Professional Documents
Culture Documents
July 2007
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 or repair procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting and
repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical
skills are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at an authorized Genie dealer
service center.
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.
Contact Us:
PO Box 97030
Redmond, WA 98073-9730 USA
www.genieindustries.com
e-mail: awp.techpub@terex.com
ii
July 2007
INTRODUCTION
Model: GS-1930
GS3005A-12345
Serial number:
Model year: 2005 Manufacture date: 04/12/05
Electrical schematic number: ES0141
Machine unladen weight: 2,714 lb / 1,231 kg
N/A
GS30 05
Gradeability: N/A
Maximum allowable side force :
100 lb / 445 kg
A - 12345
Model
Sequence
number
Year of
manufacture
Facility code
(if applicable)
ANSI A92.6-1999
B354.2-01
Genie Industries
18340 NE 76th Street
Redmond, WA 98052
USA
PN - 77055
iii
July 2007
iv
July 2007
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
operators manual are also safety hazards
when maintenance and repair procedures
are performed.
July 2007
SAFETY RULES
Personal Safety
Workplace Safety
vi
July 2007
Table of Contents
Introduction
Important Information ......................................................................................... ii
Serial Number Legend ...................................................................................... iii
Section 1
Safety Rules
General Safety Rules ........................................................................................ v
Section 2
Rev
G
Specifications
Machine Specifications ................................................................................ 2 - 1
Performance Specifications ......................................................................... 2 - 2
Hydraulic Specifications ............................................................................... 2 - 2
Hydraulic Component Specifications ........................................................... 2 - 3
Manifold Component Specifications ............................................................. 2 - 5
Valve Coil Resistance Specifications ........................................................... 2 - 5
Ford LRG-425 EFI Engine ........................................................................... 2 - 6
Deutz F4L 1011F Engine ............................................................................. 2 - 7
Deutz F3L 1011F Engine ............................................................................. 2 - 8
Deutz F3L 2011 Engine ............................................................................... 2 - 9
Deutz D2011L03i Engine ............................................................................. 2 - 9
Hydraulic Hose and Fitting Torque Specifications ...................................... 2 - 10
SAE and Metric Fasteners Torque Charts ................................................. 2 - 11
Section 3
Rev
Checklist A Procedures
A-1
A-2
A-3
A-4
A-5
vii
July 2007
TABLE OF CONTENTS
Section 3
Rev
A-7
A-8
A-9
Checklist B Procedures
B-1
B-2
B-3
B-4
B-5
B-6
B-7
B-8
Inspect the Tires and Wheels (including lug nut torque) ................... 3 - 20
B-9
Checklist C Procedure
C-1 Test the Platform Overload System (if equipped) ............................. 3 - 29
C-2 Replace the Engine Air Filter Element - Deutz Models ..................... 3 - 30
viii
July 2007
TABLE OF CONTENTS
Section 3
Rev
Checklist D Procedures
D-1 Check the Scissor Arm Wear Pads .................................................. 3 - 32
D-2 Check the Free-wheel Configuration ................................................ 3 - 33
D-3 Replace the Drive Hub Oil ................................................................ 3 - 34
D-4 Replace the Fuel Filter / Water Separator - Deutz models ................ 3 - 34
D-5 Replace the Hydraulic Tank Return Filter ......................................... 3 - 35
D-6 Perform Engine Maintenance - Deutz Models .................................. 3 - 37
Section 4
Rev
Checklist E Procedure
E-1
E-2
E-3
E-4
E-5
E-6
Repair Procedures
Introduction .................................................................................................. 4 - 1
Platform Controls
1-1
1-2
1-3
1-4
Platform Components
2-1
Platform ........................................................................................... 4 - 15
2-2
ix
July 2007
TABLE OF CONTENTS
Section 4
Rev
D
3-2
3-3
3-4
3-5
Engines
4-1
4-2
4-3
4-4
4-5
Ground Controls
5-1
5-2
5-3
5-4
5-5
5-6
5-7
Hydraulic Pumps
6-1
6-2
Manifolds
7-1
7-2
7-3
July 2007
TABLE OF CONTENTS
Section 4
Rev
7-5
7-6
7-7
7-8
7-9
8-2
9-2
9-3
9-4
Outrigger Components
11-1 Outrigger Cylinder .......................................................................... 4 - 122
xi
July 2007
TABLE OF CONTENTS
Section 5
Rev
Fault Codes
Introduction ................................................................................................. 5 - 1
Section 6
Rev
Schematics
Introduction .................................................................................................. 6 - 1
xii
June 2008
TABLE OF CONTENTS
Section 6
Rev
Schematics, continued
xiii
July 2007
TABLE OF CONTENTS
Section 6
xiv
Rev
Schematics, continued
Hydraulic Schematic
(before serial number 40519) ................................................................... 6 - 126
Hydraulic Schematic
(from serial number 40519 to GS9004-41690) ......................................... 6 - 128
Hydraulic Schematic
(from serial number GS9004-41691 to GS9005-42685) .......................... 6 - 130
July 2007
Section 2 Specifications
Specifications
REV G
Machine Specifications
Fluid capacities
Tire size
Hydraulic tank
32 gallons
121 liters
10
36 sq in
232.3 cm2
37.5 gallons
142 liters
38.25 gallons
144.8 liters
Tire width
38.75 gallons
146.7 liters
12 in
30 cm
Wheel diameter
34.25 gallons
129.6 liters
21.5 in
55 cm
Wheel width
35 gallons
132.5 liters
Fuel tank
30 gallons
114 liters
Weight
2500 lbs
1135 kg
GS-4390
1800 lbs
(some models - refer to capacity indicator decal) 816 kg
1500 lbs
680 kg
10 in
25.4 cm
257 lbs (+/- 10 lbs)
116.6 kg (+/- 4.5 kg)
33/16LL500
10
48 sq in
309.7 cm2
33 in
83.8 cm
16 in
41 cm
Wheel diameter
19.5 in
49.5 cm
Wheel width
14 in
35.6 cm
33 in
83.8 cm
GS-4390
1500 lbs
(most models - refer to capacity indicator decal) 680 kg
GS-5390
Tire diameter
9 @ 5/8-18
125 ft-lbs
169.5 Nm
Weight, foam-filled
94 ft-lbs
127.4 Nm
Weight, air-filled
157 lbs
71.2 kg
Pressure, air-filled
38 psi
2.6 bar
2-1
Section 2 Specifications
July 2007
REV G
SPECIFICATIONS
Performance Specifications
Hydraulic Specifications
Platform stowed
Platform raised
5 mph
40 ft / 5.5 sec
8 km/h
12.2 m / 5.5 sec
0.7 mph
40 ft / 39 sec
1.13 km/h
12.2 m / 39 sec
Gradeability
GS-3390 and GS-4390
GS-5390
50%
40%
15/13
200 ppm
GS-3390
Platform up
Platform down
42 to 52 seconds
25 to 35 seconds
GS-4390
Platform up
Platform down
50 to 60 seconds
32 to 42 seconds
GS-5390
Platform up
Platform down
70 to 90 seconds
42 to 52 seconds
60 inches
15.24 cm
2-2
July 2007
Section 2 Specifications
REV G
SPECIFICATIONS
Optional fluids
Biodegradable
Fire resistant
Mineral based
Hydraulic Components
Specifications
Drive pump
Type: Bi-directional, variable displacement piston pump
Flow rate @ 2500 rpm
0 to 30 gpm
(before serial number GS9004-41619) 0 to 113.6 L/min
Flow rate @ 2500 rpm
(after serial number GS9004-41618)
Drive pressure, maximum
(before serial number GS9004-41619)
Drive pressure, maximum
(after serial number GS9004-41618)
0 to 32.5 gpm
0 to 123 L/min
3500 psi
241 bar
3750 psi
258.6 bar
Charge pump
Type:
Gerotor
6.5 gpm
24.6 L/min
9.1 gpm
34.4 L/min
360 psi
24.8 bar
325 psi
22.4 bar
Function pump
Type:
Gear
Displacement
(before serial number GS9004-41619)
Displacement
(after serial number GS9004-41618)
0.98 cu in
16 cc
10.8 gpm
40.9 L/min
10.6 gpm
40.1 L/min
Hydraulic tank
return line filter
10 micron with
25 psi / 1.7 bar bypass
2-3
1.025 cu in
16.8 cc
Section 2 Specifications
July 2007
SPECIFICATIONS
REV G
Drive hubs
2000 psi
137.9 bar
Function manifold
System relief valve pressure,
GS-3390
2000 psi
138 bar
2.5 gpm
9.5 L/min
Fluid capacity
(before serial number GS9004-41619)
Fluid capacity
(after serial number GS9004-41618)
Fluid type:
17 fl oz
0.5 liters
26 fl oz
0.77 liters
0.1 gpm
0.38 L/min
Oscillate manifold
System relief valve pressure
Float relief valve pressure
Oscillate flow regulator
3500 psi
241 bar
900 psi
62 bar
1 gpm
3.8 L/min
Drive manifold
Hot oil relief pressure
(before serial number GS9004-41619)
300 psi
20.7 bar
280 psi
19.3 bar
3000 psi
207 bar
4.5 gpm
17 L/min
July 2007
Section 2 Specifications
REV G
SPECIFICATIONS
Manifold Component
Specifications
Plug torque
SAE No. 2
50 in-lbs / 6 Nm
SAE No. 4
13 ft-lbs / 18 Nm
SAE No. 6
18 ft-lbs / 24 Nm
SAE No. 8
50 ft-lbs / 68 Nm
SAE No. 10
55 ft-lbs / 75 Nm
SAE No. 12
75 ft-lbs / 102 Nm
Specification
8.2 to 10.2
3.1 to 5.1
2.6 to 4.6
6.2 to 8.2
8.2 to 10.2
4.5 to 6.5
5 to 7
6.5 to 8.5
9 to 11
2-5
Section 2 Specifications
July 2007
SPECIFICATIONS
REV G
Engine coolant
153 cu in
2.5 liters
Number of cylinders
Horsepower
70 @ 2500 rpm
52 kw @ 2500 rpm
Firing order
1-3-4-2
Capacity
Starter motor
Normal engine cranking speed
Current draw, normal load
Current draw, maximum load
1600 rpm
320 Hz
2500 rpm
500 Hz
9.4:1
140-200A
800A
0.25 in
6.35 mm
0.005 inches
0.127 mm
63 psi
4.3 bar
0.58 gpm
2.2 L/min
Alternator
Lubrication system
Oil pressure
(operating temperature @ 2500 rpm)
Oil capacity
(including filter)
Compression ratio
11.5 quarts
10.9 liters
40 to 60 psi
2.75 to 4.1 bar
4.5 quarts
4.3 liters
Output
95A, 14.5V DC
12V DC
34/78
Ignition system
Type
Quantity
2-6
Group
1
900A
125 minutes
12V DC
31
1
1000A
200 minutes
July 2007
Section 2 Specifications
REV G
SPECIFICATIONS
Injection system
166.7 cu in
2.732 liters
4351 psi
300 bar
3626 psi
250 bar
Horsepower
56 @ 3000 rpm
42 kw @ 3000 rpm
Fuel requirement
Firing order
Compression ratio
Compression pressure
1-3-4-2
18.5:1
362 to 435 psi
25 to 30 bar
Low idle
1600 rpm
320 Hz
High idle
2500 rpm
500 Hz
Governor
centrifugal mechanical
Exhaust
0.012 in
0.3 mm
0.020 in
0.5 mm
Starter motor
Current draw, no load
90A
0.5 in
12.7 mm
Alternator
Output
55A, 14V DC
3 /8
to 1/2 inch
9 to 12 mm
OMAP
Group
Quantity
Cold cranking ampere
Reserve capacity @ 25A rate
12V DC
34/78
1
900A
125 minutes
Lubrication system
Battery (after serial number 40515)
Oil pressure
Oil capacity
(including filter)
26 to 87 psi
1.8 to 6 bar
11 quarts
10.4 liters
Type
Group
Quantity
12V DC
31
1
1000A
200 minutes
2-7
Section 2 Specifications
July 2007
SPECIFICATIONS
REV G
Injection system
125 cu in
2.05 liters
OMAP
4351 psi
300 bar
3626 psi
250 bar
3
3.58 x 4.13 inches
91 x 105 mm
42 @ 2800 rpm
31.3 kW @ 2800 rpm
1-2-3
18.5:1
362 to 435 psi
25 to 30 bar
1600 rpm
320 Hz
High idle
2800 rpm
560 Hz
Governor
centrifugal mechanical
Fuel requirement
Starter motor
Current draw, no load
90A
0.748 in
19 mm
0.5 in
12.7 mm
Alternator
Output
55A, 14V DC
3 /8
to 1/2 inch
9 to 12 mm
Intake
0.012 in
0.3 mm
Exhaust
0.020 in
0.5 mm
Lubrication system
Oil pressure
Type
Group
Quantity
Cold cranking ampere
26 to 87 psi
1.8 to 6.0 bar
12V DC
34/78
1
900A
125 minutes
8.5 quarts
8 liters
Type
Group
Quantity
2-8
12V DC
31
1
1000A
200 minutes
July 2007
Section 2 Specifications
REV G
SPECIFICATIONS
Injection system
142.2 cu in
2.331 liters
3
3.7 x 4.41 inches
94 x 112 mm
Horsepower
48 @ 2800 rpm
35.8 kW @ 2800 rpm
Firing order
1-2-3
Compression ratio
19:1
Motorpal
4351 psi
300 bar
Fuel requirement
Starter motor
Current draw, no load
Brush length, minimum
Output
1500 rpm
300 Hz
High idle
2500 rpm
500 Hz
Battery
Governor
centrifugal mechanical
Intake
Exhaust
Type
Group
0.012 to 0.016 in
0.3 to 0.4 mm
0.02 to 0.024 in
0.5 to 0.6 mm
90A
0.5 in
12.7 mm
Alternator
Low idle
Quantity
55A, 14V DC
101 / 79 5 lbf
450 / 350 20 N
12V DC
31
1
1000A
200 minutes
Lubrication system
Oil pressure
Oil capacity
(including filter)
Oil change capacity
(including filter)
20 to 43 psi
1.4 to 3 bar
8.5 quarts
8 liters
6.35 quarts
6 liters
2-9
Section 2 Specifications
July 2007
SPECIFICATIONS
REV G
Torque
-4
11 ft-lbs / 14.9 Nm
-6
23 ft-lbs / 31.2 Nm
-8
40 ft-lbs / 54.2 Nm
-10
69 ft-lbs / 93.6 Nm
-12
93 ft-lbs / 126.1 Nm
-16
-20
-24
Seal-Lok fittings
1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
The O-ring cannot be re-used if the fitting or
hose end has been tightened beyond finger
tight.
Note: The O-rings used in the Parker Seal Lok
fittings and hose ends are custom-size O-rings.
They are not standard SAE size O-rings. They are
available in the O-ring field service kit (Genie part
number 49612).
2 Lubricate the O-ring before installation.
3 Be sure that the face seal O-ring is seated and
retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger
tight.
5 Tighten the nut or fitting to the appropriate
torque per given size as shown in the table.
6 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.
Seal-Lok Fittings
(hose end)
Torque
-4
16 ft-lbs / 21.7 Nm
-4
18 ft-lbs / 25 Nm
-6
35 ft-lbs / 47.5 Nm
-6
30 ft-lbs / 40 Nm
-8
60 ft-lbs / 81.3 Nm
-8
40 ft-lbs / 55 Nm
-10
-10
60 ft-lbs / 80 Nm
-12
-12
85 ft-lbs / 115 Nm
-16
-16
-20
-20
-24
-24
2 - 10
Torque
July 2007
Section 2 Specifications
REV G
SPECIFICATIONS
SIZE
Grade 5
THREAD
LUBED
20
28
1/4
DRY
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 1/2
LUBED
DRY
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
80
90
9
10.1
100
120
11.3
13.5
110
120
12.4
13.5
140
160
15.8
18
130
140
14.7
15.8
LUBED
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
Grade 8
DRY
LUBED
DRY
LUBED
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
13
14
23
26
37
41
57
64
80
90
110
130
200
220
320
350
480
530
590
670
840
930
1460
1640
17.6
19
31.2
35.2
50.1
55.5
77.3
86.7
108.4
122
149
176
271
298
433
474
650
718
800
908
1138
1260
1979
2223
17
19
31
35
49
55
75
85
110
120
150
170
270
300
430
470
640
710
790
890
1120
1240
1950
2190
23
25.7
42
47.4
66.4
74.5
101.6
115
149
162
203
230
366
406
583
637
867
962
1071
1206
1518
1681
2643
2969
18
20
33
37
50
60
80
90
120
130
160
180
280
310
450
500
680
750
970
1080
1360
1510
2370
2670
24
27.1
44.7
50.1
67.8
81.3
108.4
122
162
176
217
244
379
420
610
678
922
1016
1315
1464
1844
2047
3213
3620
25
27
44
49
70
80
110
120
150
170
210
240
380
420
610
670
910
990
1290
1440
1820
2010
3160
3560
33.9
36.6
59.6
66.4
94.7
108.4
149
162
203
230
284
325
515
569
827
908
1233
1342
1749
1952
2467
2725
4284
4826
21
24
38
43
61
68
93
105
130
140
180
200
320
350
510
560
770
840
1090
1220
1530
1700
2670
3000
28.4
32.5
51.5
58.3
82.7
92.1
126
142
176
189
244
271
433
474
691
759
1044
1139
1477
1654
2074
2304
3620
4067
Class 4.6
Size
(m m )
5
6
7
LUBED
DRY
LUBED
Class 10.9
8.8
DRY
LUBED
Class 12.9
10.9
DRY
LUBED
12.9
DRY
in- lbs
Nm
in-lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
in- lbs
Nm
16
19
45
1.8
3.05
5.12
21
36
60
2.4
4.07
6.83
41
69
116
4.63
7.87
13.2
54
93
155
6.18
10.5
17.6
58
100
167
6.63
11.3
18.9
78
132
223
8.84
15
25.2
68
116
1.95
7.75
13.2
22.1
91
155
260
10.3
17.6
29.4
LUBED
8
10
12
14
16
18
20
22
24
Class 8.8
4.6
DRY
LUBED
DRY
LUBED
DRY
LUBED
DRY
f t - lbs
Nm
f t -lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
ft - lbs
Nm
f t - lbs
Nm
f t - lbs
Nm
5.4
10.8
18.9
30.1
46.9
64.5
91
124
157
7.41
14.7
25.6
40.8
63.6
87.5
124
169
214
7.2
14.4
25.1
40
62.5
86.2
121
166
210
9.88
19.6
34.1
54.3
84.8
117
165
225
285
14
27.9
48.6
77.4
125
171
243
331
420
19.1
37.8
66
105
170
233
330
450
570
18.8
37.2
64.9
103
166
229
325
442
562
25.5
50.5
88
140
226
311
441
600
762
20.1
39.9
69.7
110
173
238
337
458
583
27.3
54.1
94.5
150
235
323
458
622
791
26.9
53.2
92.2
147
230
317
450
612
778
36.5
72.2
125
200
313
430
610
830
1055
23.6
46.7
81
129
202
278
394
536
682
32
63.3
110
175
274
377
535
727
925
31.4
62.3
108
172
269
371
525
715
909
42.6
84.4
147
234
365
503
713
970
1233
2 - 11
Section 2 Specifications
July 2007
2 - 12
July 2007
Symbols Legend
Safety alert symbolused to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
3-1
July 2007
Checklist
A
A+B
A+B+C
A+B+C+D
A+B+C+D+E
3-2
Pre-Deliver
Pre-Deliveryy Preparation
Fundamentals
Instructions
Pre-Delivery Preparation
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
Genie Industries USA
18340 NE 76th Street
PO Box 97030
Redmond, WA 98073-9730
(425) 881-1800
Genie UK
The Maltings, Wharf Road
Grantham, Lincolnshire
NG31- 6BH England
(44) 1476-584333
July 2007
3-4
July 2007
Checklist A - Rev E
Y N R
Checklist B - Rev G
B-1 Battery
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Serial number
Instructions
Make copies of this report to use for
each inspection.
