTIC
DISPLAY
(OPTION) (OPTION)
TS67
FUNCTION RD WH
ENABLE
LS6 LS5 LS1 PS3 N.C.
PLATFORM PLATFORM EXTENSION PLATFORM
DOWN UP DECK OVERLOAD
LS12 LS13 LS14 LS15
LEFT RIGHT LEFT RIGHT
FRONT FRONT REAR REAR LEVEL
OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER SENSOR
N.C. N.C. N.C. N.O. CIRCUIT
DOWN
S7
PLATFORM
BN
J2-A1
J3-A1
J2-C1/C10
J2-A2
J3-A3
J3-A2
J2-A7
J2-A8
J2-A10
J3-A6
J3-B5
J3-B4
J3-A4
J1-C7,C8
J3-A5
J2-A6
J2-B10
U5
ELECTRONIC CONTROL MODULE
J2-B10
J1-A10
J1-A12
J1-A11
J1-B6
J1-B7
J2-B3
J1-A7
J1-B8
J1-B3
J1-B5
J1-A3
J1-A4
J1-A6
J1-A8
J1-B2
J3-B2
J1-A5
J1-A2
J3-B1
J2-B1
J1-A1
RD
BL
YL
S8
2-AXIS
LEVEL
SENSOR
BK
Y3 Y4 Y8 Y2 Y6 Y5 Y6A Y5A Y1 Y1A Y1B Y9 Y35 Y36 Y33 Y34 Y40 Y39 Y44 S9
STEER LEFT
DRIVE FORWARD
DRIVE PARALLEL
DRIVE PARALLEL
DRIVE PARALLEL
PLATFORM UP
BRAKE RELEASE
DRIVE REVERSE
STEER RIGHT
DRIVE REVERSE
FLOW CONTROL
PROPORTIONAL
OUTRIGGER
RIGHT FRONT
DRIVE FORWARD
OUTRIGGER
RIGHT REAR
SLOW
OUTRIGGER EXTEND
OUTRIGGER
LEFT REAR
OUTRIGGER EXTEND
OUTRIGGER RETRACT
OUTRIGGER
LEFT FRONT
SENSOR
AUTO LEVELING
- NOTE -
MACHINE SHOWN IN THE STOWED
ES7140N POSITION WITH THE POWER OFF
Electrical Schematic
Diesel Models (from serial number 40940 to 41199) REV B
Part 3 of 3
P2 P2
EMERGENCY EMERGENCY
QD3 STOP QD3 STOP
BK BK
C C BK POWER TO PLATFORM C C BK POWER TO PLATFORM
RD RD
A A RD POWER TO GROUND A A RD POWER TO GROUND
SW25 U3 D7 5V DC
SW25 U3 D7 5V DC
1 1
2 2
3 OR 3 OR
4 JC1 4 JC1
5 BN R15 JOYSTICK 5 BN R15 JOYSTICK
6 5K CONTROLLER 6 5K CONTROLLER
7 PP POTENTIOMETER 7 PP POTENTIOMETER
8 8
WH/BK WH/YL WH/BK WH/YL
RIGHT
LEFT
RIGHT
PIN18 PIN18
WH/RD WH/RD
PIN15 PIN15
WH WH
PIN14 PIN14
Electrical Schematic
Diesel Models (from serial number 41200 to 41823) REV B
Part 1 of 3
PLATFORM
KS1
GROUND
85 86
CR43
GROUND POWER TO
87 ECM
30
(+)
85 86
CR25 C2
CR1 87
30 ENGINE RUN 33000 uf
ENGINE
START
B4
( )
- 12V DC 86 30
R7 2000
85 86
87
CR8 BN68
85 87 30 FUEL START
85 86
87
CR15
30 GLOW
CB1 PLUG
20A
85 86
R
D1 F 87
CR4
30 HIGH IDLE
J4-C3
J2-A5
J4-B4
J4-C4
J1-C11,C12 J2-B12
J4-B5
J4-A5
J4-A2
G6
L30 J1-C1\C4
U5
ELECTRONIC CONTROL MODULE
HYDRAULIC
J2-B11
J2-B7
J4-B6
J2-B8
J4-B2
J1-A9
J4-B1
OIL COOLER
J1-B1
(OPTION)
(+) B1 F9A
12V DC
20A
SW4 30
CR5 86
N.O.
L27
30 86 87 85
H1 SW1 SW2 L41
F9 Q3
30A CR17 H2
M3
87 85
N.O. N.C.
(HOLD)
(PULL)
U32
L42
( ) M1 FB1
-
Q8
B1 M3 D1 Q8 M1 SW4 G6 U32 Q3 L30 H2 Y7 Y10 Y7A Y10A H1 FB1 SW1 SW2 L41 L42 L27 Y29
TEMPERATURE SWITCH
COOLANT
HOURMETER
GLOW PLUG
(OPTION)
AUTOMOTIVE-STYLE HORN
ALTERNATOR
BATTERY 12V DC
GENERATOR (OPTION)
COOLING FAN (OPTION)
HYDRAULIC OIL
TILT ALARM
GENERATOR ON LED
TEMPERATURE SWITCH
HYDRAULIC OIL
FUEL SHUT OFF
TEMPERATURE LED
COOLANT
PLATFORM DOWN
AUXILIARY PLATFORM
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7140P
Electrical Schematic
REV B Diesel Models (from serial number 41200 to 41823)
Part 2 of 3
P1
EMERGENCY
STOP QD4
C C
A A
B B
D D
E E
G8
OUTRIGGERS DIAGNOSTIC
DISPLAY
(OPTION) (OPTION)
BN44 FUNCTION RD WH
ENABLE
BN
J3-A1
J2-C1/C10
J4-A3
J4-A4
J2-A1
J2-A2
J3-A2
J3-A3
J2-A7
J2-A8
J2-A10
J3-A6
J3-B5
J3-B4
J3-A4
J1-C7,C8
J3-A5
J2-A6
J2-B10
U5
ELECTRONIC CONTROL MODULE
J2-B10
J1-A10
J1-A12
J1-A11
J1-B6
J1-B7
J2-B3
J1-A7
J1-B8
J1-B3
J1-B5
J1-A3
J1-A4
J1-A6
J1-A8
J1-B2
J3-B2
J1-A5
J1-A2
J3-B1
J2-B1
J1-A1
RD
BL
YL
S8
2-AXIS
LEVEL
SENSOR
BK
Y3 Y4 Y8 Y2 Y6 Y5 Y6A Y5A Y1 Y1A Y1B Y9 Y35 Y36 Y33 Y34 Y40 Y39 Y44 S9
STEER LEFT
DRIVE FORWARD
DRIVE PARALLEL
DRIVE PARALLEL
DRIVE PARALLEL
PLATFORM UP
BRAKE RELEASE
DRIVE REVERSE
STEER RIGHT
DRIVE REVERSE
FLOW CONTROL
PROPORTIONAL
OUTRIGGER
RIGHT FRONT
DRIVE FORWARD
OUTRIGGER
RIGHT REAR
SLOW
OUTRIGGER EXTEND
OUTRIGGER
LEFT REAR
OUTRIGGER EXTEND
OUTRIGGER RETRACT
OUTRIGGER
LEFT FRONT
SENSOR
AUTO LEVELING
- NOTE -
MACHINE SHOWN IN THE STOWED
ES7140P POSITION WITH THE POWER OFF
Electrical Schematic
Diesel Models (from serial number 41200 to 41823) REV B
Part 3 of 3
P2 P2
EMERGENCY EMERGENCY
QD3 STOP QD3 STOP
BK BK
C C BK POWER TO PLATFORM C C BK POWER TO PLATFORM
RD RD
A A RD POWER TO GROUND A A RD POWER TO GROUND
SW25 U3 D7 5V DC