A
A+B
Y N R
Comments
3-5
July 2007
Model
Checklist C - Rev E
Serial number
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Y N R
Y N R
Inspector title
Checklist D - Rev E
Checklist E - Rev C
Y N R
Inspector company
Instructions
Make copies of this report to use for
each inspection.
D-2 Free-wheel
configuration
A
A+B
3-6
July 2007
REV E
Checklist A Procedures
A-1
Inspect the Manuals and Decals
Genie specifications require that this procedure be
performed every 8 hours or daily, whichever
comes first.
Maintaining the operators and safety manuals in
good condition is essential to safe machine
operation. Manuals are included with each
machine and should be stored in the container
provided in the platform. An illegible or missing
manual will not provide safety and operational
information necessary for a safe operating
condition.
In addition, maintaining all of the safety and
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators
and personnel to the many possible hazards
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.
3-7
CHECKLIST A
July 2007
REV E
PROCEDURES
A-2
Perform Pre-operation Inspection
A-3
Perform Function Tests
3-8
July 2007
REV E
CHECKLIST A
PROCEDURES
A-4
Perform Engine Maintenance Ford Models
A-5
Perform Engine Maintenance Deutz Models
84792
52883
84794
3-9
CHECKLIST A
July 2007
PROCEDURES
REV E
A-6
Perform 30 Day Service
A-7
Perform Engine Maintenance Deutz Models
A-8
D-5
C-3
D-4
D-5
52883
84794
D-4
D-5
3 - 10
July 2007
REV E
CHECKLIST A
A-8
Perform Engine Maintenance Ford Models
PROCEDURES
A-9
Check the Hydraulic Return Filter
Condition Indicator (if equipped)
Genie specifications require that this procedure be
performed every 100 hours of operation.
84792
3 - 11
CHECKLIST A
July 2007
PROCEDURES
REV E
A-10
Perform Engine Maintenance Deutz 1011F Models
A-11
Drain the Fuel Filter/ Water
Separator - Deutz Models
52883
3 - 12
July 2007
REV E
CHECKLIST A
PROCEDURES
A-12
Perform Engine Maintenance Ford Models
84792
a
b
fuel filter
drain plug
3 - 13
July 2007
Checklist B Procedures
REV G
B-1
Inspect the Battery
3 - 14
July 2007
REV G
CHECKLIST B
B-2
Inspect the Electrical Wiring
PROCEDURES
Scissor arms
Platform controls
3 Inspect for a liberal coating of dielectric grease
in the following locations:
Between the ECM and platform controls
Engine ECM (Ford models)
3 - 15
CHECKLIST B
July 2007
REV G
PROCEDURES
B-3
Perform Engine Maintenance Deutz 1011F Models
B-4
Check the Exhaust System
52883
3 - 16
July 2007
REV G
CHECKLIST B
B-5
Inspect the Engine Air Filter
PROCEDURES
Deutz models:
1 Release the latches on the engine tray and fully
slide the engine tray out.
2 Insert a 6 inch / 15 cm screwdriver or rod into
the engine tray lock hole located near the
engine tray roller wheels to prevent the engine
tray from moving.
3 Remove the air intake hose from the engine
slide out tray.
4 Disconnect the retaining clamp from the air
cleaner canister.
5 Remove the filter element.
6 Clean the inside of the canister and the gasket
with a damp cloth.
7 Inspect the air filter element. If needed, blow
from the inside out using low pressure dry
compressed air, or carefully tap out dust.
8 Install the filter element.
9 Install the air filter canister end cap and connect
the end cap retaining clamp.
Note: Be sure the air cleaner intake hose is
inserted in the hole in the front of the engine slide
out tray.
3 - 17
CHECKLIST B
July 2007
PROCEDURES
REV G
Deutz models:
B-6
Check and Adjust the
Engine RPM
Ford models:
a
3 - 18
July 2007
REV G
CHECKLIST B
PROCEDURES
3 - 19
CHECKLIST B
July 2007
REV G
PROCEDURES
B-7
Confirm the Proper
Brake Configuration
B-8
Inspect the Tires and Wheels
(including lug nut torque)
disengaged position
engaged position
3 - 20
July 2007
REV G
CHECKLIST B
B-9
Check the Oil Level in
the Drive Hubs
PROCEDURES
B-10
Test the Key Switch
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes
first.
3 - 21
CHECKLIST B
July 2007
REV G
PROCEDURES
B-11
Test the Emergency Stop
B-12
Test the Automotive-style Horn
3 - 22
July 2007
REV G
CHECKLIST B
B-13
Test the Fuel Select Operation Ford Models
PROCEDURES
3 - 23
CHECKLIST B
July 2007
REV G
PROCEDURES
B-14
Test the Drive Brakes
B-15
Test the Drive Speed Stowed Position
3 - 24
July 2007
REV G
CHECKLIST B
PROCEDURES
B-16
Test the Drive Speed Raised Position
3 - 25
CHECKLIST B
PROCEDURES
July 2007
REV G
B-17
Perform Hydraulic Oil Analysis
3 - 26
July 2007
REV G
CHECKLIST B
B-18
Inspect the Fuel and Hydraulic
Tank Cap Venting Systems
PROCEDURES
3 - 27
CHECKLIST B
July 2007
REV G
PROCEDURES
B-19
Replace the Engine Air Filter
Element - Ford Models
B-20
Perform Engine Maintenance Ford Models
84792
3 - 28
July 2007
Checklist C Procedures
REV E
C-1
Test the Platform Overload
System (if equipped)
3 - 29
CHECKLIST
July 2007
REV E
PROCEDURES
C-2
Replace the Engine Air Filter
Element - Deutz Models
3 - 30
July 2007
REV E
CHECKLIST
C-3
Perform Engine Maintenance Deutz Models
52883
84794
C PROCEDURES
C-4
Replace the Hydraulic Tank
Breather Cap - Models with
Optional Hydraulic Oil
C-5
Perform Engine Maintenance Ford Models
84792
3 - 31
July 2007
Checklist D Procedures
D-1
Check the Scissor Arm Wear
Pads
REV E
3 - 32
July 2007
REV E
CHECKLIST
D PROCEDURES
D-2
Check the Free-wheel
Configuration
engaged position
3 - 33
CHECKLIST
July 2007
PROCEDURES
REV E
D-3
Replace the Drive Hub Oil
D-4
Replace the Diesel Fuel
Filter/Water Separator Deutz Models
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side hole.
Apply pipe thread sealant to the plugs. Install
the plugs. Refer to Section 2, Specifications.
3 - 34
July 2007
REV E
CHECKLIST
D PROCEDURES
D-5
Replace the Hydraulic Filters
a
b
oil filter
fuel filter/water separator
5 Fill the new filter with fresh diesel fuel and apply
a thin layer of diesel fuel to the new fuel filter
gasket.
6 Install the new filter and tighten it securely by
hand. Clean up any diesel fuel that might have
spilled during the procedure.
7 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the filter.
8 Turn the manual fuel shutoff valves, located at
the fuel tank, to the open position.
9 Start the engine from the ground controls and
inspect the fuel filter for leaks.
Explosion and fire hazard. If a fuel
leak is discovered, keep any
additional personnel from entering
the area and do not operate the
machine. Repair the leak
immediately.
3 - 35
CHECKLIST
July 2007
REV E
PROCEDURES
3 - 36
July 2007
REV E
CHECKLIST
D PROCEDURES
D-6
Perform Engine Maintenance Deutz Models
52883
84794
3 - 37
July 2007
Checklist E Procedures
E-1
Test or Replace the Hydraulic Oil
REV C
3 - 38
July 2007
REV C
CHECKLIST E
PROCEDURES
open
closed
3 - 39
CHECKLIST E
July 2007
PROCEDURES
REV C
E-2
Perform Engine Maintenance Deutz 1011F Models
52883
3 - 40
July 2007
REV C
CHECKLIST E
PROCEDURES
E-3
Perform Engine Maintenance Ford Models
E-4
Perform Engine Maintenance Deutz Models
84792
52883
84794
3 - 41
CHECKLIST E
July 2007
PROCEDURES
REV C
E-5
Perform Engine Maintenance Deutz 2011 Models
E-6
Perform Engine Maintenance Ford Models
(before serial number GS9003-41369)
84794
Ford LRG 425 Operator Handbook
Genie part number
3 - 42
84792
July 2007
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.
Wheels chocked
All external AC power supply disconnected
from the machine
4-1
July 2007
Platform Controls
REV E
NC 1
2
a
b
c
e
d
e
f
g
a
b
e
f
g
h
i
4-2
alarm H1
function enable/high speed select
button for platform up/down function
BN12
function enable/low speed select
button for platform up/down function
BN13
platform up/down toggle switch TS20
OR platform up/down and outrigger
up/down toggle switch TS21
circuit board U3
DIP switch SW25
joystick controller JC1
potentiometer
red Emergency Stop button P2
July 2007
REV E
PLATFORM CONTROLS
1-1
Circuit Boards
1-2
Joystick Controller
4-3
July 2007
PLATFORM CONTROLS
REV E
JC1
JOYSTICK
CONTROLLER
c
U3
PLATFORM
CONTROLS
CIRCUIT
BOARD
ON
a
b
c
d
e
f
g
DIP
4-4
July 2007
REV E
PLATFORM CONTROLS
1-3
Controller Adjustments
SYSTEM
20 AMP
HOUR METER
a
Function
Enable
Stop
a
b
c
4-5
July 2007
REV E
PLATFORM CONTROLS
Stop
STOP
Stop
AUTO
LEVEL
STOP
a
b
c
4-6
July 2007
PLATFORM CONTROLS
REV E
Stop
STOP
Stop
AUTO
LEVEL
STOP
a
b
c
d
4-7
July 2007
REV E
PLATFORM CONTROLS
Stop
STOP
Stop
AUTO
LEVEL
STOP
a
b
c
d
4-8
July 2007
REV E
PLATFORM CONTROLS
Stop
STOP
Stop
AUTO
LEVEL
STOP
a
b
c
d
4-9
July 2007
PLATFORM CONTROLS
REV E
Stop
d
a
c
b
STOP
Stop
AUTO
LEVEL
STOP
a
b
c
4 - 10
July 2007
REV E
PLATFORM CONTROLS
1-4
Software Configuration
e
b
ON
OFF (0)
DIP
ON (1)
a
b
c
d
e
f
4 - 11
July 2007
PLATFORM CONTROLS
REV E
SYSTEM
20 AMP
HOUR METER
a
Stop
Function
Enable
a
b
c
4 - 12
July 2007
01
01011010
02
00111010
04
01010001
05
10100110
07
01011011
08
00111011
10
01010000
11
10100111
13
01010100
14
00110000
16
00100100
17
10100100
19
01011000
20
00111000
22
00101100
23
10101100
25
01010011
26
00110011
28
00100101
29
10100101
31
01010111
32
00110111
34
00101001
35
10101001
37
01011100
38
00111100
40
00101101
41
10101101
43
01011111
44
00111111
46
00101111
47
10101111
No Simultaneous
Operation
Descent Delay
Overload Sensor
Motion Beacon
Diesel
DIP
Switch
Code
Motion Alarm
Diagnostic
Display
Code
Gasoline/LPG
10000000
52
01110001
53
10000001
55
01110010
56
10000010
58
10011111
59
01111111
61
01110111
62
01111000
64
10011000
65
10011001
67
01110011
68
10001011
70
10001101
71
01111100
73
10011011
74
10000111
76
01110100
77
10010011
79
01110110
80
00011010
82
10000100
83
10001100
85
01110101
86
10000110
88
10000101
89
10011110
91
10001000
92
00011100
94
01111011
95
10011100
No Simultaneous
Operation
01110000
50
Descent Delay
49
Overload Sensor
DIP
Switch
Code
Motion Alarm
Diagnostic
Display
Code
Diesel
Gasoline/LPG
Motion Beacon
PLATFORM CONTROLS
REV E
4 - 13
July 2007
01111010
109
00101000
110
00011101
112
00011111
113
00000000
115
00000010
116
00000011
118
00000101
119
00000110
121
00001000
122
00001001
124
00001011
125
00001100
127
00001110
128
00001111
130
00100001
131
00100010
133
00100110
134
00100111
136
00101011
137
00101110
139
00110010
140
00110100
142
00110110
143
00111001
4 - 14
01000011
151
01000101
152
01000110
154
01001000
155
01001001
157
01001011
158
01001100
160
01001110
161
01001111
163
01010101
164
01010110
166
01011101
167
01011110
169
01100001
170
01100010
172
01100110
173
01100111
175
01101110
176
10100000
178
10100010
179
10100011
181
10101010
182
10101011
184
10110000
185
10110001
187
10110011
188
10110100
190
10110110
191
10110111
No Simultaneous
Operation
107
01000010
149
Descent Delay
00011001
148
Overload Sensor
106
01000000
Motion Beacon
00010111
00111110
146
104
145
Motion Alarm
00010110
DIP
Switch
Code
Diesel
103
Diagnostic
Display
Code
Gasoline/LPG
00010100
No Simultaneous
Operation
00010011
101
Descent Delay
100
Overload Sensor
00010001
Motion Beacon
00010000
98
97
REV E
Motion Alarm
DIP
Switch
Code
Diesel
Diagnostic
Display
Code
Gasoline/LPG
PLATFORM CONTROLS
July 2007
Platform Components
REV C
2-1
Platform
4 - 15
July 2007
REV C
PLATFORM COMPONENTS
4 - 16
July 2007
REV C
PLATFORM COMPONENTS
2-2
Platform Extension Deck
4 - 17
July 2007
Scissor Components
REV D
2
11
3
12
4
13
5
14
6
7
15
16
17
18
10
19
Steer End
Non-steer End
1
2
3
4
5
6
7
8
9
10
4 - 18
11
12
13
14
15
16
17
18
19
July 2007
REV D
SCISSOR COMPONENTS
3-1
Scissor Assembly , GS-3390
4 - 19
July 2007
REV D
SCISSOR COMPONENTS
4 - 20
July 2007
REV D
SCISSOR COMPONENTS
4 - 21
July 2007
SCISSOR COMPONENTS
REV D
4 - 22
July 2007
REV D
SCISSOR COMPONENTS
How to
Disassemble a Scissor Arm Pair
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is required.
a
b
outer arm
inner arm
4 - 23
July 2007
SCISSOR COMPONENTS
REV D
1
2
14
15
16
5
17
18
6
19
7
20
21
9
10
22
11
12
23
13
24
Steer End
Non-steer End
1
2
3
4
5
6
7
8
9
10
11
12
13
4 - 24
14
15
16
17
18
19
20
21
22
23
24
July 2007
REV D
SCISSOR COMPONENTS
3-2
Scissor Assembly, GS-4390
How to Disassemble the
Scissor Assembly, GS-4390
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is required.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose must be
replaced and then torqued to specification during
installation. Refer to Section Two, Hydraulic Hose
and Fitting Torque Specifications.
Before serial number 41073:
1 Remove the platform. See 2-1, How to Remove
the Platform.
4 - 25
July 2007
SCISSOR COMPONENTS
REV D
16 Loosen the wheel lug nuts on one of the nonsteer wheels. Do not remove them.
17 Raise the machine approximately
2 inches / 5 cm. Place blocks under the chassis
for support.
Crushing hazard. The chassis will
fall if not properly supported.
18 Remove the wheel lug nuts. Remove the tire
and wheel assembly.
19 Tag, disconnect and plug the hydraulic hoses
from the lift cylinder. Cap the fittings on the
cylinder.
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.
20 Cut the zip ties attaching the hydraulic hoses to
the lift cylinder. Lay the hoses out of the way.
Component damage hazard.
Hoses can be damaged if they are
kinked or pinched.
4 - 26
July 2007
REV D
SCISSOR COMPONENTS
4 - 27
July 2007
SCISSOR COMPONENTS
REV D
4 - 28
July 2007
REV D
SCISSOR COMPONENTS
4 - 29
July 2007
SCISSOR COMPONENTS
REV D
4 - 30
July 2007
REV D
SCISSOR COMPONENTS
4 - 31
July 2007
SCISSOR COMPONENTS
REV D
4 - 32
July 2007
REV D
SCISSOR COMPONENTS
a
b
outer arm
inner arm
4 - 33
July 2007
REV D
SCISSOR COMPONENTS
1
18
2
3
4
19
20
21
22
23
24
10
25
11
26
12
27
13
28
14
29
15
30
16
31
17
Non-steer End
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Steer End
4 - 34
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
July 2007
REV D
SCISSOR COMPONENTS
3-3
Scissor Assembly, GS-5390
How to Disassemble the
Scissor Assembly, GS-5390
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is required.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose must be
replaced and then torqued to specification during
installation. Refer to Section Two, Hydraulic Hose
and Fitting Torque Specifications.
Before serial number 41073:
1 Remove the platform. See 2-1, How to Remove
the Platform.
4 - 35
July 2007
SCISSOR COMPONENTS
REV D
4 - 36
July 2007
REV D
SCISSOR COMPONENTS
4 - 37
July 2007
SCISSOR COMPONENTS
REV D
4 - 38
July 2007
REV D
SCISSOR COMPONENTS
4 - 39
July 2007
SCISSOR COMPONENTS
REV D
4 - 40
July 2007
REV D
SCISSOR COMPONENTS
4 - 41
July 2007
REV D
SCISSOR COMPONENTS
4 - 42
July 2007
REV D
SCISSOR COMPONENTS
4 - 43
July 2007
REV D
SCISSOR COMPONENTS
4 - 44
July 2007
REV D
SCISSOR COMPONENTS
4 - 45
July 2007
SCISSOR COMPONENTS
REV D
a
b
outer arm
inner arm
4 - 46
July 2007
REV D
SCISSOR COMPONENTS
3-4
Wear Pads
4 - 47
July 2007
REV D
SCISSOR COMPONENTS
4 - 48
July 2007
REV D
SCISSOR COMPONENTS
3-5
Lift Cylinder(s)
4 - 49
July 2007
SCISSOR COMPONENTS
REV D
4 - 50
July 2007
REV D
SCISSOR COMPONENTS
GS-5390:
Bodily injury hazard. The
counterbalance valves in the lift
cylinders are factory set. Do not
attempt to adjust the
counterbalance valves. Attempting
to adjust the counterbalance
valves will result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
4 - 51
July 2007
SCISSOR COMPONENTS
REV D
4 - 52
July 2007
Engines
REV D
4-1
RPM Adjustment
4-3
Flex Plate
4-2
Engine Fault Codes Ford Models
See 5-7, Engine Fault Codes, Ford Models
f
a
b
c
d
e
f
pump
pump shaft
coupler
flex plate
flywheel
7/16 inch / 11 mm gap
4 - 53
July 2007
ENGINES
REV D
4 - 54
July 2007
REV D
ENGINES
Deutz models:
2
Flex plate bolt torque sequence
4 - 55
July 2007
ENGINES
REV D
f
a
b
c
d
e
f
pump
pump shaft
pump coupler
flex plate with raised spline
engine flywheel
7/16 inch / 11 mm gap
1
8
10
5
4
11
12
2
Bell housing bolt torque sequence
(Ford models)
4 - 56
July 2007
REV D
ENGINES
4-4
Oil Temperature and
Oil Pressure Switches Deutz Models
How to
Install the Oil Temperature and
Oil Pressure Switches
Hex size
Temperature switch point
11/16 inches
300F
149C
8-10 ft-lbs
11-14 Nm
8-10 ft-lbs
11-14 Nm
11/16 inches
7 psi
0.48 bar
4 - 57
July 2007
ENGINES
REV D
4-5
Coolant Temperature and
Oil Pressure Switches Ford Models
a
b
Hex size
4 - 58
Torque
Hex size
Oil pressure switch point
8-10 ft-lbs
11-14 Nm
13/16
inch
230F
110C
8-10 ft-lbs
11-14 Nm
11/16 inches
8 psi
0.55 bar
July 2007
Ground Controls
REV D
5-1
Auxiliary Platform Lowering
In the event of an engine failure, activating the
back-up manual lowering and manual lowering
enable switches will lower the platform when the
red Emergency Stop buttons are pulled out to the
on position at both the ground and platform
controls. The auxiliary down switches/buttons are
located at the ground control panel. There is no
adjustment required.
One 12V DC battery is used to start the engine,
power the auxiliary pump and the ECM. The
battery is located behind the ground control door
assembly.
5-2
Controller Adjustments
(after serial number GS9003-41522)
All machine function speeds are determined by the
percentage of total ECM voltage output. The
speeds of the following machine functions may be
adjusted to compensate for wear in the hydraulic
pump and drive motors.
Stowed drive speed
High torque drive speed
Raised drive speed
Platform lift speed
Platform lower speed
Steer speed
Platform settling speed
For further information or assistance, consult the
Genie Industries Service Department.
Tip-over hazard. Do not adjust the
lift and/or drive speed higher than
specified in this procedure. Setting
drive speed greater than
specifications could cause the
machine to tip over resulting in
death or serious injury.
Tip-over hazard. This procedure
must only be performed by a
trained service professional.
Attempting this procedure without
the necessary skills will result in
death or serious injury.
Note: Select a test area that is firm, level and free
of obstructions.
How to
Determine the Revision Level
1 Turn the key switch to ground controls and pull
out the red Emergency Stop buttons to the on
position at both platform and ground controls.
Result: The revision level of the ECM will
appear in the LED display window.
Part No. 72863
4 - 59
July 2007
REV D
GROUND CONTROLS
a
b
c
d
diagnostic display
blue platform up button
lift function enable button
yellow platform down button
4 - 60
July 2007
REV D
GROUND CONTROLS
a
b
c
d
diagnostic display
blue platform up button
lift function enable button
yellow platform down button
4 - 61
July 2007
REV D
GROUND CONTROLS
a
b
c
d
diagnostic display
blue platform up button
lift function enable button
yellow platform down button
4 - 62
July 2007
REV D
GROUND CONTROLS
a
b
c
d
diagnostic display
blue platform up button
lift function enable button
yellow platform down button
4 - 63
July 2007
REV D
GROUND CONTROLS
a
b
c
d
diagnostic display
blue platform up button
lift function enable button
yellow platform down button
4 - 64
July 2007
REV D
GROUND CONTROLS
a
b
c
d
diagnostic display
blue platform up button
lift function enable button
yellow platform down button
4 - 65
July 2007
REV D
GROUND CONTROLS
4 - 66
a
b
c
d
diagnostic display
blue platform up button
lift function enable button
yellow platform down button
July 2007
REV D
GROUND CONTROLS
diagnostic display
blue platform up button
lift function enable button
yellow platform down button
4 - 67
July 2007
REV D
GROUND CONTROLS
a
b
c
d
diagnostic display
blue platform up button
lift function enable button
yellow platform down button
4 - 68
July 2007
REV D
GROUND CONTROLS
a
b
c
d
diagnostic display
blue platform up button
lift function enable button
yellow platform down button
4 - 69
July 2007
GROUND CONTROLS
REV D
5-3
Software Configuration
(after serial number GS9003-41522)
a
b
c
d
4 - 70
diagnostic display
blue platform up button
lift function enable button
yellow platform down button
July 2007
REV D
GROUND CONTROLS
4 - 71
July 2007
REV D
GROUND CONTROLS
CE models:
1 Pull out the red Emergency Stop button to the
on position at the platform controls.
a
b
c
d
diagnostic display
blue platform up button
lift function enable button
yellow platform down button
4 - 72
July 2007
REV D
GROUND CONTROLS
4 - 73
July 2007
REV D
GROUND CONTROLS
5-4
Level Sensor Models without Outriggers
(before serial number 41158)
The Electronic Control Module (ECM) is
programmed to deactivate the lift and drive
functions and activate an alarm when a signal is
received from the level sensor.
The tilt alarm sounds when the incline of the
chassis exceeds 2 to the side, 3 to the front or 5
to the rear.
4 - 74
July 2007
REV D
GROUND CONTROLS
MODELS
WITHOUT
OUTRIGGERS
Y
b
chassis
level sensor
"X" indicator
"Y" indicator
4 - 75
July 2007
REV D
GROUND CONTROLS
4 - 76
July 2007
REV D
GROUND CONTROLS
5-5
Level Sensor Models without Outriggers
(after serial number 41157)
4 - 77
July 2007
REV D
GROUND CONTROLS
MODELS
d
c
OUTRIGGERS
Y
WITHOUT
a
4 - 78
chassis
level sensor
"X" indicator
"Y" indicator
July 2007
REV D
GROUND CONTROLS
5-6
Level Sensor Models with Outriggers
The Electronic Control Module (ECM) is
programmed to deactivate the lift and drive
functions and activate an alarm when a signal is
received from the level sensor.
When the outriggers are stowed, the tilt alarm
sounds when the incline of the chassis exceeds 2
to the side.
When the outriggers are deployed, the tilt alarm
sounds when the incline of the chassis exceeds
0.8 to the side.
At all times, the tilt alarm sounds when the incline
of the chassis exceeds 3 to the front or rear.
4 - 79
July 2007
GROUND CONTROLS
REV D
MODELS
WITH
OUTRIGGERS
X
c
4 - 80
chassis
level sensor
"Y" indicator
"X" indicator
July 2007
REV D
GROUND CONTROLS
4 - 81
July 2007
REV D
GROUND CONTROLS
4 - 82
July 2007
REV D
GROUND CONTROLS
4 - 83
July 2007
GROUND CONTROLS
REV D
5-7
Engine Fault Codes Ford Models
How to Retrieve Engine Fault
Codes
When a engine malfunction is detected by the
Electronic Control Module (ECM), a fault code is
recorded and the check engine light will illuminate
at the ground controls. Use the following procedure
to retrieve the engine fault code to determine the
engine malfunction.
Note: Perform this procedure with the key switch in
the off position.
1 Open the ground controls side cover.
4 - 84
July 2007
REV D
GROUND CONTROLS
4 - 85
July 2007
Hydraulic Pumps
6-1
Lift/Steer Pump
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
REV D
Deutz models
a
manual fuel shut-off lever
4 - 86
July 2007
REV D
HYDRAULIC PUMPS
open
closed
4 - 87
July 2007
HYDRAULIC PUMPS
REV D
6-2
Drive Pump
The drive pump is a bi-directional variable
displacement piston pump. The pump output is
controlled by the electronic displacement controller
(EDC), located on the pump. The only adjustment
that can be made to the pump is the neutral or null
adjustment. Any internal service to the pump
should only be performed at an authorized
Sundstrand-Sauer service center. Contact the
Genie Industries Service Department to locate
your local authorized service center.
4 - 88
July 2007
REV D
HYDRAULIC PUMPS
Deutz models
a
manual fuel shut-off lever
4 - 89
July 2007
Manifolds
REV G
7-1
Function Manifold Components - Models with Outriggers
(before serial number 40519)
The function manifold is located in the chassis tray on the ground controls side of the machine.
Index
No.
Description
Schematic
Item
Relief valve, 3500 psi / 241.3 bar ...... D ........... System relief ............................................... 20 ft-lbs / 27 Nm
Relief valve, 2000 psi / 138 bar ......... E ........... Steer and outrigger circuit ........................... 20 ft-lbs / 27 Nm
Function
Torque
Solenoid valve, 3 position 4 way ....... G ........... Steer left/right .............................................. 20 ft-lbs / 27 Nm
DO3 valve, 3 position 4 way .............. I ............ Platform up/down ................................. 30-35 in-lbs / 3-4 Nm
10
DO3 valve, 3 position 4 way .............. J ........... Outrigger up/down ............................... 30-35 in-lbs / 3-4 Nm
11
Counterbalance valve,
3000 psi / 207 bar .............................. K ........... Outrigger extend circuit ............................... 35 ft-lbs / 47 Nm
12
Counterbalance valve,
3000 psi / 207 bar .............................. L ........... Outrigger retract circuit ............................... 35 ft-lbs / 47 Nm
4 - 90
July 2007
REV G
MANIFOLDS
B
A
12
11
4
D
5
E
6
F
Y3
Y4
Y9
Y7
Y40
10
Y8
Y39
4 - 91
July 2007
MANIFOLDS
REV G
7-2
Function Manifold Components - Models with Outriggers
(after serial number 40518)
The function manifold is located in the chassis tray on the ground controls side of the machine.
Index
No.
1
Description
Schematic
Item
Function
Torque
Check valve,
5 psi / 0.3 bar .................................... AA .......... Platform down circuit .................................. 20 ft-lbs / 27 Nm
Relief valve, 3500 psi / 241.3 bar .... AC .......... System relief ............................................... 20 ft-lbs / 27 Nm
Relief valve, 2000 psi / 138 bar ........ AE .......... Steering and outrigger circuit ...................... 25 ft-lbs / 34 Nm
DO3 valve, 3 position 4 way ............ AG .......... Platform up/down ................................. 30-35 in-lbs / 3-4 Nm
Solenoid valve, 3 position 4 way ..... AH .......... Steer left/right .............................................. 25 ft-lbs / 34 Nm
Orifice - Plug, 0.150 inch / 3.8 mm ... AI ........... Platform down circuit
10
Flow regulator,
0.1 gpm / 0.38 L/min ......................... AJ .......... Bleeds off proportional
valve to tank ................................................ 20 ft-lbs / 27 Nm
11
DO3 valve, 3 position 4 way ............. AK .......... Outrigger up/down ............................... 30-35 in-lbs / 3-4 Nm
4 - 92
July 2007
REV G
MANIFOLDS
AA
AB
AC
3
AD
4
Y9
AE
5
AF
Y4
6
Y3
AH
AJ
AI
Y7
Y40
AG
7
11
AK
Y8
Y39
10
4 - 93
July 2007
MANIFOLDS
REV G
7-3
Function Manifold Components - Models without Outriggers
(before serial number 40519)
The function manifold is located in the chassis tray on the ground controls side of the machine.
Index
No.
Description
Schematic
Item
Relief valve, 3500 psi / 241.3 bar ...... D ........... System relief ............................................... 20 ft-lbs / 27 Nm
Relief valve, 2000 psi / 138 bar ......... E ........... Steer circuit ................................................. 20 ft-lbs / 27 Nm
Function
Torque
Solenoid valve, 3 position 4 way ....... G ........... Steer left/right .............................................. 20 ft-lbs / 27 Nm
DO3 valve, 3 position 4 way .............. I ............ Platform up/down ................................. 30-35 in-lbs / 3-4 Nm
4 - 94
July 2007
REV G
MANIFOLDS
B
A
4
D
5
E
6
F
Y3
G
Y4
H
Y9
Y7
9
I
Y8
4 - 95
July 2007
MANIFOLDS
REV G
7-4
Function Manifold Components - Models without Outriggers
(after serial number 40518)
The function manifold is located in the chassis tray on the ground controls side of the machine.
Index
No.
1
Description
Schematic
Item
Function
Torque
Check valve,
5 psi / 0.3 bar .................................... AA .......... Platform down circuit .................................. 20 ft-lbs / 27 Nm
Relief valve, 3500 psi / 241.3 bar .... AC .......... System relief ............................................... 20 ft-lbs / 27 Nm
Relief valve, 2000 psi / 138 bar ........ AE .......... Steer circuit ................................................. 25 ft-lbs / 34 Nm
DO3 valve, 3 position 4 way ............ AG .......... Platform up/down ................................. 30-35 in-lbs / 3-4 Nm
Solenoid valve, 3 position 4 way ..... AH .......... Steer left/right .............................................. 25 ft-lbs / 34 Nm
Orifice - Plug, 0.150 inch / 3.8 mm ... AI ........... Platform down circuit
10
Flow regulator,
0.1 gpm / 0.38 L/min ......................... AJ .......... Bleeds off proportional
valve to tank ................................................ 20 ft-lbs / 27 Nm
4 - 96
July 2007
REV G
MANIFOLDS
AA
AB
AC
3
AD
4
Y9
AE
5
AF
Y4
6
Y3
AH
AI
AJ
Y7
AG
7
Y8
10
4 - 97
July 2007
MANIFOLDS
REV G
7-5
Drive Manifold Components (before serial number GS9004-41691)
The drive manifold is located under the function manifold.
Index
No.
Description
Solenoid valve, 2 position 2 way ....... BA ......... High speed bypass ...................................... 25 ft-lbs / 34 Nm
Solenoid valve, 2 position 2 way ....... BB ......... High speed bypass ...................................... 25 ft-lbs / 34 Nm
Shuttle valve, 2 position 3 way .......... BE ......... Charge pressure circuit that
gets hot oil out of low pressure
side of drive pump and allows
low pressure flow path for brake
release and 2-speed motor shift .................. 25 ft-lbs / 34 Nm
Relief valve, 300 psi / 20.7 bar .......... BH ........ Charge pressure circuit ................................ 20 ft-lbs / 27 Nm
Solenoid valve, 2 position 3 way ....... BI .......... Brake release circuit .................................... 20 ft-lbs / 27 Nm
10
Solenoid valve, 2 position 3 way ....... BJ ......... 2-speed motor shift circuit ............................ 20 ft-lbs / 27 Nm
11
12
Orifice - Plug, 0.045 inch / 1.1 mm .... BL ......... 2-speed motor shift circuit
13
Orifice - Plug, 0.045 inch / 1.1 mm .... BM ........ 2-speed motor shift circuit
14
15
16
Flow divider/combiner valve .............. BP ......... Controls flow to steer end drive
motors in forward and reverse ..................... 30 ft-lbs / 41 Nm
17
4 - 98
Schematic
Item
Function
Torque
July 2007
REV G
MANIFOLDS
Y49A
Y49
BA
BB
2
3
BC
4
BE
BD
BF
BG
BH
Y2
BK
BL
BI
Y1
BM
BJ
10
11
12
13
BN
BO
BP
BQ
14
15
16
17
4 - 99
July 2007
MANIFOLDS
REV G
7-6
Drive Manifold Components (after serial number GS9004-41690)
The drive manifold is located under the function manifold.
Index
No.