SW25 U3 D7 5V DC
1 1
2 2
3 OR 3 OR
4 JC1 4 JC1
5 BN R15 JOYSTICK 5 BN R15 JOYSTICK
6 5K CONTROLLER 6 5K CONTROLLER
7 PP POTENTIOMETER 7 PP POTENTIOMETER
8 8
WH/BK WH/YL WH/BK WH/YL
RIGHT
LEFT
RIGHT
PIN18 PIN18
WH/RD WH/RD
PIN15 PIN15
WH WH
PIN14 PIN14
Electrical Schematic
Diesel Models (from serial number 41824 to GS6803-42381) REV A
Part 1 of 3
PLATFORM 2
B
B1 GROUND
4
85 86
CR43
GROUND 3 POWER TO
87 30 ECM
KS1
KEY SWITCH
85 86
C2
CR25 33000 uf
CR1 87 30 ENGINE RUN
ENGINE
START
86 30
R7 2000
85 86
CR8 BN68
85 87 87 30 FUEL START
87a
85 86
CR15
87 30 GLOW
CB1 PLUG
20A
85 86
R
D1 F CR4
87 30 HIGH IDLE
J4-C3
J2-A5
J4-B4
J4-C4
J1-C11,C12 J2-B12
J4-B5
J4-A5
J4-A2
G6
L30 J1-C1\C4
U5
ELECTRONIC CONTROL MODULE
HYDRAULIC
J2-B11
J2-B7
J4-B6
J2-B8
J4-B2
J1-A9
J4-B1
OIL COOLER
J1-B1
(OPTION)
(+) B1 F9A
12V DC
20A
SW4 30
CR5 86
N.O.
L27
30 86 87 85
H1 SW1 SW2 L41
F9 Q3
30A CR17 H2
M3
87 85
N.O. N.C.
(HOLD)
(PULL)
U32
L42
( ) M1 FB1
-
Q8
B1 M3 D1 Q8 M1 SW4 G6 U32 Q3 L30 H2 Y7 Y10 Y7A Y10A H1 FB1 SW1 SW2 L41 L42 L27 Y29
TEMPERATURE SWITCH
COOLANT
HOURMETER
GLOW PLUG
(OPTION)
AUTOMOTIVE-STYLE HORN
ALTERNATOR
BATTERY 12V DC
GENERATOR (OPTION)
COOLING FAN (OPTION)
HYDRAULIC OIL
TILT ALARM
GENERATOR ON LED
TEMPERATURE SWITCH
HYDRAULIC OIL
FUEL SHUT OFF
TEMPERATURE LED
COOLANT
PLATFORM DOWN
AUXILIARY PLATFORM
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7140R
Electrical Schematic
REV A Diesel Models (from serial number 41824 to GS6803-42381)
Part 2 of 3
P1
EMERGENCY
STOP QD4
C C
A A
B B
D D
E E
G8
OUTRIGGERS DIAGNOSTIC
DISPLAY
(OPTION) (OPTION)
BN44 FUNCTION RD WH
ENABLE
BN
J3-A1
J2-C1/C10
J4-A3
J4-A4
J2-A1
J2-A2
J3-A2
J3-A3
J2-A7
J2-A8
J2-A10
J3-A6
J3-B5
J3-B4
J3-A4
J1-C7,C8
J3-A5
J2-A6
J2-B10
U5
ELECTRONIC CONTROL MODULE
J2-B10
J1-A10
J1-A12
J1-A11
J1-B6
J1-B7
J2-B3
J1-A7
J1-B8
J1-B3
J1-B5
J1-A3
J1-A4
J1-A6
J1-A8
J1-B2
J3-B2
J1-A5
J1-A2
J3-B1
J2-B1
J1-A1
RD
BL
YL
S8
2-AXIS
LEVEL
SENSOR
BK
Y3 Y4 Y8 Y2 Y6 Y5 Y6A Y5A Y1 Y1A Y1B Y9 Y35 Y36 Y33 Y34 Y40 Y39 Y44 S9
STEER LEFT
DRIVE FORWARD
DRIVE PARALLEL
DRIVE PARALLEL
DRIVE PARALLEL
PLATFORM UP
BRAKE RELEASE
DRIVE REVERSE
STEER RIGHT
DRIVE REVERSE
FLOW CONTROL
PROPORTIONAL
OUTRIGGER
RIGHT FRONT
DRIVE FORWARD
OUTRIGGER
RIGHT REAR
SLOW
OUTRIGGER EXTEND
OUTRIGGER
LEFT REAR
OUTRIGGER EXTEND
OUTRIGGER RETRACT
OUTRIGGER
LEFT FRONT
SENSOR
AUTO LEVELING
- NOTE -
MACHINE SHOWN IN THE STOWED
ES7140R POSITION WITH THE POWER OFF
Electrical Schematic
Diesel Models (from serial number 41824 to GS6803-42381) REV A
Part 3 of 3
P2 P2
EMERGENCY EMERGENCY
QD3 STOP QD3 STOP
BK BK
C C BK POWER TO PLATFORM C C BK POWER TO PLATFORM
RD RD
A A RD POWER TO GROUND A A RD POWER TO GROUND
SW25 U3 D7 5V DC
SW25 U3 D7 5V DC
1 1
2 2
3 OR 3 OR
4 JC1 4 JC1
5 BN R15 JOYSTICK 5 BN R15 JOYSTICK
6 5K CONTROLLER 6 5K CONTROLLER
7 PP POTENTIOMETER 7 PP POTENTIOMETER
8 8
WH/BK WH/YL WH/BK WH/YL
RIGHT
LEFT
RIGHT
PIN18 PIN18
WH/RD WH/RD
PIN15 PIN15
WH WH
PIN14 PIN14
Electrical Schematic
ANSI Models with Diesel Power REV A
(from serial number GS6803-42382 to GS6805-43594)
Part 1 of 3
KS1 KEY SWITCH P1
B1 EMERGENCY STOP
2
PLATFORM
CONTROL
B 4
GROUND
CONTROL
AB1
CB2 20A
AB7 AB3 AB3 AB3
AB28
J2-A4
J2-B7
J2-B8
J2-B11
J1-C2
J2-C12
J2-A2
J2-C1/C3
J2-A5
J2-A3
U5
ECM
BAT
STA
EXCT D1 J1-C7
BN23 BN91
J2-C4 AUXILIARY DOWN AUXILIARY DOWN
J1-A3
J1-A9
J2-B9 ENABLE
F9 L30
30A CR15 CR4 WORK
B1 STARTING HIGH IDLE LIGHTS
STARTER
AID
+
7 8
(HOLD)
86 30 86 30
(PULL)
M3 85 87 87A 85 87 87A
Y7A Y10A
KUBOTA DIESEL ONLY
Q8 U32 C5
4700 uF
-
FUEL
SHUT
GLOW
PLUG
Q3
HIGH IDLE
H2 OFF (OPTION)
SOLENOID Y8 Y7 Y10
H2 AUTOMOTIVE-STYLE HORN
K1 STARTER RELAY
B1 12 VOLT BATTERY
M3 STARTER MOTOR
D1 ALTERNATOR
Q8 FUEL SHUT OFF
G6 ENGINE HOURMETER
U32 GLOW PLUG (OPTION)
Y8 PLATFORM UP
Y7 PLATFORM DOWN
(GS-3268 ONLY)
Y7A PLATFORM DOWN
(GS-3268 ONLY)
Y10A AUX PLATFORM DOWN
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7162A
Electrical Schematic
REV A ANSI Models with Diesel Power
(from serial number GS6803-42382 to GS6805-43594)
Part 2 of 3
RD
WH
F9A SW4
N.O.
20A
CR17 30 86
N.C.
LEVEL SENSOR
87 85 CIRCUIT BOARD
HYDRAULIC
OIL COOLER
(OPTION) M1 S7 LEVEL
SENSOR
MODELS WITHOUT
BATTERY (-) OUTRIGGERS
AB23
BK AB29
AB1
J2-B2
J2-A6
J2-B10
U5
ELECTRONIC CONTROL MODULE
J2-B12
J1-A10
J1-A12
J2-C11
J1-A11
J1-C8
J1-C9
J1-A2
J1-A5
J1-A4
J1-A7
J1-A1
J1-A6
J1-B3
J1-A8
J2-C7
J1-B1
Y4 Y1 Y1B Y6 Y6A Y9
H5 ALARM
Y4 STEER LEFT
Y1 DRIVE PARALLEL
Y2 BRAKE RELEASE
Y9
ECM GROUND
S7 LEVEL SENSOR
FLOW CONTROL
PROPORTIONAL
- NOTE -
MACHINE SHOWN IN THE STOWED
ES7162A POSITION WITH THE POWER OFF
Electrical Schematic
ANSI Models with Diesel Power REV A
(from serial number GS6803-42382 to GS6805-43594)
Part 3 of 3
QD4 QD3 P2
BK EMERGENCY
WH/RD 4 4 4 4 BK POWER TO PLATFORM STOP
RD
RD/WH 3 3 3 3 RD POWER TO GROUND
BL 1 1 1 1 WH GROUND WH J5 PIN1
BK 2 2 DATA LINK (HIGH) BL
2 2 BL J5 PIN4
OR 5 5 5 5 OR OR
DATA LINK (LOW) J5 PIN5
OUTRIGGERS
(OPTION) J5 PIN2
12V DC
AB3 AB3 AB2 AB2 U3 D7
PLATFORM CONTROLS VOLTAGE 5V DC
PRINTED CIRCUIT BOARD REGULATOR
S8
2 AXIS GY
TILT LEVEL J2 PIN1
SENSOR
HALL EFFECT
J2 PIN2
YL
JC1
GROUND
GENERATOR
POWER
WH JOYSTICK
PITCH
J2 PIN12
ROLL
BL
YL
BK
J2 PIN4
DATA LINK (-)
DATA LINK (+)
GND FROM PLAT
LEFT
RIGHT
N.O. N.O. N.O. N.O. OR STEER
J2 PIN5
BK LEFT/ RIGHT
AB23 AB24 J2 PIN6
RD
J2 PIN7
AB27 AB26 AB17 AB16 AB25 AB1 J2 PIN8
WH/BL
J2 PIN14
J1-C5
J1-C3
J1-C6
J1-C4
J2-B10
J2-B1
J2-B3
J2-B2
J2-A10
J2-A11
J2-A12
POUT1
MODULE
J1-B7
J1-B6
J1-B8
J1-B5
J1-B9
YL
J1 PIN4
PLATFORM UP/DOWN TS20
BL -OR-
J1 PIN3
PLATFORM & OUTRIGGER
RD UP/DOWN
J1 PIN1 TS21
BK
J1 PIN5
J3 PIN1
RD +
- NOTE - J3 PIN2
BK
H1
ALARM PLATFORM
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7162A
CONTROLS
Electrical Schematic
ANSI Models with Diesel Power REV A
(from serial number GS6805-43595 to GS6805-44770)
Part 1 of 3
F9 5A FUSE P1EMERGENCY STOP
KS1 KEY SWITCH
2
B1
PLATFORM
CONTROL
4
B
3
GROUND
CONTROL
AB1
CB2 20A
AB7 AB3 AB3 AB3
AB28
J2-A4
J2-B7
J2-B8
J2-B11
J1-C2
J2-C12
J2-A2
J2-C1/C3
J2-A5
J2-A3
U5
ECM
BAT
STA
EXCT D1 J1-C7
BN23 BN91
J2-C4 AUXILIARY DOWN AUXILIARY DOWN
J1-A3
J1-A9
J2-B9 ENABLE
F9 L30
30A CR15 CR4 WORK
B1 STARTING HIGH IDLE LIGHTS
STARTER
AID
+
7 8
(HOLD)
86 30 86 30
(PULL)
M3 85 87 87A 85 87 87A
Y7A Y10A
KUBOTA DIESEL ONLY
Q8 U32 C5
4700 uF
-
FUEL
SHUT
GLOW
PLUG
Q3
HIGH IDLE
H2 OFF (OPTION)
SOLENOID Y8 Y7 Y10
H2 AUTOMOTIVE-STYLE HORN
K1 STARTER RELAY
B1 12 VOLT BATTERY
M3 STARTER MOTOR
D1 ALTERNATOR
Q8 FUEL SHUT OFF
G6 ENGINE HOURMETER
U32 GLOW PLUG (OPTION)
Y8 PLATFORM UP
Y7 PLATFORM DOWN
(GS-3268 ONLY)
Y7A PLATFORM DOWN
(GS-3268 ONLY)
Y10A AUX PLATFORM DOWN
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7162D
Electrical Schematic
REV A ANSI Models with Diesel Power
(from serial number GS6805-43595 to GS6805-44770)
Part 2 of 3
RD
WH
F9A SW4
N.O.