Description
Schematic
Item
Function
Torque
Orifice - Plug, 0.043 inch / 1.1 mm .... EB ......... Balances flow from flow divider/
combiner (item EL) to front drive
motors
Orifice - Plug, 0.046 inch / 1.2 mm .... ED ........ Balances flow from flow divider/
combiner (item ED) to rear drive
motors .......................................................... 25 ft-lbs / 34 Nm
Relief valve, 280 psi / 19.3 bar .......... EE ......... Charge pressure circuit ................................ 20 ft-lbs / 27 Nm
Solenoid valve, 2 position 3 way ....... EF ......... 2-speed motor shift circuit ............................ 20 ft-lbs / 27 Nm
Orifice - Plug, 0.045 inch / 1.1 mm .... EH ........ 2-speed motor shift circuit
Shuttle valve, 2 position 3 way .......... EI .......... Charge pressure circuit that
gets hot oil out of low pressure
side of drive pump and allows
low pressure flow path for brake
release and 2-speed motor shift .................. 25 ft-lbs / 34 Nm
10
Solenoid valve, 2 position 3 way ....... EJ ......... Brake release circuit .................................... 20 ft-lbs / 27 Nm
11
12
Flow divider/combiner valve .............. EL ......... Controls flow to steer end drive
motors in forward and reverse ..................... 30 ft-lbs / 41 Nm
13
Orifice - Plug, 0.090 inch / 2.3 mm .... EM ........ Balances flow from flow divider/
combiner (item EA) to flow divider/
combiner valves ED and EL ........................ 25 ft-lbs / 34 Nm
14
4 - 100
July 2007
REV G
MANIFOLDS
EA
EB
EC
ED
3
4
EE
Y2
EH
5
Y1
EF
EG
14
13
12
11
EN
EM
EL
EK
Y2
10
EJ
EI
Y1
4 - 101
July 2007
MANIFOLDS
REV G
7-7
Oscillate Manifold Components
(optional after serial number GS9004-41690)
The oscillate manifold is located under the function manifold.
Index
No.
Description
Solenoid valve, 2 position 2 way ....... DA ........ Oscillate activation ....................................... 25 ft-lbs / 34 Nm
Relief valve, 3500 psi / 241.3 bar ...... DB ........ System relief ................................................ 20 ft-lbs / 27 Nm
Relief valve, 900 psi / 62 bar ............. DC ........ Float circuit relief .......................................... 20 ft-lbs / 27 Nm
Solenoid valve, 2 position 3 way ....... DE ........ Right oscillate circuit .................................... 20 ft-lbs / 27 Nm
Solenoid valve, 2 position 3 way ....... DF ......... Left oscillate circuit ...................................... 20 ft-lbs / 27 Nm
Solenoid valve, 2 position 2 way ....... DG ........ Oscillate float ............................................... 25 ft-lbs / 34 Nm
4 - 102
Schematic
Item
Function
Torque
July 2007
REV G
MANIFOLDS
DA
Y55
DB
DG
Y54
DC
DF
Y56
Y57
DE
Y55
DD
Y54
Y56
4 - 103
July 2007
REV G
MANIFOLDS
7-8
Valve Adjustments Function Manifold
GS-3390
2500 lbs
1135 kg
GS-4390
1500 lbs
(most models - refer to capacity indicator decal) 680 kg
GS-4390
1800 lbs
(some models - refer to capacity indicator decal) 816 kg
GS-5390
1500 lbs
680 kg
4 - 104
July 2007
REV G
MANIFOLDS
500 lbs
227 kg
GS-4390
375 lbs
(most models - refer to capacity indicator decal) 170 kg
GS-4390
450 lbs
(some models - refer to capacity indicator decal) 204 kg
GS-5390
375 lbs
170 kg
4 - 105
July 2007
REV G
MANIFOLDS
7-9
Valve Adjustments Drive Manifold
How to Adjust the Charge
Pressure Relief Valve
1 Connect a 0 to 600 psi / 0 to 50 bar pressure
4 - 106
July 2007
REV G
MANIFOLDS
4 - 107
July 2007
MANIFOLDS
REV G
7-10
Generator Manifold Components
The generator manifold is located below the ground controls.
Index
No.
Description
Schematic
Item
Solenoid valve, 2 position 3 way ............. AL .......... Generator on/off .................................... 25 ft-lbs / 34 Nm
Flow regulator, 4.3 gpm / 16.3 L/min ...... AM .......... Generator speed ................................... 20 ft-lbs / 27 Nm
Relief valve, 3000 psi / 206.8 bar ........... AN .......... Generator circuit ................................... 20 ft-lbs / 27 Nm
Function
Torque
AL
1
Y29
AM
2
AN
3
4 - 108
July 2007
REV G
MANIFOLDS
7-11
Valve Adjustments Generator Manifold
AM
AN
generator manifold
flow regulator
4 - 109
July 2007
REV G
MANIFOLDS
7-12
Valve Coils
Description
3.1 to 5.1
2.6 to 4.6
6.2 to 8.2
4 - 110
Specification
8.2 to 10.2
8.2 to 10.2
4.5 to 6.5
5 to 7
6.5 to 8.5
9 to 11
July 2007
REV G
MANIFOLDS
10 W
RESISTOR
Resistor, 10
Genie part number
27287
9V
BATTERY
a
b
c
d
e
COIL
multimeter
diode
9V battery
10 resistor
coil
4 - 111
July 2007
REV C
8-1
Fuel Tank
4 - 112
July 2007
REV C
8-2
Hydraulic Tank
The primary functions of the hydraulic tank are to
cool, clean and deaerate the hydraulic fluid during
operation. It utilizes internal suction strainers for
the pump supply lines and has an external return
line filter with a filter condition indicator.
open
closed
4 - 113
July 2007
REV C
4 - 114
July 2007
REV C
9-1
Yoke and Drive Motor
4 - 115
July 2007
REV C
Torque specifications
Drive hub mounting bolts, dry
120 ft-lbs
163 Nm
90 ft-lbs
122 Nm
75 ft-lbs
102 Nm
56 ft-lbs
76 Nm
4 - 116
July 2007
REV C
9-2
Steer Cylinder
75 ft-lbs
102 Nm
56 ft-lbs
76 Nm
4 - 117
July 2007
REV C
9-3
Tie Rod
4 - 118
0 0.125 inch
0 3.2 mm
July 2007
REV C
9-4
Oscillating Axle Option
(after serial number GS9004-41690)
How the
Oscillating Axle Functions
When driving the GS-90 with the platform in the
stowed position, the oscillating axle function
ensures that all four wheels maintain solid contact
with the ground, delivering the maximum traction
available.
When driving the GS-90 with the platform raised
above the down limit switch height, the oscillating
axle function is limited in that the oscillating
cylinders only respond to input from the oscillating
axle limit switches, located on the rear axle.
LS6
PLAT
N.C.
DOWN
LIMIT
SWITCH
J2-C5
CR42
POWER
CR84
CR85
OSCILLATE
STOWED
OSCILLATE
RAISED
J2-C6
86
85
30
87
87A
86
85
11
30
87
86
87A
85
30
87
ELECTRONIC
CONTROL
MODULE
87A
N.C.H.O.
U5
12
N.C.H.O.
CB2
LS23
LS22
20A
LEFT
OSCILLATE
LIMIT SWITCH
RIGHT
OSCILLATE
LIMIT SWITCH
B1
+
Y54
Y56
Y57
B1 12 VOLT BATTERY
Y55
4 - 119
July 2007
REV B
10-1
Drive Motor and Brake
75 ft-lbs
102 Nm
56 ft-lbs
76 Nm
4 - 120
July 2007
REV B
10-2
Drive Hub
10-3
Oscillating Axle
120 ft-lbs
163 Nm
90 ft-lbs
122 Nm
4 - 121
July 2007
Outrigger Components
REV A
11-1
Outrigger Cylinder
4 - 122
July 2007
REV A
12-1
Platform Overload System
Calibrate the Platform Overload
System (if equipped)
1878 kg
GS-4390
1286 kg
(most models - refer to capacity indicator decal)
GS-4390
1421 kg
(some models - refer to capacity indicator decal)
GS-5390
1410 kg
4 - 123
July 2007
REV A
4 - 124
July 2007
REV A
1135 kg
GS-4390
680 kg
(most models - refer to capacity indicator decal)
GS-4390
816 kg
(some models - refer to capacity indicator decal)
GS-5390
680 kg
4 - 125
July 2007
REV A
4 - 126
July 2007
REV A
Parallel
to cylinder
Perpendicular
to cylinder
4 - 127
July 2007
REV A
4 - 128
680 kg
July 2007
REV A
4 - 129
July 2007
REV A
All models:
a
b
c
d
diagnostic display
blue platform up button
lift function enable button
yellow platform down button
4 - 130
July 2007
REV A
4 - 131
July 2007
REV A
POSSIBLE CAUSE
RELIEF VALVE SET TOO LOW
4 - 132
SOLUTION
INCREASE RELIEF VALVE PRESSURE
TURN OFF RED EMERGENCY STOP
BUTTON, WAIT THREE SECONDS AND TURN
BACK ON
LOWER THE UP LIMIT SWITCH SLIGHTLY
-OR- REPLACE CONTACTS
PUT CORRECT RATED LOAD IN PLATFORM
TURN THE PRESSURE SWITCH NUT 1/4
TURN INTO THE HYDRAULIC LINE
CHARGE BATTERIES
REPEAT CALIBRATION PROCEDURE
LUBRICATE SLIDER CHANNELS
TURN OFF RED EMERGENCY STOP
BUTTON, WAIT THREE SECONDS AND TURN
BACK ON
RAISE THE DOWN LIMIT SWITCH
PUT CORRECT RATED LOAD IN PLATFORM
TURN THE PRESSURE SWITCH NUT 1/4
TURN INTO THE HYDRAULIC LINE -ORREPEAT CALIBRATION PROCEDURE
July 2007
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.
Wheels chocked
All external AC power supply disconnected
from the machine
5-1
July 2007
FAULT CODES
Malfunction
discovered
Identify
symptoms
Troubleshoot
problem
still exists
Return to
service
5-2
problem
solved
Inspect
and test
Perform
repair
July 2007
REV C
Code
Dot
Possible Causes
Solution
01
Flash
Normal operation
Solid
Replace ECM
02
Solid
ECM/Platform
communication error
03
Solid
14
Solid
20
Flash
21
Flash
22
Flash
23
Flash
24
Flash
26
Flash
27
Solid
28
Solid
29
Solid
Platform drive
enable switch fault
30
40
41
42
43
44
Solid
Flash
Flash
Flash
Flash
Flash
Malfunctioning coil OR
wire disconnected from coil
45
Flash
47
Flash
48
Flash
55
56
Flash
Flash
5-3
July 2007
Dot
Problem
60
Flash
61
Flash
Flash
66
REV C
Possible Causes
Solution
Malfunctioning coil OR
wire disconnected from coil
Troubleshoot coil OR
inspect wire connection
67
Flash
High temperature
68
Solid
Battery discharged
Charge battery
69
Flash
Low RPM
70
Flash
High RPM
5-4
July 2007
REV A
Fault Code
LED
SYSTEM READY
Green
01
INTERNAL ECU
FAULT
02
PLATFORM ECU
FAULT
20
CHASSIS START
SW FAULT
21
CHASSIS CHOKE
SW FAULT
22
CHASSIS UP SW
FAULT
23
CHASSIS LIFT SW
FAULT
24
25
26
RIGHT TURN SW
FAULT
27
DRIVE ENABLE
SW FLT
28
OFF NEUTRAL
DRIVE JOYSTICK
29
PLATFORM LIFT
SW FAULT
30
OFF NEUTRAL
LIFT JOYSTICK
32
PLATFORM
START SW FAULT
33
LEFT FRONT
OUTRIG SW FLT
Solution
System shutdown.
Replace ECM.
Red
Platform/ECM communication
error.
System shutdown.
Red
Replace ECM.
Red
Replace ECM.
Red
Replace ECM.
Red
Replace ECM.
Red
Replace ECM.
Red
Red
Red
Red
Red
Red
Red
Red
Red
Outriggers disabled.
31
PLATFORM
CHOKE SW
FAULT
Result
Red
DOWN SW FAULT
LEFT TURN SW
FAULT
Condition
Normal operation
5-5
July 2007
34
RIGHT FRONT
OUTRIG SW FLT
35
LEFT REAR
OUTRIG SW FLT
36
RIGHT REAR
OUTRIG SW FLT
37
AUTO LEVEL
SWITCH FAULT
49
DRIVE COIL 1
FAULT
50
DRIVE COIL 2
FAULT
51
DRIVE COIL 3
FAULT
52
FUNC PROP COIL
FAULT
54
LED
Condition
REV A
Result
Solution
Red
Outriggers disabled.
Red
Outriggers disabled.
Red
Outriggers disabled.
Red
Outriggers disabled.
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
UP COIL FAULT
55
DOWN COIL
FAULT
56
RIGHT TURN COIL
FAULT
57
LEFT TURN COIL
FAULT
58
BRAKE COIL
FAULT
60
FORWARD 1 COIL
FAULT
61
REVERSE 1 COIL
FAULT
62
FORWARD 2 COIL
FAULT
63
REVERSE 2 COIL
FAULT
5-6
July 2007
REV A
Fault Code
66
LOW OIL
PRESSURE
67
HIGH COOLANT
TEMPERATURE
68
LOW ECU
VOLTAGE
69
LOW ENGINE
RPM
70
HIGH ENGINE
RPM
80
LEFT FRONT
OTRG COIL FLT
81
LEFT REAR OTRG
COIL FLT
82
RIGHT FRONT
OTRG COIL FLT
83
RIGHT REAR
OTRG COIL FLT
84
OUTRIGGER EXT
COIL FLT
85
OUTRIGGER RET
COIL FLT
86
OUTRIGGER
SLOW COIL FLT
90
2 SPEED COIL
FAULT
92
DRIVE FWD PROP
COIL FAULT
93
DRIVE REV PROP
COIL FAULT
94
MACHINE TYPE
FAULT
Condition
Result
Solution
Check the engine oil level OR check
wiring from the oil pressure switch to
ECM
OR replace the oil pressure switch.
Gasoline/LPG models: Check the
engine radiator coolant level OR check
the wiring from the water temperature
switch to ECM OR replace the water
temperature switch.
Diesel models: Check the engine oil
level OR check the wiring from the oil
temperature switch to ECM OR replace
the oil temperature switch.
Red
Engine stops.
Red
Red
System shutdown.
Charge battery.
Red
Low RPM.
Red
High RPM.
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Correct selection.
5-7
July 2007
REV A
Problem
Cause
11
---
---
12
14
21
22
24
31
32
33
35
41
42
5-8
Solution
Normal operation
Check for poor terminal connections or
shorted wires from the TP sensor to the
ECM OR replace the TP sensor.
Check for poor terminal connections OR
wires shorted to ground OR replace MAP
sensor.
Check for obstructions in the throttle body
that could cause binding of the throttle
assembly OR replace ECM.
Check for poor terminal connections or
shorted wires from the TP sensor to the
ECM OR replace the TP sensor.
Check for poor terminal connections or
shorted wires from the MAP sensor to the
ECM to ground OR replace MAP sensor.
Test the fuel pump relay, see the Repair
Section OR check for poor terminal
connection from the fuel pump relay to
fuel pump OR replace the fuel pump.
Check for water in the fuel, misfiring
cylinder or plugged fuel filter OR check for
poor terminal connections or shorted wires
from the HO2 sensor to the ECM to
ground OR replace HO2 sensor.
Check engine coolant level OR check for
shorted wires or poor terminal connections
from the ECT sensor to the ECM OR
replace the ECT sensor.
Check for poor terminal connections or
shorted wires from the IAT sensor to the
ECM to ground OR replace IAT sensor.
Test the fuel pump relay, see the Repair
Section OR check for poor terminal
connections from the fuel pump relay to
fuel pump OR replace the ECM.
Test for a leaking or malfunctioning fuel
injector, misfiring cylinder or bad TP
sensor. Remove HO2 sensor and check
condition of sensor for contamination OR
check for poor terminal connections or
shorted wires from the HO2 sensor to the
ECM to ground OR replace HO2 sensor.
July 2007
REV A
Code
Problem
Cause
43
45
51
52
53
54
55
56
61
62
Solution
Check engine coolant level OR check for
shorted wires or poor terminal connections
from the ECT sensor to the ECM OR
replace the ECT sensor.
The IAT sensor shares the same ground
wire as the ECT and MAP sensors. Check
for shorted wires or poor terminal
connections from the IAT sensor to the
ECT and MAP sensors to the ECM OR
replace the IAT sensor.
Check engine oil level OR check for
shorted wires or poor terminal connections
from the oil pressure switch to the ECM
OR replace the oil pressure switch.
Check for shorted wires or poor terminal
connections from the CKP and CMP
sensors to the ECM OR replace the CKP
or CMP sensor.
5-9
July 2007
REV A
Problem
Cause
Solution
111
112
HO2S Open/Inactive
(Bank 1)
113
HO2S Open/Inactive
(Bank 2)
114
Post-cat oxygen
sensor open
121
142
143
144
122
124
133
134
135
NG cat monitor
141
5 - 10
July 2007
REV A
Code
Cause
Solution
161
162
211
212
213
214
215
221
222
223
224
231
232
234
235
BP High Pressure
BP Low Pressure
242
243
244
5 - 11
July 2007
REV A
Code
Problem
Cause
245
253
254
311
312
313
314
315
316
321
322
351
352
353
MegaJector Delivery
Pressure Higher Than
Expected
354
MegaJector Delivery
Pressure Lower Than
Expected
355
MegaJector
Communication Lost
361
MegaJector Voltage
Supply High
362
MegaJector Voltage
Supply Low
5 - 12
Solution
July 2007
REV A
Code
Cause
363
MegaJector Internal
Actuator Fault Detection
364
MegaJector Internal
Circuitry Fault Detection
365
MegaJector Internal
Communication Fault
Detection
411
412
413
414
511
512
513
Not used.
514
521
522
531
532
533
534
535
536
537
538
545
Solution
5 - 13
July 2007
Problem
551
552
553
611
COP Failure
612
Invalid Interrupt
613
A/D Loss
614
RTI 1 Loss
615
616
RAM Failure
631
External 5V DC Ref
Lower than Expected
632
External 5V DC Ref
Higher than Expected
655
RTI2 Loss
656
5 - 14
REV A
Cause
Solution
RTI3 Loss
July 2007
Section 6 Schematics
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics
Hydraulic Schematics
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.
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.