20A
CR17 30 86
N.C.
LEVEL SENSOR
87 85 CIRCUIT BOARD
HYDRAULIC
OIL COOLER
(OPTION) M1 S7 LEVEL
SENSOR
MODELS WITHOUT
BATTERY (-) OUTRIGGERS
AB23
BK AB29
AB1
J2-B2
J2-A6
J2-B10
U5
ELECTRONIC CONTROL MODULE
J2-B12
J1-A10
J1-A12
J2-C11
J1-A11
J1-C8
J1-C9
J1-A2
J1-A5
J1-A4
J1-A7
J1-A1
J1-A6
J1-B3
J1-A8
J2-C7
J1-B1
Y4 Y1 Y1B Y6 Y6A Y9
H5 ALARM
Y4 STEER LEFT
Y1 DRIVE PARALLEL
Y2 BRAKE RELEASE
Y9
ECM GROUND
S7 LEVEL SENSOR
FLOW CONTROL
PROPORTIONAL
- NOTE -
MACHINE SHOWN IN THE STOWED
ES7162D POSITION WITH THE POWER OFF
Electrical Schematic
ANSI Models with Diesel Power REV A
(from serial number GS6805-43595 to GS6805-44770)
Part 3 of 3
QD4 QD3 P2
BK EMERGENCY
WH/RD 4 4 4 4 BK POWER TO PLATFORM STOP
RD
RD/WH 3 3 3 3 RD POWER TO GROUND
BL 1 1 1 1 WH GROUND WH J5 PIN1
BK 2 2 DATA LINK (HIGH) BL
2 2 BL J5 PIN4
OR 5 5 5 5 OR OR
DATA LINK (LOW) J5 PIN5
OUTRIGGERS
(OPTION) J5 PIN2
12V DC
AB3 AB3 AB2 AB2 U3 D7
PLATFORM CONTROLS VOLTAGE 5V DC
PRINTED CIRCUIT BOARD REGULATOR
S8
2 AXIS GY
TILT LEVEL J2 PIN1
SENSOR
HALL EFFECT
J2 PIN2
YL
JC1
GROUND
GENERATOR
POWER
WH JOYSTICK
PITCH
J2 PIN12
ROLL
BL
YL
BK
J2 PIN4
DATA LINK (-)
DATA LINK (+)
GND FROM PLAT
LEFT
RIGHT
N.O. N.O. N.O. N.O. OR STEER
J2 PIN5
BK LEFT/ RIGHT
AB23 AB24 J2 PIN6
RD
J2 PIN7
AB27 AB26 AB17 AB16 AB25 AB1 J2 PIN8
WH/BL
J2 PIN14
J1-C5
J1-C3
J1-C6
J1-C4
J2-B10
J2-B1
J2-B3
J2-B2
J2-A10
J2-A11
J2-A12
POUT1
MODULE
J1-B7
J1-B6
J1-B8
J1-B5
J1-B9
YL
J1 PIN4
PLATFORM UP/DOWN TS20
BL -OR-
J1 PIN3
PLATFORM & OUTRIGGER
RD UP/DOWN
J1 PIN1 TS21
BK
J1 PIN5
J3 PIN1
RD +
- NOTE - J3 PIN2
BK
H1
ALARM PLATFORM
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7162D
CONTROLS
Electrical Schematic
CE Models with Diesel Power REV B
(from serial number GS6803-42382 to GS6805-43594)
Part 1 of 3
KS1 KEY SWITCH P1
B1 EMERGENCY STOP
2
PLATFORM
CONTROL
B 4
GROUND
CONTROL
AB1
CB2 20A
AB3 AB4 AB3
AB28
PS2
PLATFORM
OVERLOAD
PRESSURE
SWITCH
AB20
J2-A4
J2-B7
J2-B8
J2-B11
J1-C2
J2-C12
J2-A2
J2-C1/C3
J2-A5
J2-A3
U5
ECM
BAT
STA
EXCT D1 J1-C7
BN23 BN91
J2-C4 AUXILIARY DOWN AUXILIARY DOWN
J1-A3
J1-A9
J2-B9 ENABLE
CR15
STARTING L30
AID CR4 WORK AB12
F9 86 30 7
HIGH IDLE LIGHTS N.C.
N.C.
30A
LS24 LS25
B1 85 87 87A
86 30 8 MAXIMUM LOAD SENSE
STARTER HEIGHT DELAY
+ LIMIT SW LIMIT SW
(HOLD)
85 87 87A
(PULL)
86 30 9
M3 CR77
DOWN 85 87 87A
Y7A Y10A
KUBOTA DIESEL ONLY
ENABLE
Q8 U32 C5
4700 uF
FUEL GLOW
- SHUT PLUG
H2 OFF (OPTION)
Q3
HIGH IDLE Y8 Y7 Y10
SOLENOID
H2 AUTOMOTIVE-STYLE HORN
K1 STARTER RELAY
B1 12 VOLT BATTERY
M3 STARTER MOTOR
D1 ALTERNATOR
Q8 FUEL SHUT OFF
G6 ENGINE HOURMETER
U32 GLOW PLUG (OPTION)
Y8 PLATFORM UP
Y7 PLATFORM DOWN
(GS-3268 ONLY)
Y7A PLATFORM DOWN
(GS-3268 ONLY)
Y10A AUX PLATFORM DOWN
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7184A
Electrical Schematic
REV B CE Models with Diesel Power
(from serial number GS6803-42382 to GS6805-43594)
Part 2 of 3
RD
WH
F9A SW4
N.O.
20A
CR17 30 86
N.C.
LEVEL SENSOR
87 85 CIRCUIT BOARD
HYDRAULIC
OIL COOLER
(OPTION) M1 S7 LEVEL
SENSOR
MODELS WITHOUT
BATTERY (-) OUTRIGGERS
AB23
BK AB29
AB1
J2-B2
J2-A6
J2-B10
U5
ELECTRONIC CONTROL MODULE
J2-B12
J1-A10
J1-A12
J2-C11
J1-A11
J1-C8
J1-C9
J1-A2
J1-A5
J1-A4
J1-A7
J1-A1
J1-A6
J1-B3
J1-A8
J2-C7
J1-B1
Y4 Y1 Y1B Y6 Y6A Y9
H5 ALARM
Y4 STEER LEFT
Y1 DRIVE PARALLEL
Y2 BRAKE RELEASE
Y9
ECM GROUND
S7 LEVEL SENSOR
FLOW CONTROL
PROPORTIONAL
- NOTE -
MACHINE SHOWN IN THE STOWED
ES7162A POSITION WITH THE POWER OFF
Electrical Schematic
CE Models with Diesel Power REV B
(from serial number GS6803-42382 to GS6805-43594)
Part 3 of 3
QD4 QD3 P2
BK EMERGENCY
WH/RD 4 4 4 4 BK POWER TO PLATFORM STOP
RD
RD/WH 3 3 3 3 RD POWER TO GROUND
BL 1 1 1 1 WH GROUND WH J5 PIN1
BK 2 2 DATA LINK (HIGH) BL
2 2 BL J5 PIN4
OR 5 5 5 5 OR OR
DATA LINK (LOW) J5 PIN5
OUTRIGGERS
(OPTION) J5 PIN2
12V DC
AB3 AB3 AB2 AB2 U3 D7
PLATFORM CONTROLS VOLTAGE 5V DC
PRINTED CIRCUIT BOARD REGULATOR
S8
2 AXIS GY
TILT LEVEL J2 PIN1
SENSOR
HALL EFFECT
J2 PIN2
YL
JC1
GROUND
GENERATOR
POWER
WH JOYSTICK
PITCH
J2 PIN12
ROLL
BL
YL
BK
J2 PIN4
DATA LINK (-)
DATA LINK (+)
GND FROM PLAT
LEFT
RIGHT
N.O. N.O. N.O. N.O. OR STEER
J2 PIN5
BK LEFT/ RIGHT
AB23 AB24 J2 PIN6
RD
J2 PIN7
AB27 AB26 AB17 AB16 AB25 AB1 J2 PIN8
WH/BL
J2 PIN14
J1-C5
J1-C3
J1-C6
J1-C4
J2-B10
J2-B1
J2-B3
J2-B2
J2-A10
J2-A11
J2-A12
POUT1
MODULE
J1-B7
J1-B6
J1-B8
J1-B5
J1-B9
YL
J1 PIN4
PLATFORM UP/DOWN TS20
BL -OR-
J1 PIN3
PLATFORM & OUTRIGGER
RD UP/DOWN
J1 PIN1 TS21
BK
J1 PIN5
J3 PIN1
RD +
- NOTE - J3 PIN2
BK
H1
ALARM PLATFORM
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7162A
CONTROLS
Electrical Schematic
CE Models with Diesel Power REV B
(from serial number GS6805-43595 to GS6805-44168)
Part 1 of 3
F9 5A FUSE P1EMERGENCY STOP
KS1 KEY SWITCH
2
B1
PLATFORM
CONTROL
PS2A PLATFORM OVERLOAD PRESSURE SWITCH
4
B
3
GROUND
CONTROL
AB20
AB1
CB2 20A
AB4 AB3
AB28
J2-A4
J2-B7
J2-B8
J2-B11
J1-C2
J2-C12
J2-A2
J2-C1/C3
J2-A5
J2-A3
U5
ECM
BAT
STA
EXCT D1 J1-C7
BN23 BN91
J2-C4 AUXILIARY DOWN AUXILIARY DOWN
J1-A3
J1-A9
J2-B9 ENABLE
CR15
STARTING L30
AID CR4 WORK AB12
F9 86 30 7
HIGH IDLE LIGHTS N.C.
N.C.
30A
LS24 LS25
B1 85 87 87A
86 30 8 MAXIMUM LOAD SENSE
STARTER HEIGHT DELAY
+ LIMIT SW LIMIT SW
(HOLD)
85 87 87A
(PULL)
86 30 9
M3 CR77
DOWN 85 87 87A
Y7A Y10A
KUBOTA DIESEL ONLY
ENABLE
Q8 U32 C5
4700 uF
FUEL GLOW
- SHUT PLUG
H2 OFF (OPTION)
Q3
HIGH IDLE Y8 Y7 Y10
SOLENOID
H2 AUTOMOTIVE-STYLE HORN
K1 STARTER RELAY
B1 12 VOLT BATTERY
M3 STARTER MOTOR
D1 ALTERNATOR
Q8 FUEL SHUT OFF
G6 ENGINE HOURMETER
U32 GLOW PLUG (OPTION)
Y8 PLATFORM UP
Y7 PLATFORM DOWN
(GS-3268 ONLY)
Y7A PLATFORM DOWN
(GS-3268 ONLY)
Y10A AUX PLATFORM DOWN
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7184B
Electrical Schematic
REV B CE Models with Diesel Power
(from serial number GS6805-43595 to GS6805-44168)
Part 2 of 3
RD
WH
F9A SW4
N.O.
20A
CR17 30 86
N.C.