Malfunction
discovered
Identify
symptoms
Troubleshoot
problem
still exists
Return to
service
problem
solved
Inspect
and test
Perform
repair
6-1
Section 6 Schematics
July 2007
REV A
Platform controls
Engine
Pump
Down limit switch
Up limit switch
To outriggers
Level
sensor
Function manifold
Drive manifold
Horn
Ground controls
6-2
Section 6 Schematics
July 2007
6
B 1
A 1
C 1
12
12
12
B 1
A 1
12
12
12
C 1
B 1
12
Electronic Control
Module
J2
J1
(ECM)
A 1
12
C 1
A 1
B 1
12
B 1
A 1
J3
J4
C 1
C 1
REV A
J3 Connector
J1 Connector
J2 Connector
Pin
Description
Pin
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
Flashing Beacon
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
C12
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
C12
Diagnostic Display G8
Description
Platform Up/Down toggle switch TS66
Plug
Plug
Key Switch KS1
Level Sensor S7 (white)
Platform Up/Down toggle switch TS66
Left Front Outrigger Limit Switch LS12
Plug
Right Front Outrigger Limit Switch LS13
Plug
Plug
Plug
Level Sensor S8 (yellow)
Pin
Description
A1
A2
A3
A4
A5
A6
B1
B2
B3
B4
B5
B6
C1
C2
C3
C4
C5
C6
Pin
Description
Plug
Plug
J4 Connector
Plug
Plug
Plug
Forward/Reverse Relay CR58-86
Level Sensor S8 (red)
Horn Relay CR5-86
Alarm H5
Diagnostic Display G8
Diagnostic Display G8
Diagnostic Display G8
Diagnostic Display G8
Diagnostic Display G8
Diagnostic Display G8
Diagnostic Display G8
Diagnostic Display G8
Diagnostic Display G8
Plug
Plug
A1
A2
A3
A4
A5
A6
B1
B2
B3
B4
B5
B6
C1
C2
C3
C4
C5
C6
6-3
Section 6 Schematics
July 2007
REV A
Platform controls
Engine
Flashing beacons
Pump
To outriggers
Up limit switch
To platform overload
(CE models)
Down limit
switch
Level
sensor
Oscillate manifold
Drive manifold
Horn
Function manifold
6-4
Ground controls
Section 6 Schematics
July 2007
REV A
12
12
12
12
B 1
12
12
12
J1 Connector
Pin
J2
J1
12
C 1
A 1
A 1
B 1
A 1
12
B 1
C 1
C 1
Electronic Control
Module
(ECM)
J2 Connector
Description
Pin
Description
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
C12
Plug
Platform Overload (input)
Right Front Outrigger Limit Switch LS13 (input)
Right Rear Outrigger Limit Switch LS15 (input)
Left Front Outrigger Limit Switch LS12 (input)
Left Rear Outrigger Limit Switch LS14 (input)
Alternator (input)
Engine Oil Pressure SW2 (input)
Engine Water Temp SW1 / Engine Oil Temp SW3
(Input)
Plug
Plug
Plug
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
C12
6-5
Section 6 Schematics
July 2007
Power
Relay
F4-15A F3-20A
F2-5A
Starter
Relay
F1-30A
Fuel Pump
Relay
Note:
For detailed wire color information, refer to
the Ford engine wiring harness diagrams.
6-6
Section 6 Schematics
July 2007
REV A
P2
EMERGENCY STOP
BUTTON
RD
NC 1
BK
RD
JC1
JOYSTICK
CONTROLLER
BN
WH/BL
WH/RD
WH
U3
PLATFORM
CONTROLS
CIRCUIT
BOARD
WH/BK
PP
OR
D7
SW25
VOLTAGE
REGULATOR
DIP SWITCH
ON
DIP
YL
BL
WH
RD
WH
BK
BK
BL
BK
WH
YL
BK
RD
TO
COIL
CORD
ASSEMBLY
H1
BN12
BN13
ALARM
FUNCTION
ENABLE/
HIGH SPEED
BUTTON
FUNCTION
ENABLE/
LOW SPEED
BUTTON
6-7
Section 6 Schematics
July 2007
REV A
H1
ALARM
BK
NC 1
2
RD
P2
EMERGENCY
STOP
OR
BL
JC1
WH
JOYSTICK
CONTROLLER
J5
GY
J3
BK
RD
U3
PLATFORM
CONTROLS
CIRCUIT
BOARD
BK
PP
YL
WH/BL
14
1
GY
J2
BL
OR
RD
WH
BN
BK
YL
BL
TS20
OR
TS21
RD
J1
6-8
Section 6 Schematics
July 2007
Code
B1
BN
Description
Code
Description
Battery
GND
H
Ground
Button
BN1
BN2
BN3
BN4
BN5
BN6
BN7
BN9
BN12
BN13
BN14
BN15
BN16
BN17
BN18
BN20
BN23
BN24
BN85
BN86
BN87
BN91
Engine stop
Engine start
Starting aid
High idle
Horn
High torque
Generator
Platform up
High speed lift enable
Low speed lift enable
LPG select
Horn/left rear outrigger
Outrigger function enable
High torque/left front outrigger
Generator/right front outrigger
Autolevel
Auxiliary down
Right rear outrigger
Left front outrigger
Right front outrigger
Left rear outrigger
Auxiliary down enable
C5
CB
Capacitor, 4700 uF
CR
Control relay
CR1 Engine start
CR1A Power to starter
CR4 High idle
CR5 Horn
CR8 Ignition
CR15 Starting aid
CR17 Oil cooler
CR23 Auxiliary down
CR41 Control system
CR42 Power
CR58 Forward/reverse
CR84 Oscillate stowed
CR85 Oscillate raised
FB1
FL1
G
JC1
KS1
L
Circuit breaker
CB2 System power, 20A
CB7 Oil cooler, 20A
Power supply
D1
Alternator
D7
Voltage regulator
Flashing Beacons
Horn or alarm
H1
Alarm
H2
Automotive-style horn
H5
Alarm
S8
Joystick controller
Key switch
Motor
M1
M2
M3
M4
M5
TS
Cooling fan
Auxiliary pump
Engine starter
Fuel pump
Hydraulic power unit
N.C.
N.O.
P
Normally closed
PS2
Q
QD
Quick disconnect
QD3 Control cable to ground
QD4 Control cable to platform
SW
LED or light
Check engine
L2
L19 Power
L21 High torque
L22 LPG
L23 High idle
L25 Fault
L27 Generator
L39 Auxiliary power/lift disable
L50 System status
Limit switch
LS5 Platform up (5390 only)
LS6 Platform down
LS12 Left front outrigger
LS13 Right front outrigger
LS14 Left rear outrigger
LS15 Right rear outrigger
LS22 Right oscillate
LS23 Left oscillate
Volt meter
Hour meter
Diagnostic display
Description
Sensor
S5
S7
LS
Code
Normally open
Power switch
P1
Emergency stop button (ground)
P2
Emergency stop button (platform)
Solenoid
Q3
High idle
Q8
Fuel shut off
Resistor
R6
Resistor, 510 ohm
R15 Potentiometer, 5K ohm
Switch
SW1
SW2
SW3
SW4
SW5
SW6
SW25
Toggle switch
TS20 Platform up/down
TS21 Platform, outrigger up/down
TS52 Engine start
TS53 Fuel select
TS54 Engine high idle
TS56 Starting aid
TS66 Platform up/down
TS67 Function enable
TS69 Auxiliary function enable
TS70 Auxiliary down
Electronic component
U3
Platform controls circuit board
U5
Electronic control module
U32 Glow plug (option)
Valve coil
Y1
Y2
Y3
Y4
Y7
Y8
Y9
Y29
Y33
Y34
Y35
Y36
Y39
Y40
Y49
Y50
Y51
Y54
Y55
Y56
Y57
Parallel
Brake release
Steer right
Steer left
Platform down
Platform up
Proportional control
Generator on (option)
Left rear outrigger
Right rear outrigger
Left front outrigger
Right front outrigger
Outrigger retract
Outrigger extend
High speed bypass
LPG
Electronic displacement control
Oscillate float
Oscillate enable
Left oscillate
Right oscillate
BLUE
BLACK
BROWN
DARK BLUE
DARK GREEN
GREEN
GY
LB
LG
N
O
PK
GREY
LIGHT BLUE
LIGHT GREEN
NATURAL
ORANGE
PINK
P
R
T
W
Y
PURPLE
RED
TAN
WHITE
YELLOW
BLUE
BLACK
BROWN
GY GREY
OR ORANGE
PP PURPLE
RD RED
WH WHITE
YL YELLOW
6-9
Section 6 Schematics
July 2007
6 - 10
outrigger deployed
(all models)
left front LS12
right front LS13
left rear LS14
right rear LS15
outrigger deployed
(GS-5390 CE models) (lower)
left front LS12A
right front LS13A
left rear LS14A
right rear LS15A
July 2007
Section 6 Schematics
6 - 11
Section 6 Schematics
July 2007
Circuit breaker
Fuse or
Fusible link
AUX
PUMP
STARTER
M2
M3
B
T
Auxiliary pump
G6
GROUND
CONTROL
Hour meter
Key switch
Emergency Stop
button
Engine starter
QD4
N.O.
C
LEVEL SENSOR
CIRCUIT BOARD
86
85
Horn
K5
30
87
Flashing beacon
87A
S7
LEVEL
SENSOR
Level sensor
Quick disconnect
Relay
D1
A
S
Pressure
switch
S8
2 AXIS
TILT LEVEL
SENSOR
Solenoid valve
Level sensor
Alternator
Temperature
switch
LED
JC1
R15
JOYSTICK
CONTROLLER
5K
POTENTIOMETER
Spark plug
Resistor
WH/YL
WH/BK
SW6 STEER
LEFT/ RIGHT
SW5
RIGHT
LEFT
FUNCTION ENABLE
Toggle switch
REV
FWD
Diode
HALL EFFECT
GENERATOR
Solenoid
JC1
JOYSTICK
CONTROLLER
M5
SW5
RIGHT
FUNCTION ENABLE
N.O.
LEFT
N.C.
SW6
STEER
LEFT/ RIGHT
Limit switch
Joystick
12V DC
Battery
6 - 12
Section 6 Schematics
July 2007
CR41
CONTROL
SYSTEM
86
85
30
87
K5
U5
87A
LS24
N.C.
MAXIMUM
HEIGHT
LIMIT
SWITCH
J1-A9
J1-A3
J4-B3
PS2
PLATFORM
OVERLOAD
PRESSURE
SWITCH
LS25
N.C.
LOAD SENSE
DELAY
LIMIT
SWITCH
86
86
30
K6
4700 uF
K7
CR27
OVERLOAD
85
C5
30
87
87A
CR42
POWER
85
87
87A
Y8
Y7
GROUND
Y7 PLATFORM DOWN
Y8 PLATFORM UP
ES7167B
6 - 13
Section 6 Schematics
July 2007
REV B
THROTTLE ACTUATOR/
POSITION SENSOR
FUEL INJECTOR VALVES
#4
#3
#2
#1
WATER TEMP.
SWITCH (NO)
361JR14
264W/LB18
359CGY/R18
355GY/W18
351BBR/W18
361AR14
555T18
361BR14
556W18
361CR14
557BR/Y18
361DR14
558BR/LB18
570BK/W12
39RW20
2
1
8
16
9
5
31
34
42
22
14
37
18
24
25
6
7
11
3
15
33
13
26
11T/Y20
16AR/LG16
37BY18
39RW20
37Y12
787PK/BK16
351DBR/W20
570CBK/W12
570EBK/W12
107P20
151LB/BK20
198DG/O20
209W/P20
306T/LB20
307BK/Y20
658PK/LG20
674Y/BK20
914T/O20
915PK/LB20
32ADKBL16
359LGY/Y20
32R/LB16
253DG/W20
42
34
361PR18
242DG18
351CBR/W20
358LG/BK20
359KGY/Y20
354LG/R18
359DGY/Y20
COIL
IGNITION
SYSTEM
CRANKSHAFT
POSITION
SENSOR
(CKP)
HEATED
OXYGEN
SENSOR
(HO2S)
96T/O18
16CR/LG16
95AT/W18
OIL PRESSURE
SWITCH (NC)
349DB18
350GY18
253ADG/W20
74GY/LB18
89AO18
570NBK/W18
34LB/O18
57BK18
MATING FACE
SHOWN
ENGINE
COOLANT
TEMPERATURE
SENSOR
(ECT)
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
(MAP)
LPG
LOCKOUT VALVE
ES7144A
6 - 14
Section 6 Schematics
July 2007
REV B
85
87
86
85
86
30
87A
STARTER
CR-FC
30
87A
FUEL PUMP
CR-FB
87
30
85
86
87
87A
POWER
CR-FA
32R/LB16
16R/LG16
342LG/P16
32ADKBL16
37CY16
361ER16
926ALB/O16
787APK/BK16
37AY12
16BR/LG18
570DBK/W18
361R12
FORD
ENGINE CONTROL MODULE (ECM)
QUICK DISCONNECTS
(TO ECM)
95TW18
361LR18
37BY18
349DB18
350GY18
282DB/O18
355GY/W18
238ADG/Y18
555T18
556W18
557BR/Y18
558BR/LB18
351BR/W18
77DB/Y18
570BK/W18
570ABK/W18
570BBK/W18
570HBK/W18
107P20
151LB/BK20
198DG/O20
209W/P20
306T/LB20
307BK/Y20
658PK/LG20
674BR/W20
914T/O20
915PK/LB20
926ALB/O16
359FGY/R20
743GY20
358LG/BK20
354LG/R18
342LG/P16
264W/LB18
225BK/Y20
253BDG/W20
57BK18
242DG18
96T/O18
74GY/LB18
X1
F1
K1
F2
H1
A3
G1
H2
J1
C1
F3
Y3
Y2
W3
S3
S2
S1
T1
A2
R2
B3
C2
X2
X3
W1
W2
C3
E3
G2
G3
M1
A1
L1
H3
J2
K2
R3
K3
M2
N2
P3
L2
M3
B2
N1
N3
P1
D1
B1
D2
T2
L3
E1
R1
D3
J3
T3
P2
Y1
E2
IGNITION COIL 1
NOT USED
VPWR
KEEP ALIVE PWR
NOT USED
NOT USED
CRANKSHAFT SENSOR RETURN (+)
CRANKSHAFT SENSOR RETURN ( -)
CAMSHAFT SENSOR FEED (+)
THROTTLE POSITION SENSOR INPUT
FUEL PUMP MONITOR
NOT USED
NOT USED
NOT USED
FUEL INJECTOR #1
FUEL INJECTOR #2
FUEL INJECTOR #3
FUEL INJECTOR #4
VREF
DRY FUEL MODULATOR
NOT USED
NOT USED
POWER GROUND
POWER GROUND
POWER GROUND
POWER GROUND
NOT USED
NOT USED
NOT USED
NOT USED
DATA LINK
DRIVE BY WIRE
AUXILLARY INPUT
SELF TEST INPUT
GOVERNOR SELECT #1
GOVERNOR SELECT #2
MALFUNCTION INDICATOR LAMP
FUEL SELECT
DATA LINK CONNECTOR (+)
DATA LINK CONNECTOR (-)
FUEL PUMP RELAY CONTROL
NOT USED
NOT USED
SINGLE RETURN
NOT USED
NOT USED
NOT USED
INTAKE AIR TEMP SENSOR
MAP SENSOR INPUT
ECT SENSOR
NO USAGE
STARTER LOCKOUT
NOT USED
IDLE AIR CONTROL
DRY FUEL SENSOR
OIL PRESSURE
GROUND
DRYFUEL LOCKOFF
IGNITION COIL 2
HO2S SENSOR SIDE
MATING FACE
SHOWN
A
B
C
D
E
F
G
H
J
K
1
3
L
M
N
P
R
S
T
W
X
Y
MATING FACE
SHOWN
658PK/LG20
570BK/W20
107P20
915PK/LB20
914T/O20
209W/P20
743GY20
359JGY/R18
282DB/O18
359AGY/R18
225BK/Y20
359MGY/Y20
361NR18
77DB/Y18
DIAGNOSTIC
CONNECTOR
CR4
(LOCATED INSIDE THE
GROUND CONTROL BOX)
CAMSHAFT
POSITION
SENSOR
(CMP)
INTAKE AIR
TEMPERATURE
SENSOR
(IAT)
ES7144A
6 - 15