LEVEL SENSOR
87 85 CIRCUIT BOARD
HYDRAULIC
OIL COOLER
(OPTION) M1 S7 LEVEL
SENSOR
MODELS WITHOUT
BATTERY (-) OUTRIGGERS
AB23
BK AB29
AB1
J2-B2
J2-A6
J2-B10
U5
ELECTRONIC CONTROL MODULE
J2-B12
J1-A10
J1-A12
J2-C11
J1-A11
J1-C8
J1-C9
J1-A2
J1-A5
J1-A4
J1-A7
J1-A1
J1-A6
J1-B3
J1-A8
J2-C7
J1-B1
Y4 Y1 Y1B Y6 Y6A Y9
H5 ALARM
Y4 STEER LEFT
Y1 DRIVE PARALLEL
Y2 BRAKE RELEASE
Y9
ECM GROUND
S7 LEVEL SENSOR
FLOW CONTROL
PROPORTIONAL
- NOTE -
MACHINE SHOWN IN THE STOWED
ES7184B POSITION WITH THE POWER OFF
Electrical Schematic
CE Models with Diesel Power REV B
(from serial number GS6805-43595 to GS6805-44168)
Part 3 of 3
QD4 QD3 P2
BK EMERGENCY
WH/RD 4 4 4 4 BK POWER TO PLATFORM STOP
RD
RD/WH 3 3 3 3 RD POWER TO GROUND
BL 1 1 1 1 WH GROUND WH J5 PIN1
BK 2 2 DATA LINK (HIGH) BL
2 2 BL J5 PIN4
OR 5 5 5 5 OR OR
DATA LINK (LOW) J5 PIN5
OUTRIGGERS
(OPTION) J5 PIN2
12V DC
AB3 AB3 AB2 AB2 U3 D7
PLATFORM CONTROLS VOLTAGE 5V DC
PRINTED CIRCUIT BOARD REGULATOR
S8
2 AXIS GY
TILT LEVEL J2 PIN1
SENSOR
HALL EFFECT
J2 PIN2
YL
JC1
GROUND
GENERATOR
POWER
WH JOYSTICK
PITCH
J2 PIN12
ROLL
BL
YL
BK
J2 PIN4
DATA LINK (-)
DATA LINK (+)
GND FROM PLAT
LEFT
RIGHT
N.O. N.O. N.O. N.O. OR STEER
J2 PIN5
BK LEFT/ RIGHT
AB23 AB_ J2 PIN6
RD
J2 PIN7
AB27 AB26 AB17 AB16 AB_ AB1 J2 PIN8
WH/BL
J2 PIN14
J1-C5
J1-C3
J1-C6
J1-C4
J2-B10
J2-B1
J2-B3
J2-B2
J2-A10
J2-A11
J2-A12
POUT1
MODULE
J1-B7
J1-B6
J1-B8
J1-B5
J1-B9
YL
J1 PIN4
PLATFORM UP/DOWN TS20
BL -OR-
J1 PIN3
PLATFORM & OUTRIGGER
RD UP/DOWN
J1 PIN1 TS21
BK
J1 PIN5
J3 PIN1
RD +
- NOTE - J3 PIN2
BK
H1
ALARM PLATFORM
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7184B
CONTROLS
Electrical Schematic
CE Models with Diesel Power REV A
(from serial number GS6805-44169 to GS6805-44770)
Part 1 of 3
F9 5A FUSE P1EMERGENCY STOP
KS1 KEY SWITCH
2
B1
PLATFORM
CONTROL
PS2A PLATFORM OVERLOAD PRESSURE SWITCH
4
B R25
5 OHM
3
GROUND
CONTROL
AB20
AB1
CB2 20A
AB4 AB3
AB28
J2-A4
J2-B7
J2-B8
J2-B11
J1-C2
J2-C12
J2-A2
J2-C1/C3
J2-A5
J2-A3
U5
ECM
BAT
STA
EXCT D1 J1-C7
BN23 BN91
J2-C4 AUXILIARY DOWN AUXILIARY DOWN
J1-A3
J1-A9
J2-B9 ENABLE
CR15
STARTING L30
AID CR4 WORK AB12
F9 86 30 7
HIGH IDLE LIGHTS N.C.
N.C.
30A
LS24 LS25
B1 85 87 87A
86 30 8 MAXIMUM LOAD SENSE
STARTER HEIGHT DELAY
+ LIMIT SW LIMIT SW
(HOLD)
85 87 87A
(PULL)
86 30 9
M3 CR77
DOWN 85 87 87A
Y7A Y10A
KUBOTA DIESEL ONLY
ENABLE
Q8 U32 C5
4700 uF
FUEL GLOW
- SHUT PLUG
H2 OFF (OPTION)
Q3
HIGH IDLE Y8 Y7 Y10
SOLENOID
H2 AUTOMOTIVE-STYLE HORN
K1 STARTER RELAY
B1 12 VOLT BATTERY
M3 STARTER MOTOR
D1 ALTERNATOR
Q8 FUEL SHUT OFF
G6 ENGINE HOURMETER
U32 GLOW PLUG (OPTION)
Y8 PLATFORM UP
Y7 PLATFORM DOWN
(GS-3268 ONLY)
Y7A PLATFORM DOWN
(GS-3268 ONLY)
Y10A AUX PLATFORM DOWN
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7184C
Electrical Schematic
REV A CE Models with Diesel Power
(from serial number GS6805-44169 to GS6805-44770)
Part 2 of 3
RD
WH
F9A SW4
N.O.
20A
CR17 30 86
N.C.
LEVEL SENSOR
87 85 CIRCUIT BOARD
HYDRAULIC
OIL COOLER
(OPTION) M1 S7 LEVEL
SENSOR
MODELS WITHOUT
BATTERY (-) OUTRIGGERS
AB23
BK AB29
AB1
J2-B2
J2-A6
J2-B10
U5
ELECTRONIC CONTROL MODULE
J2-B12
J1-A10
J1-A12
J2-C11
J1-A11
J1-C8
J1-C9
J1-A2
J1-A5
J1-A4
J1-A7
J1-A1
J1-A6
J1-B3
J1-A8
J2-C7
J1-B1
Y4 Y1 Y1B Y6 Y6A Y9
H5 ALARM
Y4 STEER LEFT
Y1 DRIVE PARALLEL
Y2 BRAKE RELEASE
Y9
ECM GROUND
S7 LEVEL SENSOR
FLOW CONTROL
PROPORTIONAL
- NOTE -
MACHINE SHOWN IN THE STOWED
ES7184C POSITION WITH THE POWER OFF
Electrical Schematic
CE Models with Diesel Power REV A
(from serial number GS6805-44169 to GS6805-44770)
Part 3 of 3
QD4 QD3 P2
BK EMERGENCY
WH/RD 4 4 4 4 BK POWER TO PLATFORM STOP
RD
RD/WH 3 3 3 3 RD POWER TO GROUND
BL 1 1 1 1 WH GROUND WH J5 PIN1
BK 2 2 DATA LINK (HIGH) BL
2 2 BL J5 PIN4
OR 5 5 5 5 OR OR
DATA LINK (LOW) J5 PIN5
OUTRIGGERS
(OPTION) J5 PIN2
12V DC
AB3 AB3 AB2 AB2 U3 D7
PLATFORM CONTROLS VOLTAGE 5V DC
PRINTED CIRCUIT BOARD REGULATOR
S8
2 AXIS GY
TILT LEVEL J2 PIN1
SENSOR
HALL EFFECT
J2 PIN2
YL
JC1
GROUND
GENERATOR
POWER
WH JOYSTICK
PITCH
J2 PIN12
ROLL
BL
YL
BK
J2 PIN4
DATA LINK (-)
DATA LINK (+)
GND FROM PLAT
LEFT
RIGHT
N.O. N.O. N.O. N.O. OR STEER
J2 PIN5
BK LEFT/ RIGHT
AB23 AB24 J2 PIN6
RD
J2 PIN7
AB27 AB26 AB17 AB16 AB25 AB1 J2 PIN8
WH/BL
J2 PIN14
J1-C5
J1-C3
J1-C6
J1-C4
J2-B10
J2-B1
J2-B3
J2-B2
J2-A10
J2-A11
J2-A12
POUT1
MODULE
J1-B7
J1-B6
J1-B8
J1-B5
J1-B9
YL
J1 PIN4
PLATFORM UP/DOWN TS20
BL -OR-
J1 PIN3
PLATFORM & OUTRIGGER
RD UP/DOWN
J1 PIN1 TS21
BK
J1 PIN5
J3 PIN1
RD +
- NOTE - J3 PIN2
BK
H1
ALARM PLATFORM
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7184C
CONTROLS
REV A
HYDRAULIC COMPONENT
LEGEND
Item Function
A Drive circuit – directs oil to left front
and right rear wheels motors
B Drive circuit – directs oil to right front
and left rear wheels motors
C Check valve – drive speed select
circuit
D Check valve – prevents engine from
running backward when on an incline
and reversing direction of travel
E Check valve – steer circuit
F Check valve – proportional circuit
G Relief valve – pump 1
H Check valve – proportional circuit
I Test port 1
J Test port 2
K Relief valve – lift circuit
L Check valve - drive circuit
M Shuttle valve – brake release circuit
N Check valve - drive circuit
O Relief valve – pump 2
P Platform up/down
Q Priority flow regulator
R Steer left/right
S Orifice – brake release circuit
T Proportional valve – lift/drive circuit
U Brake release
V Relief valve – steer circuit
W Drive speed select circuit
X Drive speed select circuit
Y Drive speed select circuit
Z Check valve – prevents overflowing
the drive motors when in high speed
AA Check valve – prevents engine from
running backward when on an incline
and reversing direction of travel
AB Generator on/off
AC Flow regulator - generator speed
AD Relief valve – generator circuit
AE Platform down
AF Shuttle valve – brake release circuit
AG Pilot operated check valve – brake
release circuit
AH Hand pump – brake release circuit
AI Needle valve – brake release enable
AJ Orifice – platform down circuit
AK Platform overload (option)
BA Relief valve – outrigger circuit
BB 2 position, 2 way solenoid valve –
outrigger lowering slow
BC Orifice – outrigger lowering slow
BD 3 position, 4 way directional valve –
outrigger cylinder extend/retract
BE Counterbalance valve – outrigger
CA Right front outrigger autolevel valve
CB Left front outrigger autolevel valve
CC Right rear outrigger autolevel valve
CD Left rear outrigger autolevel valve
E
Solenoid operated
Engine 2 position 2 way
directional valve
Solenoid operated
Solenoid operated 2 position 3 way
2 position 3 way directional valve
Fixed displacement directional valve
pump
Relief valve
Proportional
solenoid valve
Dual acting cylinder Platform overload
pressure switch
Shuttle valve
Solenoid operated
Single acting cylinder 3 position 4 way Hand pump
directional valve
0.063 in
1.6 mm
Orifice
Solenoid operated Pilot operated
with size
2 position 2 way valve, check valve with
normally closed needle valve
Hydraulic Schematic
(before serial number 35557) REV C
Part 1 of 2
OUTRIGGERS GENERATOR
(OPTION) (OPTION)
C2 C1
COUNTERBALANCE
VALVE
3000 psi
207 bar
MANIFOLD STEER CYLINDER
4.5:1
BE
I J LEFT RIGHT
TEST 1 TEST 2
V2 V1 S1 S2
LEFT RIGHT X X
B B R R
REAR REAR
OUTRIGGER OUTRIGGER OUTRIGGER Y3 Y4
MANIFOLD
Y33 Y34 R
CD BC CC
0.063 in
BB E
Y44
1.6 mm
Y40 Y39 V
1500 psi
BD 103.4 bar
BA
2000 psi P1
137.8 bar
IN OUT
Q
2 gpm
7.5 L/min
P2
O
3500 psi
FUNCTION
241.3 bar MANIFOLD
HYDRAULIC TANK
HS0032B
HS0027J
Hydraulic Schematic
REV C (before serial number 35557)
Part 2 of 2
COM N.O.
PLATFORM LIFT BRAKE RELEASE
CYLINDER
OVERLOAD 0.037 in
0.89 mm
MANIFOLD
(OPTION) AK
LEFT RIGHT
0.059 in
AJ 1.5 mm FRONT FRONT
Y7 Y10
UPPER
AI
LIFT CYLINDER
(GS-3268) AG AE
0.059 in
1.5 mm
AJ AF
L
A B
N
Y6 Y5 Y6A Y5A
AB
U
MODELS WITH
DYNAMIC BRAKING
Y2 5 psi
P AA 0.35 bar AC
MODELS WITH
C DYNAMIC BRAKING
Z
G
S
Y8
Y1 Y1A Y1B
3500 psi M 0.035 in
241.3 bar 0.89 mm Y W X
H F
5 psi
D 0.35 bar
K
Y9
T GS-3268:
2800 psi / 193 bar FUNCTION
GS-2668:
3600 psi / 248.2 bar
MANIFOLD
HS7044A
HS0027J
Hydraulic Schematic
(from serial number 35557 to 40484) REV B
Part 1 of 2
OUTRIGGERS GENERATOR
(OPTION) (OPTION)
OUT-B IN-R
Y33 Y34 R
CD BC CC
0.063 in Y44
BB E
1.6 mm
Y40 Y39 V
1500 psi
BD 103.4 bar
BA
2000 psi P1
137.8 bar
IN OUT
Q
2 gpm
7.5 L/min
P2
O
3500 psi
FUNCTION
241.3 bar MANIFOLD
HYDRAULIC TANK
Hydraulic Schematic
REV B (from serial number 35557 to 40484)
Part 2 of 2
COM N.O.
PLATFORM LIFT BRAKE RELEASE
CYLINDER
OVERLOAD 0.037 in
0.89 mm
MANIFOLD
(OPTION) AK
LEFT RIGHT
0.059 in
AJ 1.5 mm FRONT FRONT
Y7 Y10
UPPER
AI
LIFT CYLINDER
(GS-3268) AG AE
0.059 in
1.5 mm
AJ AF
L
A B
N
Y6 Y5 Y6A Y5A
AB
U
MODELS WITH
DYNAMIC BRAKING
Y2 5 psi
P AA 0.35 bar AC
MODELS WITH
C DYNAMIC BRAKING
Z
G
S
Y8
Y1 Y1A Y1B
3500 psi M 0.035 in
241.3 bar 0.89 mm Y W X
H F
5 psi
D 0.35 bar
K
Y9
T GS-3268:
2800 psi / 193 bar FUNCTION
GS-2668:
3600 psi / 248.2 bar
MANIFOLD
HS7044A
HS0027J
Hydraulic Schematic
(from serial number 40485 to GS6803-42379) REV B
Part 1 of 2
GENERATOR
(OPTION)
GENERATOR
DC
OUTRIGGERS DA MANIFOLD
(OPTION) Y29
DB 4.5 gpm
LEFT FRONT RIGHT FRONT 3000 psi 17 L/min
OUTRIGGER OUTRIGGER 206.8 bar
Y35 Y36
CB CA
STEER CYLINDER
OUT-B IN-R I J LEFT RIGHT
IN-B OUT-R
TEST 1 TEST 2
X S1 S2
X
0.063 in
1.6 mm
BC BB
Y44
Y3 Y4
Y40 Y39 R
BD
E
OUTRIGGER BA
V
MANIFOLD 2000 psi
137.8 bar OUT 1500 psi
103.4 bar
IN
Y33 Y34 P1
CD CC
Q
LEFT REAR RIGHT REAR 2 gpm
OUTRIGGER OUTRIGGER 7.5 L/min
P2
O
3500 psi
FUNCTION
241.3 bar MANIFOLD
HYDRAULIC TANK
HS0032D
HS0027L
Hydraulic Schematic
REV B (from serial number 40485 to GS6803-42379)
Part 2 of 2
COM N.O.