Section 6 Schematics
July 2007
REV A
361 R 16
361 R 16
555 T 16
8
9
557 BR-Y 16
558 BR-LB 16
10
556 W 16
555 T 16
557 BR-Y 16
558 BR-LB 16
556 W 16
11
743 GY 18
12
359 GY-R 18
31
21
19
20
15
27
18 O-Y 18
198 DG-O 18
358 LG-BK 18
151 LB-BK 18
151 LB-BK
28
743 GY 18
354 LG-R 18
17
307 BK-Y 18
18
150 DG-W 18
16
114 LB-Y 18
22
352 BR-LG 18
23
1
360 BR-PK 18
570 BK-W 16
570 BK-W 16
570 BK-W 16
570 BK-W 16
13
359 GY-R 18
570 BK-W 16
351 BR-W 18
307 BK-Y 18
354 LG-R 18
14
351 BR-W 18
16 R-LG 18
33
350 GY 18
32
349 DB 18
35
452 GY-R 18
18 O-Y 18
34
282 DB-O 18
198 DG-O 18
361 R 16
361 R 16
16 R-LG 18
358 LG-BK 18
359 GY-R 18
CAM
361 R 14
CRANK
25
24
74 GY-LB 18
361 R 14
29
30
O2
SENSOR
361A R 16
570 BK-W 16
355 GY-W 18
74 GY-LB 18
357 Y-W 18
151 LB-BK 18
359 GY-R 18
317 GY-O 18
J2 GREY
COIL 1
COIL 2
COIL 3
COIL 4
COIL 5
COIL 6
STARTER LOCKOUT
FUEL LOCKOFF
FUEL PUMP
RELAY CONTROL
TPS1
TPS2
DBW +
DBW BRAKE SWITCH
OIL PRESSURE
TACH
MIL
FUEL PUMP MON
AUX OUT 1
FUEL SELECT
AUX ANA PU2
GOV SELECT 1
GOV SELECT 2
ROAD SPEED +
ROAD SPEED GASEOUS TRIM
OVERSPEED
CAN +
CAN RS 485 +
RS 485 RS 232 TX
RS 232 RX
114 LB-Y 18
360 BR-PK 18
26
J1 BLACK
150 DG-W 18
352 BR-LG 18
570 BK-W 16
850 Y-BK 18
851 Y-R 18
TWR
1 COIL 1
361A R 16
2 VBAT
A
B
242 DG 18
342 LG-P 18
361A R 16
3 COIL 2
13
LOCKOFF SOLENOID
24
669 DG-W 18
458 O-BK 18
25
22
342 LG-P 18
23
242 DG 18
926A LB-O 18
32
15 R-Y 18
30
355 GY-W 18
31
357 Y-W 18
28
29
151 LB-BK 18
317 GY-O 18
511 LG-R 18
511 LG-R 18
253 DG-W 18
253 DG-W 18
11 T-Y 18
27
658 PK-LG 18
658 PK-LG 18
10
238 DG-Y 18
238 DG-Y 18
71 O-LG 18
72 Y-BK 18
71 O-LG 18
14
15
148 Y-R 18
148 Y-R 18
16
306 T-LB 18
306 T-LB 18
17
307 BK-Y 18
11
307 BK-Y 18
169 LG-BK 18
12
172 LB-R 18
26
33
77 DB-Y 18
349A DB 18
349A DB 18
18
662 DG-P 18
662 DG-P 18
19
459 O-LG 18
459 O-LG 18
20
642 DG-O 18
461 O 18
642 DG-O 18
21
34
669 DG-W 18
669 DG-W 18
35
458 O-BK 18
458 O-BK 18
926A LB-O 18
15 R-Y 18
11 T-Y 18
72 Y-BK 18
169 LG-BK 18
172 LB-R 18
461 O 18
TRIM VALVE
TWR
77 DB-Y 18
A
B
361A R 16
361A R 16
WPTWR2_GY
6 - 16
E1280B
Section 6 Schematics
July 2007
REV A
361 R 16
361 R 16
555 T 16
361 R 16
361 R 16
557 BR-Y 16
558 BR-LB 16
556 W 16
INJECTOR #1
743 GY 18
INJECTOR #3
INJECTOR #4
INJECTOR #2
570 BK-W 16
359 GY-R 18
39 R-W 18
16 WATER TEMP
WATER
TEMP
ACT
151 LB-BK
151 LB-BK
307 BK-Y 18
307 BK-Y 18
354 LG-R 18
FORD
42 PIN
CONNECTOR
14 FPP1
25 IVS
359 GY-R 18
570 BK-W 16
F1 30A
570 BK-W 16
ECT
570 BK-W 12
570 BK-W 12
34 GROUND
570 BK-W 16
F2
5A
16 R-LG 18
16 R-LG 18
1 VSW
570 BK-W 16
570 BK-W 16
MAP_CONN
F3 20A
570 BK-W 16
361 R 14
351 BR-W 18
361 R 14
361 R 12
TWR
351 BR-W 18
9 VBATT
16 R-LG 18
361 R 14
358 LG-BK 18
358 LG-BK 18
359 GY-R 18
359 GY-R 18
B
A
18 O-Y 18
18 O-Y 18
198 DG-O 18
198 DG-O 18
150 DG-W 18
150 DG-W 18
114 LB-Y 18
114 LB-Y 18
352 BR-LG 18
352 BR-LG 18
360 BR-PK 18
360 BR-PK 18
38 EGR ANA IN
32 ANA AUX PD1
37 ANA AUX PU1
12 FPP2
40 EGR PWM
41 EGR REC
361 R 14
359 GY-R 18
359 GY-R 18
351 BR-W 18
351 BR-W 18
MTRTWR6 MTRSHD6
SHD
TWR
A
355 GY-W 18
357 Y-W 18
151 LB-BK 18
317 GY-O 18
351 BR-W 18
359 GY-R 18
E
F
16 R-LG 18
THROTTLE
355 GY-W 18
357 Y-W 18
151 LB-BK 18
317 GY-O 18
351 BR-W 18
359 GY-R 18
FUEL PUMP
RELAY
6
5
86
85
4
1
86
32 R-LB 16
87
31 VREF
15 STARTER SWITCH
STARTER
RELAY
30
30
33 ANA RTN
87A
32 R-LB 16
13 STARTER CONTROL
3
2
85
87
87A
342 LG-P 18
342 LG-P 18
359 GY-R 18
351 BR-W 18
669 DG-W 18
458 O-BK 18
FPP_COMM
787A PK-BK 16
RTN
F4 15A
787A PK-BK 16
5 FUEL PUMP
5V
TX
RX
TWR
86
85
926A LB-O 18
POWER
RELAY
30
87
87A
F5 15A
15 R-Y 18
361 R 16
OIL PRESSURE
361 R 16
253 DG-W 18
511 LG-R 18
511 LG-R 18
253 DG-W 18
253 DG-W 18
11 T-Y 18
11 T-Y 18
658 PK-LG 18
658 PK-LG 18
238 DG-Y 18
71 O-LG 18
71 O-LG 18
72 Y-BK 18
72 Y-BK 18
148 Y-R 18
148 Y-R 18
306 T-LB 18
306 T-LB 18
307 BK-Y 18
307 BK-Y 18
169 LG-BK 18
172 LB-R 18
169 LG-BK 18
172 LB-R 18
349A DB 18
349A DB 18
662 DG-P 18
662 DG-P 18
459 O-LG 18
459 O-LG 18
642 DG-O 18
642 DG-O 18
461 O 18
461 O 18
669 DG-W 18
669 DG-W 18
458 O-BK 18
458 O-BK 18
4 BRAKE
26 OIL PRES
2 TACH
6 MIL
39 AUX OUT1
7 FUEL SELECT
10 AUX ANA PU2
24 GOV SELECT 1
23 GOV SELECT 2
35 ROADSPEED +
36 ROADSPEED 30 OVERSPEED
28 CAN +
29 CAN 20 RS 485+
21 RS 48511 RS 232+
3 RS 232-
361A R 16
E1280B
6 - 17
Section 6 Schematics
July 2007
REV A
361 R 16
361 R 16
555 T 16
8
9
557 BR-Y 16
558 BR-LB 16
10
556 W 16
555 T 16
557 BR-Y 16
558 BR-LB 16
556 W 16
11
743 GY 18
12
359 GY-R 18
31
21
19
20
15
27
18 O-Y 18
198 DG-O 18
358 LG-BK 18
151 LB-BK 18
151 LB-BK
28
743 GY 18
354 LG-R 18
17
307 BK-Y 18
18
150 DG-W 18
16
114 LB-Y 18
22
352 BR-LG 18
23
1
360 BR-PK 18
570 BK-W 16
570 BK-W 16
570 BK-W 16
570 BK-W 16
13
359 GY-R 18
570 BK-W 16
351 BR-W 18
307 BK-Y 18
354 LG-R 18
14
351 BR-W 18
16 R-LG 18
33
350 GY 18
32
349 DB 18
35
452 GY-R 18
18 O-Y 18
34
282 DB-O 18
198 DG-O 18
4
5
361 R 16
361 R 16
25
392 R-LG 18
24
74 GY-LB 18
16 R-LG 18
358 LG-BK 18
359 GY-R 18
CAM
361 R 14
CRANK
361 R 14
29
30
O2
SENSOR
361A R 16
361A R 16
570 BK-W 16
570 BK-W 16
74 GY-LB 18
392 R-LG 18
357 Y-W 18
151 LB-BK 18
359 GY-R 18
359 GY-R 18
317 GY-O 18
J2 GREY
COIL 1
COIL 2
COIL 3
COIL 4
COIL 5
COIL 6
STARTER LOCKOUT
FUEL LOCKOFF
FUEL PUMP
RELAY CONTROL
TPS1
TPS2
DBW +
DBW BRAKE SWITCH
OIL PRESSURE
TACH
MIL
FUEL PUMP MON
AUX OUT 1
FUEL SELECT
AUX ANA PU2
GOV SELECT 1
GOV SELECT 2
ROAD SPEED +
ROAD SPEED GASEOUS TRIM
OVERSPEED
CAN +
CAN RS 485 +
RS 485 RS 232 TX
RS 232 RX
114 LB-Y 18
360 BR-PK 18
O2 SENSOR
26
J1 BLACK
150 DG-W 18
352 BR-LG 18
570 BK-W 16
850 Y-BK 18
851 Y-R 18
TWR
1 COIL 1
361A R 16
2 VBAT
A
B
242 DG 18
355 GY-W 18
342 LG-P 18
361A R 16
3 COIL 2
13
LOCKOFF SOLENOID
24
669 DG-W 18
458 O-BK 18
25
22
342 LG-P 18
23
242 DG 18
926A LB-O 18
32
15 R-Y 18
30
355 GY-W 18
31
357 Y-W 18
28
29
151 LB-BK 18
317 GY-O 18
511 LG-R 18
511 LG-R 18
253 DG-W 18
253 DG-W 18
11 T-Y 18
27
658 PK-LG 18
658 PK-LG 18
10
238 DG-Y 18
238 DG-Y 18
71 O-LG 18
72 Y-BK 18
71 O-LG 18
14
15
148 Y-R 18
148 Y-R 18
16
306 T-LB 18
306 T-LB 18
17
307 BK-Y 18
11
307 BK-Y 18
169 LG-BK 18
12
172 LB-R 18
26
33
77 DB-Y 18
349A DB 18
349A DB 18
18
662 DG-P 18
662 DG-P 18
19
459 O-LG 18
459 O-LG 18
20
642 DG-O 18
461 O 18
642 DG-O 18
21
34
669 DG-W 18
669 DG-W 18
35
458 O-BK 18
458 O-BK 18
926A LB-O 18
15 R-Y 18
11 T-Y 18
72 Y-BK 18
169 LG-BK 18
172 LB-R 18
461 O 18
TRIM VALVE
TWR
77 DB-Y 18
A
B
361A R 16
361A R 16
WPTWR2_GY
6 - 18
E1429B
Section 6 Schematics
July 2007
REV A
361 R 16
361 R 16
555 T 16
361 R 16
361 R 16
557 BR-Y 16
558 BR-LB 16
556 W 16
INJECTOR #1
743 GY 18
INJECTOR #3
INJECTOR #4
INJECTOR #2
570 BK-W 16
359 GY-R 18
39 R-W 18
16 WATER TEMP
WATER
TEMP
ACT
151 LB-BK
151 LB-BK
307 BK-Y 18
307 BK-Y 18
354 LG-R 18
FORD
42 PIN
CONNECTOR
14 FPP1
25 IVS
359 GY-R 18
570 BK-W 16
F1 30A
570 BK-W 16
ECT
570 BK-W 12
570 BK-W 12
34 GROUND
570 BK-W 16
F2
5A
16 R-LG 18
16 R-LG 18
1 VSW
570 BK-W 16
570 BK-W 16
MAP_CONN
F3 20A
570 BK-W 16
361 R 14
351 BR-W 18
361 R 14
361 R 12
TWR
351 BR-W 18
9 VBATT
16 R-LG 18
361 R 14
358 LG-BK 18
358 LG-BK 18
359 GY-R 18
359 GY-R 18
B
A
18 O-Y 18
18 O-Y 18
198 DG-O 18
198 DG-O 18
150 DG-W 18
150 DG-W 18
114 LB-Y 18
114 LB-Y 18
352 BR-LG 18
352 BR-LG 18
360 BR-PK 18
360 BR-PK 18
38 EGR ANA IN
32 ANA AUX PD1
37 ANA AUX PU1
12 FPP2
40 EGR PWM
41 EGR REC
361 R 14
359 GY-R 18
359 GY-R 18
351 BR-W 18
351 BR-W 18
MTRTWR6 MTRSHD6
SHD
TWR
A
355 GY-W 18
357 Y-W 18
151 LB-BK 18
317 GY-O 18
359 GY-R 18
351 BR-W 18
E
F
16 R-LG 18
THROTTLE
355 GY-W 18
357 Y-W 18
151 LB-BK 18
317 GY-O 18
351 BR-W 18
359 GY-R 18
FUEL PUMP
RELAY
6
5
4
1
86
85
86
32 R-LB 16
32 R-LB 16
32 R-LB 16
87
87A
342 LG-P 18
13 STARTER CONTROL
87A
30
3
85
31 VREF
STARTER
RELAY
30
87
33 ANA RTN
15 STARTER IN (INTERUPT)
39 STARTER IN (AUTOCRANK)
342 LG-P 18
359 GY-R 18
351 BR-W 18
669 DG-W 18
458 O-BK 18
FPP_COMM
787A PK-BK 16
RTN
F4 15A
787A PK-BK 16
5 FUEL PUMP
5V
TX
RX
86
TWR
85
926A LB-O 18
POWER
RELAY
30
87
87A
F5 15A
15 R-Y 18
361 R 16
OIL PRESSURE
361 R 16
253 DG-W 18
511 LG-R 18
511 LG-R 18
253 DG-W 18
253 DG-W 18
11 T-Y 18
11 T-Y 18
658 PK-LG 18
658 PK-LG 18
238 DG-Y 18
71 O-LG 18
71 O-LG 18
72 Y-BK 18
72 Y-BK 18
148 Y-R 18
148 Y-R 18
306 T-LB 18
306 T-LB 18
307 BK-Y 18
307 BK-Y 18
169 LG-BK 18
172 LB-R 18
169 LG-BK 18
172 LB-R 18
349A DB 18
349A DB 18
662 DG-P 18
662 DG-P 18
459 O-LG 18
459 O-LG 18
642 DG-O 18
642 DG-O 18
461 O 18
461 O 18
669 DG-W 18
669 DG-W 18
458 O-BK 18
458 O-BK 18
570 BK-W 16
361A R 16
361A R 16
459 O-LG 18
662 DG-P 18
E1429B
MTRTWR4
TWR
4 BRAKE
26 OIL PRES
2 TACH
6 MIL
21 AUX OUT1
7 FUEL SELECT
10 AUX ANA PU2
24 GOV SELECT 1
23 GOV SELECT 2
35 ROADSPEED +
36 ROADSPEED 30 OVERSPEED
28 CAN +
29 CAN 11 RS 485+
3 RS 48520 RS 232+
18 RS 232-
SHD
PLUG (GROUND)
PLUG (CAN -)
MEGAJECTOR
PLUG (CAN +)
MTRSHD4
6 - 19
Section 6 Schematics
July 2007
Electrical Schematic
Ford Models (before serial number 40428)
Part 1 of 3
REV F
P1
EMERGENCY STOP
B
PLATFORM
CONTROL
B
T
GROUND
CONTROL
CB2
20A
CR41
CONTROL
SYSTEM
(ESTOP 1)
86
85
30
87
CR42
POWER
(ESTOP 2)
K5
86
87A
85
30
87
K6
86
87A
85
CR5
CR8
CR1
CR58
HORN
IGNITION
ENGINE START
FWD/REV
30
87
K4
86
87A
85
30
87
K2
86
87A
85
30
87
K1
86
87A
85
30
87
K3
87A
J1-C11,C12
U5
J2-A5
J2-B11
J4-C4
J4-B5
J2-B9
J1-C1-C4
J1-B3
L2
AUXILIARY
FUNCTION ENABLE
B1
M5
J2-B12
TS69
J1-A3
EDC
J1-A2
Y51
FWD
R6
510 W
J1-A9
J4-A5
A
S
I
J1-B2
D1
REV
FUSE
LINK
M4
H2
TS70
AUXILIARY
PLATFORM DOWN
Y4
H5
3
STARTER
G6
M3
AUX
PUMP
M2
Y7
Y8
H5 ALARM
Y8 PLATFORM UP
Y4 STEER LEFT
Y7 PLATFORM DOWN
M2 AUXILIARY PUMP
M4 FUEL PUMP
M5 HYDRAULIC PUMP
Y51 FORWARD/REVERSE COIL
G6 ENGINE HOURMETER
D1 ALTERNATOR
M3 STARTER MOTOR
K1 STARTER RELAY
H2 AUTOMOTIVE-STYLE
HORN
B1 12 VOLT BATTERY
6 - 20
ES0138G
Section 6 Schematics
July 2007
Electrical Schematic
Ford Models (before serial number 40428)
Part 2 of 3
REV F
QD4
WH/RD
RD/WH
BL
BK
OR
KEY ON R/GN
STARTER INPUT BL
13
OUTRIGGERS
ENGINE
HIGH IDLE
PLATFORM
UP/DOWN
FORD
ENGINE
HARNESS
N.O.
U5
Y35
Y33
N.C.
Y50
S7 LEVEL
SENSOR
MODELS WITHOUT
OUTRIGGERS
BN
Y50 LPG
S7 LEVEL SENSOR
U5 ECM GROUND
SW2 ENGINE OIL PRESSURE
Y3 STEER RIGHT
Y2 BRAKE RELEASE
- NOTE -
ES0138G
Y39
LEVEL SENSOR
CIRCUIT BOARD
J4-C1
SW2
WH
S8
2 AXIS
TILT LEVEL
SENSOR
BK
Y49
Y9
Y3
FB1
J2-A6
Y40
RD
Y34
TS64
FAULT CODE
DISPLAY
J2-B10
Y36
YL
SW1
BL
Y49A
Y29
Y1
J2-B1
RD
Y2
J2-B3
J1-B7
J2-B10
J1-B6
J3-B6
J4-C2
J1-A12
J1-B5
J4-B1
J1-B1
J1-A11
J4-B6
J1-B4
J1-A10
J1-A1
J1-A4
J1-C7,C8
J4-B2
G8
DIAGNOSTIC
DISPLAY
J2-C1/C10
J3-B5
J3-A6
J2-A10
J2-A8
J4-B3
J3-A2
J3-A1
J2-A2
J2-A7
J4-A4
J4-A1
J2-A1
J4-B4
N.O.
THROTTLE
N.O.
J3-A5
N.O.
J3-A4
S5
PLATFORM
OVERLOAD
PRESSURE
SWITCH
(OPTION)
PLAT
DOWN
LIMIT
SWITCH
LS6
LS5
J3-B4
N.C.
PLAT
UP
LIMIT
SWITCH
(GS-5390)
LF
RF
LR
RR
O-RIG
O-RIG
O-RIG
O-RIG
LIMIT
LIMIT
LIMIT
LIMIT
SWITCH SWITCH SWITCH SWITCH
N.O.
N.C.