PLATFORM LIFT BRAKE RELEASE
CYLINDER
OVERLOAD 0.037 in
0.89 mm
MANIFOLD
(OPTION) AK
LEFT RIGHT
0.059 in
AJ 1.5 mm FRONT FRONT
Y7 Y10
UPPER
AI
LIFT CYLINDER
(GS-3268) AG AE
0.059 in
1.5 mm
AJ AF
L
A B
N
Y6 Y5 Y6A Y5A
AB
U
MODELS WITH
DYNAMIC BRAKING
Y2 5 psi
P AA 0.35 bar AC
MODELS WITH
C DYNAMIC BRAKING
Z
G
S
Y8
Y1 Y1A Y1B
3500 psi M 0.035 in
241.3 bar 0.89 mm Y W X
H F
5 psi
D 0.35 bar
K
Y9
T ITEMS D AND AA CHANGED
GS-3268: TO 200 PSI / 13.8 BAR
2800 psi / 193 bar AFTER SERIAL NUMBER 40958
FUNCTION
GS-2668:
3600 psi / 248.2 bar
MANIFOLD
HS7044A
HS0027L
Hydraulic Schematic
(from serial number GS6803-42380 to GS6804-43183) REV B
Part 1 of 2
GENERATOR
(OPTION)
GENERATOR
DC
OUTRIGGERS DA MANIFOLD
(OPTION) Y29
DB 4.5 gpm
LEFT FRONT RIGHT FRONT 3000 psi 17 L/min
OUTRIGGER OUTRIGGER 206.8 bar
Y35 Y36
CB CA
STEER CYLINDER
OUT-B IN-R I J LEFT RIGHT
IN-B OUT-R
TEST 1 TEST 2
X S1 S2
X
0.063 in
1.6 mm
BC BB
Y44
Y3 Y4
Y40 Y39 R
BD
E
OUTRIGGER BA
V
MANIFOLD 2000 psi
137.8 bar OUT 1500 psi
103.4 bar
IN
Y33 Y34 P1
CD CC
Q
LEFT REAR RIGHT REAR 2 gpm
OUTRIGGER OUTRIGGER 7.5 L/min
P2
O
3500 psi
FUNCTION
241.3 bar MANIFOLD
HYDRAULIC TANK
HS0032D
HS0027L
Hydraulic Schematic
REV B (from serial number GS6803-42380 to GS6804-43183)
Part 2 of 2
COM N.O.
PLATFORM LIFT BRAKE RELEASE
CYLINDER
OVERLOAD 0.037 in
0.89 mm
MANIFOLD
(OPTION) AK
LEFT RIGHT
0.059 in
AJ 1.5 mm FRONT FRONT
Y7 Y10
UPPER
AI
LIFT CYLINDER
(GS-3268) AG AE
0.059 in
1.5 mm
AJ AF
L
A B
N
Y6 Y5 Y6A Y5A
1500 psi
103.4 bar AB
U 10:1
MODELS WITH
DYNAMIC BRAKING
Y2 1500 psi
200 psi
P AA 13.8 bar
103.4 bar
AC
10:1
MODELS WITH
C DYNAMIC BRAKING
Z
G
S
Y8
Y1 Y1A Y1B
3500 psi M 0.035 in
241.3 bar 0.89 mm Y W X
H F
200 psi
D 13.8 bar
K
Y9
T GS-3268:
2800 psi / 193 bar FUNCTION
GS-2668:
3600 psi / 248.2 bar
MANIFOLD
HS7044A
HS0027L
Hydraulic Schematic
(from serial number GS6804-43184 to GS6805-44770) REV B
Part 1 of 2
GENERATOR
(OPTION)
GENERATOR
DC
OUTRIGGERS DA MANIFOLD
(OPTION) Y29
DB 4.5 gpm
LEFT FRONT RIGHT FRONT 3000 psi 17 L/min
OUTRIGGER OUTRIGGER 206.8 bar
Y35 Y36
CB CA
STEER CYLINDER
OUT-B IN-R I J LEFT RIGHT
IN-B OUT-R
TEST 1 TEST 2
X S1 S2
X
0.063 in
1.6 mm
BC BB
Y44
Y3 Y4
Y40 Y39 R
BD
E
OUTRIGGER BA
V
MANIFOLD 2000 psi
137.8 bar OUT 1500 psi
103.4 bar
IN
Y33 Y34 P1
CD CC
Q
LEFT REAR RIGHT REAR 2 gpm
OUTRIGGER OUTRIGGER 7.5 L/min
P2
O
3500 psi
FUNCTION
241.3 bar MANIFOLD
HYDRAULIC TANK
HS0032D
HS0027P
Hydraulic Schematic
REV B (from serial number GS6804-43184 to GS6805-44770)
Part 2 of 2
COM N.O.
PLATFORM LIFT BRAKE RELEASE
CYLINDER
OVERLOAD 0.037 in
0.89 mm
MANIFOLD
(OPTION) AK
LEFT RIGHT
0.059 in
BRAKE
AJ 1.5 mm FRONT FRONT
Y7 Y10
UPPER
AI
LIFT CYLINDER
(GS-3268)
0.059 in
1.5 mm AG
AJ
L
A B
N
Y6 Y5 Y6A Y5A
1500 psi
103.4 bar AB
U 10:1
MODELS WITH
DYNAMIC BRAKING
Y2 1500 psi
200 psi
P AA 13.8 bar
103.4 bar
AC
10:1
MODELS WITH
C DYNAMIC BRAKING
Z
G
S
Y8
Y1 Y1A Y1B
3500 psi M 0.035 in
241.3 bar 0.89 mm Y W X
H F
200 psi
D 13.8 bar
K
Y9
T GS-3268:
2800 psi / 193 bar FUNCTION
GS-2668:
3600 psi / 248.2 bar
MANIFOLD
HS7044A
HS0027P
Warning
The exhaust from this product
contains chemicals known to
the State of California to
cause cancer, birth defects
or other reproductive harm.
800.536.1800
Fax 425.883.3475
52302
Rev F
(from serial number 101 to GS6805-44770)
GS-2668 RT•GS-3268 RT