DOWN
FUEL
SELECT
UP
ENGINE
START
(STANDARD ON GS-5390)
(OPTION ON GS-3390, GS-4390)
TS66
24
18
FUNCTION
ENABLE
TS67
15
6 - 21
Section 6 Schematics
July 2007
Electrical Schematic
Ford Models (before serial number 40428)
Part 1 of 3
REV F
P2
C
P2
EMERGENCY
STOP
QD3
BK
POWER TO PLATFORM
BK
RD
RD
WH
GROUND
PIO3
BL
PIO4
YL
PIO5
POWER TO GROUND
EMERGENCY
STOP
QD3
PIO2
BK
BK
POWER TO PLATFORM
RD
POWER TO GROUND
WH
GROUND
PIO3
BL
PIO4
YL
PIO5
RD
PIO2
12V DC
OR
R15
PP
5K
POTENTIOMETER
WH/YL
PIN18
PIN15
PLATFORM CONTROLS
MEMBRANE DECAL
POUT2
R15
PP
5K
POTENTIOMETER
JOYSTICK
CONTROLLER
WH/YL
SW6 STEER
LEFT/ RIGHT
SW5
PIN14
POUT3
JC1
BN
WH/BL
FUNCTION ENABLE
WH/RD
RIGHT
WH
BK
OR
LEFT
RIGHT
WH/RD
LEFT
PIN15
PIN14
FUNCTION ENABLE
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
WH/BK
SW6 STEER
LEFT/ RIGHT
SW5
WH/BL
JOYSTICK
CONTROLLER
1
2
3
4
5
6
7
8
D7
U3
SW25
DIP
SWITCH
JC1
BN
WH/BK
PIN18
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
DIP
SWITCH
1
2
3
4
5
6
7
8
D7
U3
SW25
12V DC
WH
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POUT3
POUT4
POUT4
POUT5
POUT5
POUT6
POUT6
POUT7
POUT7
POUT8
POUT8
PIN5
PIN5
PIN6
PIN6
PIN10
PIN10
PIN19
HORN BN5
PIN19
PIN23
PIN23
PIN24
GENERATOR BN7
PIN24
PIN13
PIN13
PIN25
PIN25
PIN29
PIN25
PIN29
PIN1
PIN2
PIN3
PIN4
POUT1
PIN11
WH
BL
RD
YL
RD
BK
PIN1
UP
PIN2
DOWN
PIN3
PIN4
H1
POUT1
ALARM
PIN11
WH
BL
RD
UP
YL
RD
BK
DOWN
H1
ALARM
PLATFORM CONTROLS
PLATFORM CONTROLS
6 - 22
July 2007
Section 6 Schematics
6 - 23
Section 6 Schematics
July 2007
Electrical Schematic
Ford Models (from serial number 40428 to 40793)
Part 1 of 3
REV E
P1
EMERGENCY STOP
B
PLATFORM
CONTROL
B
T
GROUND
CONTROL
CB2
20A
CR41
CONTROL
SYSTEM
(ESTOP 1)
86
85
30
87
CR42
POWER
(ESTOP 2)
K5
86
87A
85
K6
86
87A
85
CR8
CR1
CR58
HORN
IGNITION
ENGINE START
FWD/REV
30
87
30
87
K1
86
87A
85
30
87
K3
87A
L2
U5
87A
J2-A5
20A
FUSE
85
J1-C11,C12
POWER SUPPLY
TO STARTER
86
87A
J2-B11
87
K2
J4-C4
30
30
87
J4-B5
CR1A
85
J2-B9
86
86
87A
J1-C1-C4
85
K4
J1-B3
F16
30
87
CR5
AUXILIARY
FUNCTION ENABLE
B1
M4
M5
J2-B12
TS69
J1-A3
EDC
J1-A2
Y51
J1-A9
R6
510 W
J1-B2
J4-A5
A
S
I
FWD
D1
REV
FUSE
LINK
H2
TS70
AUXILIARY
PLATFORM DOWN
Y4
H5
3
STARTER
G6
M3
AUX
PUMP
M2
Y7
Y8
H5 ALARM
Y8 PLATFORM UP
Y4 STEER LEFT
Y7 PLATFORM DOWN
M2 AUXILIARY PUMP
M4 FUEL PUMP
M5 HYDRAULIC PUMP
Y51 FORWARD/REVERSE COIL
G6 ENGINE HOURMETER
D1 ALTERNATOR
K1 STARTER RELAY
M3 STARTER MOTOR
H2 AUTOMOTIVE-STYLE
HORN
B1 12 VOLT BATTERY
6 - 24
Section 6 Schematics
July 2007
Electrical Schematic
Ford Models (from serial number 40428 to 40793)
Part 2 of 3
REV E
QD4
WH/RD
RD/WH
BL
BK
OR
VPWR Y
KEY ON R/GN
1
15
STARTER INPUT BL
13
TS66
ENGINE
START
PLATFORM
UP/DOWN
FORD
ENGINE
HARNESS
N.O.
N.O.
N.O.
THROTTLE
N.O.
WH
S8
2 AXIS
TILT LEVEL
SENSOR
J4-C1
J2-A6
RD
Y40
J2-B10
Y34
YL
Y36
BL
SW1
J2-B1
RD
Y49A
Y29
Y1
J2-B3
J1-B7
J2-B10
J1-B6
J3-B6
J4-C2
J1-A12
J1-B5
J1-C7,C8
J4-B2
J4-B1
J1-B1
J1-A11
J4-B6
J1-B4
J1-A10
J1-A1
J1-A4
Y2
TS64
FAULT CODE
DISPLAY
J2-C1/C10
U5
ELECTRONIC CONTROL MODULE
G8
DIAGNOSTIC
DISPLAY
J4-B4
J3-B5
J3-A6
J2-A10
J2-A8
J4-B3
J3-A2
J3-A1
J2-A2
J2-A7
J4-A4
J4-A1
J2-A1
J3-A5
PLATFORM
OVERLOAD
PRESSURE
SWITCH
(OPTION)
J3-A4
S5
PLAT
DOWN
LIMIT
SWITCH
LS6
PLAT
UP
LIMIT
SWITCH
(GS-5390)
LS5
J3-B4
N.C.
LF
RF
LR
RR
O-RIG
O-RIG
O-RIG
O-RIG
LIMIT
LIMIT
LIMIT
LIMIT
SWITCH SWITCH SWITCH SWITCH
N.O.
N.C.
DOWN
ENGINE
HIGH IDLE
UP
FUEL
SELECT
OUTRIGGERS
(STANDARD ON GS-5390)
(OPTION ON GS-3390, GS-4390)
18
5
24
ENABLE
TS67 FUNCTION
N.C.
LEVEL SENSOR
CIRCUIT BOARD
Y50
BK
FB1
Y9
Y3
S7 LEVEL
SENSOR
MODELS WITHOUT
OUTRIGGERS
SW2
Y49
Y35
Y33
Y39
BN
Y50 LPG
S7 LEVEL SENSOR
U5 ECM GROUND
SW2 ENGINE OIL PRESSURE
Y3 STEER RIGHT
Y2 BRAKE RELEASE
6 - 25
Section 6 Schematics
July 2007
Electrical Schematic
Ford Models (from serial number 40428 to 40793)
Part 3 of 3
REV E
P2
C
P2
EMERGENCY
STOP
QD3
BK
POWER TO PLATFORM
BK
RD
RD
WH
GROUND
PIO3
BL
PIO4
YL
PIO5
POWER TO GROUND
EMERGENCY
STOP
QD3
PIO2
BK
BK
POWER TO PLATFORM
RD
POWER TO GROUND
WH
GROUND
PIO3
BL
PIO4
YL
PIO5
RD
PIO2
12V DC
OR
R15
PP
5K
POTENTIOMETER
WH/YL
PIN18
PIN15
PLATFORM CONTROLS
MEMBRANE DECAL
POUT2
R15
PP
5K
POTENTIOMETER
JOYSTICK
CONTROLLER
WH/YL
SW6 STEER
LEFT/ RIGHT
SW5
PIN14
POUT3
JC1
BN
WH/BL
FUNCTION ENABLE
WH/RD
RIGHT
WH
BK
OR
LEFT
RIGHT
WH/RD
LEFT
PIN15
PIN14
FUNCTION ENABLE
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
WH/BK
SW6 STEER
LEFT/ RIGHT
SW5
WH/BL
JOYSTICK
CONTROLLER
1
2
3
4
5
6
7
8
D7
U3
SW25
DIP
SWITCH
JC1
BN
WH/BK
PIN18
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
DIP
SWITCH
1
2
3
4
5
6
7
8
D7
U3
SW25
12V DC
WH
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POUT3
POUT4
POUT4
POUT5
POUT5
POUT6
POUT6
POUT7
POUT7
POUT8
POUT8
PIN5
PIN5
PIN6
PIN6
PIN10
PIN10
PIN19
HORN BN5
PIN19
PIN23
PIN23
PIN24
GENERATOR BN7
PIN24
PIN13
PIN13
PIN25
PIN25
PIN29
PIN25
PIN29
PIN1
PIN2
PIN3
PIN4
POUT1
PIN11
WH
BL
RD
YL
RD
BK
PIN1
UP
PIN2
DOWN
PIN3
PIN4
H1
POUT1
ALARM
PIN11
WH
BL
RD
UP
YL
RD
BK
DOWN
H1
ALARM
PLATFORM CONTROLS
PLATFORM CONTROLS
6 - 26
July 2007
Section 6 Schematics
6 - 27
Section 6 Schematics
July 2007
Electrical Schematic
Ford Models (from serial number 40794 to 40995)
Part 1 of 3
REV D
P1
EMERGENCY STOP
B
PLATFORM
CONTROL
B
T
GROUND
CONTROL
CB2
20A
CR41
CONTROL
SYSTEM
(ESTOP 1)
86
85
30
87
CR42
POWER
(ESTOP 2)
K5
86
87A
85
30
87
K6
86
87A
85
CR5
CR8
HORN
IGNITION
30
87
K4
86
87A
85
30
87
K2
86
87A
85
CR1
CR58
ENGINE
START
FORWARD/
REVERSE
30
87
K1
86
87A
85
30
87
K3
87A
J2-B12
H2
J1-A3
M4
M5
J1-A2
AUXILIARY
FUNCTION ENABLE
510 W
B1
J1-B2
EDC
R6
TS69
FWD
Y51
J2-A5
J4-A5
A
S
I
REV
FUSE
LINK
D1
J1-C11,C12
J2-B11
J4-C4
J4-C4
J4-B5
J2-B9
J1-B3
U5
L2
TS70
AUXILIARY
PLATFORM DOWN
Y4
H5
3
STARTER
G6
M3
AUX
PUMP
M2
Y7
Y8
H5 ALARM
Y8 PLATFORM UP
Y4 STEER LEFT
Y7 PLATFORM DOWN
M2 AUXILIARY PUMP
M4 FUEL PUMP
M5 HYDRAULIC PUMP
Y51 FORWARD/REVERSE COIL
G6 ENGINE HOURMETER
D1 ALTERNATOR
M3 STARTER MOTOR
K1 STARTER RELAY
H2 AUTOMOTIVE-STYLE
HORN
B1 12 VOLT BATTERY
6 - 28
ES0138H
Section 6 Schematics
July 2007
Electrical Schematic
Ford Models (from serial number 40794 to 40995)
Part 2 of 3
REV D
QD4
FUEL
SELECT
ENGINE
HIGH IDLE
VPWR Y
KEY ON R/GN
6
5
24
OUTRIGGERS
(STANDARD ON GS-5390)
(OPTION ON GS-3390, GS-4390)
FORD
ENGINE
HARNESS
PLATFORM
UP/DOWN
N.O.
N.O.
N.O.
THROTTLE
N.O.
G8
DIAGNOSTIC
DISPLAY
U5
TS64
FAULT CODE
DISPLAY
J2-C1/C10
J4-B4
J3-B5
J3-A6
J2-A10
J2-A8
J4-B3
J3-A2
J3-A1
J2-A2
J2-A7
J4-A4
J4-A1
J2-A1
J3-A5
PLATFORM
OVERLOAD
PRESSURE
SWITCH
(OPTION)
J3-A4
S5
PLAT
DOWN
LIMIT
SWITCH
LS6
PLAT
UP
LIMIT
SWITCH
(GS-5390)
LS5
J3-B4
N.C.
LF
RF
LR
RR
O-RIG
O-RIG
O-RIG
O-RIG
LIMIT
LIMIT
LIMIT
LIMIT
SWITCH SWITCH SWITCH SWITCH
N.O.
N.C.
DOWN
BK
OR
N.C.
TS66
UP
ENGINE
START
BL
PLAT
UP
LIMIT
SWITCH
(GS-5390)
18
LS5A
FUNCTION
ENABLE
RD/WH
TS67
WH/RD
WH
S8
2 AXIS
TILT LEVEL
SENSOR
J4-C1
J2-A6
RD
Y40
J2-B10
Y34
YL
Y36
BL
SW1
J2-B1
RD
Y49A
Y29
Y1
J2-B3
J1-B7
J2-B10
J1-B6
J3-B6
J4-C2
J1-A12
J1-B5
J1-C7,C8
J4-B2
J4-B1
J1-B1
J1-A11
J4-B6
J1-B4
J1-A10
J1-A4
Y2
N.C.
LEVEL SENSOR
CIRCUIT BOARD
Y50
BK
FB1
Y9
Y3
MODELS WITHOUT
OUTRIGGERS
SW2
Y49
Y35
Y33
Y39
BN
Y50 LPG
S7 LEVEL SENSOR
U5 ECM GROUND
SW2 ENGINE OIL PRESSURE
Y3 STEER RIGHT
Y2 BRAKE RELEASE
ES0138H
S7 LEVEL
SENSOR
6 - 29
Section 6 Schematics
July 2007
Electrical Schematic
Ford Models (from serial number 40794 to 40995)
Part 3 of 3
REV D
P2
C
P2
EMERGENCY
STOP
QD3
BK
POWER TO PLATFORM
BK
RD
RD
WH
GROUND
PIO3
BL
PIO4
YL
PIO5
POWER TO GROUND
EMERGENCY
STOP
QD3
PIO2
BK
BK
POWER TO PLATFORM
RD
POWER TO GROUND
WH
GROUND
PIO3
BL
PIO4
YL
PIO5
RD
PIO2
12V DC
OR
R15
PP
5K
POTENTIOMETER
WH/YL
PIN18
PIN15
PLATFORM CONTROLS
MEMBRANE DECAL
POUT2
R15
PP
5K
POTENTIOMETER
JOYSTICK
CONTROLLER
WH/YL
SW6 STEER
LEFT/ RIGHT
SW5
PIN14
POUT3
JC1
BN
WH/BL
FUNCTION ENABLE
WH/RD
RIGHT
WH
BK
OR
LEFT
RIGHT
WH/RD
LEFT
PIN15
PIN14
FUNCTION ENABLE
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
WH/BK
SW6 STEER
LEFT/ RIGHT
SW5
WH/BL
JOYSTICK
CONTROLLER
1
2
3
4
5
6
7
8
D7
U3
SW25
DIP
SWITCH
JC1
BN
WH/BK
PIN18
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
DIP
SWITCH
1
2
3
4
5
6
7
8
D7
U3
SW25
12V DC
WH
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POUT3
POUT4
POUT4
POUT5
POUT5
POUT6
POUT6
POUT7
POUT7
POUT8
POUT8
PIN5
PIN5
PIN6
PIN6
PIN10
PIN10
PIN19
HORN BN5
PIN19
PIN23
PIN23
PIN24
GENERATOR BN7
PIN24
PIN13
PIN13
PIN25
PIN25
PIN29
PIN25
PIN29
PIN1
PIN2
PIN3
PIN4
POUT1
PIN11
WH
BL
RD
YL
RD
BK
PIN1
UP
PIN2
DOWN
PIN3
PIN4
H1
POUT1
ALARM
PIN11
WH
BL
RD
UP
YL
RD
BK
DOWN
H1
ALARM
PLATFORM CONTROLS
PLATFORM CONTROLS
6 - 30
July 2007
Section 6 Schematics
6 - 31
Section 6 Schematics
July 2007
Electrical Schematic
Ford Models (from serial number 40996 to 41065)
Part 1 of 3
REV B
P1
EMERGENCY STOP
B
PLATFORM
CONTROL
B
T
GROUND
CONTROL
CB2
20A
CR41
CONTROL
SYSTEM
(ESTOP 1)
86
85
30
87
CR42
POWER
(ESTOP 2)
K5
86
87A
85
30
87
K6
86
87A
85
CR5
CR8
HORN
IGNITION
30
87
K4
86
87A
85
30
87
K2
86
87A
85
CR1
CR58
ENGINE
START
DRIVE
FWD/REV
30
87
K1
86
87A
85
30
87
K3
87A
J2-A5
J2-B11
J1-C1-C4
J2-B12
J1-A3
J1-A2
J1-A9
TS69
J4-C4
EDC
FWD
REV
Y51
J1-B2
R6
510 W
AUXILIARY
FUNCTION ENABLE
B1
M4
M5
H2
U5
J4-A5
A
S
I
J4-B5
J2-B9
J1-B3
FUSE
LINK
D1
TS70
AUXILIARY
PLATFORM DOWN
Y4
H5
3
STARTER
1
G6
M3
AUX
PUMP
M2
Y7
Y8
H5 ALARM
Y8 PLATFORM UP
Y4 STEER LEFT
Y7 PLATFORM DOWN
M2 AUXILIARY PUMP
M4 FUEL PUMP
G6 ENGINE HOURMETER
M5 HYDRAULIC PUMP
Y51 FORWARD/REVERSE COIL
D1 ALTERNATOR
M3 STARTER MOTOR
K1 STARTER RELAY
H2 AUTOMOTIVE-STYLE
HORN
B1 12 VOLT BATTERY
6 - 32
ES0138K
Section 6 Schematics
July 2007
Electrical Schematic
Ford Models (from serial number 40996 to 41065)
Part 2 of 3
REV B
QD4
WH/RD
RD/WH
BL
BK
OR
KEY ON R/GN
OUTRIGGERS
(STANDARD ON GS-5390)
(OPTION ON GS-3390, GS-4390)
FUEL
SELECT
ENGINE
HIGH IDLE
TS66
PLATFORM
UP/DOWN
N.O.
N.O.
N.O.
N.O.
DOWN
THROTTLE
PLATFORM
OVERLOAD
PRESSURE
SWITCH
(OPTION)
G8
DIAGNOSTIC
DISPLAY
U5
TS64
FAULT CODE
DISPLAY
J2-C1/C10
J4-B4
J3-B5
J3-A6
J2-A10
J2-A8
J4-B3
J3-A2
J3-A1
J2-A2
J2-A7
J4-A4
J4-A1
J2-A1
J3-A5
S5
PLAT
DOWN
LIMIT
SWITCH
J3-A4
LS6
PLAT
UP
LIMIT
SWITCH
(GS-5390)
LS5
N.C.
J3-B4
LF
RF
LR
RR
O-RIG
O-RIG
O-RIG
O-RIG
LIMIT
LIMIT
LIMIT
LIMIT
SWITCH SWITCH SWITCH SWITCH
N.O.
N.C.
UP
FORD
ENGINE
HARNESS
6
24
18
FUNCTION
ENABLE
8
9
TS67
WH
S8
2 AXIS
TILT LEVEL
SENSOR
J4-C1
J2-A6
RD
Y40
J2-B10
Y34
YL
Y36
BL
SW1
J2-B1
RD
Y49A
Y29
Y1
J2-B3
J1-B7
J2-B10
J1-B6
J3-B6
J4-C2
J1-A12
J1-B5
J1-C7,C8
J4-B2
J4-B1
J1-B1
J1-A11
J4-B6
J1-B4
J1-A10
J1-A1
J1-A4
Y2
N.C.
LEVEL SENSOR
CIRCUIT BOARD
Y50
BK
FB1
Y9
Y3
MODELS WITHOUT
OUTRIGGERS
SW2
Y49
Y35
Y33
Y39
BN
Y50 LPG
S7 LEVEL SENSOR
U5 ECM GROUND
SW2 ENGINE OIL PRESSURE
Y3 STEER RIGHT
Y2 BRAKE RELEASE
ES0138K
S7 LEVEL
SENSOR
6 - 33
Section 6 Schematics
July 2007
Electrical Schematic
Ford Models (from serial number 40996 to 41065)
Part 3 of 3
REV B
P2
C
P2
EMERGENCY
STOP
QD3
BK
POWER TO PLATFORM
BK
RD
RD
WH
GROUND
PIO3
BL
PIO4
YL
PIO5
POWER TO GROUND
EMERGENCY
STOP
QD3
PIO2
BK
BK
POWER TO PLATFORM
RD
POWER TO GROUND
WH
GROUND
PIO3
BL
PIO4
YL
PIO5
RD
PIO2
12V DC
OR
R15
PP
5K
POTENTIOMETER
WH/YL
PIN18
PIN15
PLATFORM CONTROLS
MEMBRANE DECAL
POUT2
R15
PP
5K
POTENTIOMETER
JOYSTICK
CONTROLLER
WH/YL
SW6 STEER
LEFT/ RIGHT
SW5
PIN14
POUT3
JC1
BN
WH/BL
FUNCTION ENABLE
WH/RD
RIGHT
WH
BK
OR
LEFT
RIGHT
WH/RD
LEFT
PIN15
PIN14
FUNCTION ENABLE
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
WH/BK
SW6 STEER
LEFT/ RIGHT
SW5
WH/BL
JOYSTICK
CONTROLLER
1
2
3
4
5
6
7
8
D7
U3
SW25
DIP
SWITCH
JC1
BN
WH/BK
PIN18
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
DIP
SWITCH
1
2
3
4
5
6
7
8
D7
U3
SW25
12V DC
WH
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POUT3
POUT4
POUT4
POUT5
POUT5
POUT6
POUT6
POUT7
POUT7
POUT8
POUT8
PIN5
PIN5
PIN6
PIN6
PIN10
PIN10
PIN19
HORN BN5
PIN19
PIN23
PIN23
PIN24
GENERATOR BN7
PIN24
PIN13
PIN13
PIN25
PIN25
PIN29
PIN25
PIN29
PIN1
PIN2
PIN3
PIN4
POUT1
PIN11
WH
BL
RD
YL
RD
BK
PIN1
UP
PIN2
DOWN
PIN3
PIN4
H1
POUT1
ALARM
PIN11
WH
BL
RD
UP
YL
RD
BK
DOWN
H1
ALARM
PLATFORM CONTROLS
PLATFORM CONTROLS
6 - 34
July 2007
Section 6 Schematics
6 - 35
Section 6 Schematics
July 2007
Electrical Schematic
Ford Models (from serial number 41066 to GS9003-41368)
Part 1 of 3
REV B
P1
EMERGENCY STOP
B
PLATFORM
CONTROL
B
T
GROUND
CONTROL
CB2
20A
CR41
CONTROL
SYSTEM
(ESTOP 1)
86
85
30
87
CR42
POWER
(ESTOP 2)
K5
86
87A
85
30
87
K6
86
87A
85
CR5
CR8
HORN
IGNITION
30
87
K4
86
87A
85
30
87
K2
86
87A
85
CR1
CR58
ENGINE
START
DRIVE
FWD/REV
30
87
K1
86
87A
85
30
87
K3
87A
J2-A5
J2-B11
J1-C1-C4
J4-C4
J1-A3
TS69
J1-A2
EDC
FWD
REV
Y51
J1-A9
J1-B2
R6
J2-B12
J1-C11,C12
510 W
AUXILIARY
FUNCTION ENABLE
B1
M4
M5
H2
U5
J4-A5
A
S
I
J4-B5
J2-B9
J1-B3
FUSE
LINK
D1
TS70
AUXILIARY
PLATFORM DOWN
Y4
H5
3
STARTER
1
G6
M3
AUX
PUMP
M2
Y7
Y8
H5 ALARM
Y8 PLATFORM UP
Y4 STEER LEFT
Y7 PLATFORM DOWN
M2 AUXILIARY PUMP
M4 FUEL PUMP
G6 ENGINE HOURMETER
M5 HYDRAULIC PUMP
Y51 FORWARD/REVERSE COIL
D1 ALTERNATOR
M3 STARTER MOTOR
K1 STARTER RELAY
H2 AUTOMOTIVE-STYLE
HORN
B1 12 VOLT BATTERY
6 - 36
ES0138K
Section 6 Schematics
July 2007
Electrical Schematic
Ford Models (from serial number 41066 to GS9003-41368)
Part 2 of 3
REV B
QD4
WH/RD
RD/WH
BL
BK
OR
ENGINE
START
FUEL
SELECT
ENGINE
HIGH IDLE
FORD
ENGINE
HARNESS
PLATFORM
UP/DOWN
N.O.
N.O.
N.O.
THROTTLE
N.O.
G8
DIAGNOSTIC
DISPLAY
U5
TS64
FAULT CODE
DISPLAY
J2-C1/C10
J4-B4
J3-B5
J3-A6
J2-A10
J2-A8
J4-B3
J3-A2
J3-A1
J2-A2
J2-A7
J4-A4
J4-A1
J2-A1
J3-A5
PLATFORM
OVERLOAD
PRESSURE
SWITCH
(OPTION)
J3-A4
S5
PLAT
DOWN
LIMIT
SWITCH
LS6
PLAT
UP
LIMIT
SWITCH
(GS-5390)
LS5
J3-B4
N.C.
LF
RF
LR
RR
O-RIG
O-RIG
O-RIG
O-RIG
LIMIT
LIMIT
LIMIT
LIMIT
SWITCH SWITCH SWITCH SWITCH
N.O.
N.C.
DOWN
6
24
OUTRIGGERS
(STANDARD ON GS-5390)
(OPTION ON GS-3390, GS-4390)
TS66
UP
N.C.
KEY ON R/GN
PLAT
UP
LIMIT
SWITCH
(GS-5390)
1
5
LS5A
FUNCTION
ENABLE
18
TS67
8
9
WH
S8
2 AXIS
TILT LEVEL
SENSOR
J4-C1
J2-A6
RD
Y40
J2-B10
Y34
YL
Y36
BL
SW1
J2-B1
RD
Y49A
Y29
Y1
J2-B3
J1-B7
J2-B10
J1-B6
J3-B6
J4-C2
J1-A12
J1-B5
J1-C7,C8
J4-B2
J4-B1
J1-B1
J1-A11
J4-B6
J1-B4
J1-A10
J1-A1
J1-A4
Y2
N.C.
LEVEL SENSOR
CIRCUIT BOARD
Y50
BK
FB1
Y9
Y3
MODELS WITHOUT
OUTRIGGERS
SW2
Y49
Y35
Y33
Y39
BN
Y50 LPG
S7 LEVEL SENSOR
U5 ECM GROUND
SW2 ENGINE OIL PRESSURE
Y3 STEER RIGHT
Y2 BRAKE RELEASE
ES0138K
S7 LEVEL
SENSOR
6 - 37
Section 6 Schematics
July 2007
Electrical Schematic
Ford Models (from serial number 41066 to GS9003-41368)
Part 3 of 3
P2
QD3
EMERGENCY
STOP
BK
BK
POWER TO PLATFORM
RD
POWER TO GROUND
WH
GROUND
PIO3
BL
PIO4
YL
PIO5
REV B
P2
QD3
RD
PIO2
EMERGENCY
STOP
BK
BK
POWER TO PLATFORM
RD
POWER TO GROUND
WH
GROUND
PIO3
BL
PIO4
YL
PIO5
RD
PIO2
12V DC
WH/YL
WH/BK
SW5
WH
PIN15
PIN14
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POUT3
OR
JOYSTICK
CONTROLLER
5K
POTENTIOMETER
PP
WH/YL
WH/BK
WH/BL
JC1
R15
BN
SW5
FUNCTION ENABLE
WH/RD
SW6 STEER
LEFT/ RIGHT
RIGHT
WH/RD
PIN18
WH
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POUT3
POUT4
POUT4
POUT5
POUT5
POUT6
POUT6
POUT7
POUT7
POUT8
POUT8
PIN5
PIN5
PIN6
PIN6
PIN10
PIN10
PIN19
HORN BN5
PIN19
PIN23
PIN23
PIN24
GENERATOR BN7
PIN24
PIN13
PIN13
PIN25
PIN25
PIN29
PIN25
PIN29
PIN1
PIN2
PIN3
PIN4
POUT1
PIN11
WH
BL
RD
UP
YL
RD
BK
DOWN
PIN1
PIN2
PIN3
PIN4
H1
POUT1
ALARM
PIN11
PLATFORM CONTROLS
6 - 38
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
LEFT
FUNCTION ENABLE
SW6 STEER
LEFT/ RIGHT
RIGHT
PIN15
PIN14
5K
POTENTIOMETER
PP
WH/BL
JOYSTICK
CONTROLLER
1
2
3
4
5
6
7
8
D7
U3
SW25
DIP
SWITCH
JC1
R15
LEFT
PIN18
OR
BN
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
DIP
SWITCH
1
2
3
4
5
6
7
8
D7
U3
SW25
12V DC
WH
BL
RD
UP
YL
RD
BK
DOWN
H1
ALARM
PLATFORM CONTROLS
July 2007
Section 6 Schematics
6 - 39
Section 6 Schematics
July 2007
Electrical Schematic
Ford Models (from serial number GS9003-41369 to GS9003-41522)
Part 1 of 3
REV B
P1
EMERGENCY STOP
B
PLATFORM
CONTROL
B
T
GROUND
CONTROL
CB2
20A
CR41
CONTROL
SYSTEM
(ESTOP 1)
86
85
30
87
CR42
POWER
(ESTOP 2)
K5
86
87A
85
30
87
K6
86
87A
85
CR5
CR8
HORN
IGNITION
30
87
K4
86
87A
85
30
87
K2
86
87A
85
CR1
CR58
ENGINE
START
DRIVE
FWD/REV
30
87
K1
86
87A
85
30
87
K3
87A
J2-A5
J2-B11
J1-C1-C4
J4-C4
J1-A3
TS69
J1-A2
EDC
FWD
REV
Y51
J1-A9
J1-B2
R6
J2-B12
J1-C11,C12
510 W
AUXILIARY
FUNCTION ENABLE
B1
M4
M5
H2
U5
J4-A5
A
S
I
J4-B5
J2-B9
J1-B3
FUSE
LINK
D1
TS70
AUXILIARY
PLATFORM DOWN
Y4
H5
3
STARTER
1
G6
M3
AUX
PUMP
M2
Y7
Y8
H5 ALARM
Y8 PLATFORM UP
Y4 STEER LEFT
Y7 PLATFORM DOWN
M2 AUXILIARY PUMP
M4 FUEL PUMP
G6 ENGINE HOURMETER
M5 HYDRAULIC PUMP
Y51 FORWARD/REVERSE COIL
D1 ALTERNATOR
M3 STARTER MOTOR
K1 STARTER RELAY
H2 AUTOMOTIVE-STYLE
HORN
B1 12 VOLT BATTERY
6 - 40
ES0138L
Section 6 Schematics
July 2007
Electrical Schematic
Ford Models (from serial number GS9003-41369 to GS9003-41522)
Part 2 of 3
REV B
QD4
FUEL
SELECT
ENGINE
HIGH IDLE
24
VPWR RD
KEY ON WH
MALFUNCTION LED BL
23
OUTRIGGERS
(STANDARD ON GS-5390)
(OPTION ON GS-3390, GS-4390)
FORD
ENGINE
HARNESS
PLATFORM
UP/DOWN
N.O.
N.O.
N.O.
THROTTLE
N.O.
G8
DIAGNOSTIC
DISPLAY
U5
TS64
FAULT CODE
DISPLAY
J2-C1/C10
J4-B4
J3-B5
J3-A6
J2-A10
J2-A8
J4-B3
J3-A2
J3-A1
J2-A2
J2-A7
J4-A4
J4-A1
J2-A1
J3-A5
PLATFORM
OVERLOAD
PRESSURE
SWITCH
(OPTION)
J3-A4
S5
PLAT
DOWN
LIMIT
SWITCH
LS6
PLAT
UP
LIMIT
SWITCH
(GS-5390)
LS5
J3-B4
N.C.
LF
RF
LR
RR
O-RIG
O-RIG
O-RIG
O-RIG
LIMIT
LIMIT
LIMIT
LIMIT
SWITCH SWITCH SWITCH SWITCH
N.O.
N.C.
DOWN
BK
OR
N.C.
TS66
UP
ENGINE
START
34 GROUND BN
BL
PLAT
UP
LIMIT
SWITCH
(GS-5390)
LS5A
FUNCTION
ENABLE
RD/WH
TS67
WH/RD
WH
S8
2 AXIS
TILT LEVEL
SENSOR
J4-C1
J2-A6
RD
Y40
J2-B10
Y34
YL
Y36
BL
SW1
J2-B1
RD
Y49A
Y29
Y1
J2-B3
J1-B7
J2-B10
J1-B6
J3-B6
J4-C2
J1-A12
J1-B5
J1-C7,C8
J4-B2
J4-B1
J1-B1
J1-A11
J4-B6
J1-B4
J1-A10
J1-A1
J1-A4
Y2
N.C.
LEVEL SENSOR
CIRCUIT BOARD
Y50
BK
FB1
Y9
Y3
MODELS WITHOUT
OUTRIGGERS
SW2
Y49
Y35
Y33
Y39
BN
Y50 LPG
S7 LEVEL SENSOR
U5 ECM GROUND
SW2 ENGINE OIL PRESSURE
Y3 STEER RIGHT
Y2 BRAKE RELEASE
ES0138L
S7 LEVEL
SENSOR
6 - 41
Section 6 Schematics
July 2007
Electrical Schematic
Ford Models (from serial number GS9003-41369 to GS9003-41522)
Part 3 of 3
REV B
P2
C
P2
EMERGENCY
STOP
QD3
BK
POWER TO PLATFORM
BK
RD
RD
WH
GROUND
PIO3
BL
PIO4
YL
PIO5
POWER TO GROUND
EMERGENCY
STOP
QD3
PIO2
BK
BK
POWER TO PLATFORM
RD
POWER TO GROUND
WH
GROUND
PIO3
BL
PIO4
YL
PIO5
RD
PIO2
12V DC
OR
R15
PP
5K
POTENTIOMETER
WH/YL
PIN18
PIN15
PLATFORM CONTROLS
MEMBRANE DECAL
POUT2
R15
PP
5K
POTENTIOMETER
JOYSTICK
CONTROLLER
WH/YL
SW6 STEER
LEFT/ RIGHT
SW5
PIN14
POUT3
JC1
BN
WH/BL
FUNCTION ENABLE
WH/RD
RIGHT
WH
BK
OR
LEFT
RIGHT
WH/RD
LEFT
PIN15
PIN14
FUNCTION ENABLE
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
WH/BK
SW6 STEER
LEFT/ RIGHT
SW5
WH/BL
JOYSTICK
CONTROLLER
1
2
3
4
5
6
7
8
D7
U3
SW25
DIP
SWITCH
JC1
BN
WH/BK
PIN18
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
DIP
SWITCH
1
2
3
4
5
6
7
8
D7
U3
SW25
12V DC
WH
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POUT3
POUT4
POUT4
POUT5
POUT5
POUT6
POUT6
POUT7
POUT7
POUT8
POUT8
PIN5
PIN5
PIN6
PIN6
PIN10
PIN10
PIN19
HORN BN5
PIN19
PIN23
PIN23
PIN24
GENERATOR BN7
PIN24
PIN13
PIN13
PIN25
PIN25
PIN29
PIN25
PIN29
PIN1
PIN2
PIN3
PIN4
POUT1
PIN11
WH
BL
RD
YL
RD
BK
PIN1
UP
PIN2
DOWN
PIN3
PIN4
H1
POUT1
ALARM
PIN11
WH
BL
RD
UP
YL
RD
BK
DOWN
H1
ALARM
PLATFORM CONTROLS
PLATFORM CONTROLS
6 - 42
July 2007
Section 6 Schematics
6 - 43
Section 6 Schematics
July 2007
Electrical Schematic
ANSI Models with Ford Power
(from serial number GS9003-41523 to GS9004-41693)
Part 1 of 3
P1
REV D
EMERGENCY STOP
PLATFORM
CONTROL
4
3
GROUND
CONTROL
CB2 20A
AB7
CR41
CR42
CONTROL
SYSTEM
(ESTOP 1)
POWER
(ESTOP 2)
CR5
CR8
HORN
IGNITION
CR1
CR23
CR84
CR85
ENGINE
START
AUXILIARY
DOWN
OSCILLATE
STOWED
OSCILLATE
RAISED
AB1
86
85
86
87A
85
30
87
86
87A
85
30
87
30
87
86
87A
85
30
87
86
87A
85
86
87A
85
30
87
30
87
86
87A
85
G6
FUSE
LINK
H2
A
S
I
D1
510 W
SW20
B1
6
1
24
9
MALFUNCTION LED BL
KEY ON WH
86
87
87A
85
87A
N.C.H.O.
LS23
LS22
LEFT
OSCILLATE
LIMIT SWITCH
RIGHT
OSCILLATE
LIMIT SWITCH
CD2
CD3
CD4
Y54
CD5
Y56
Y50
FORD
ENGINE HARNESS
M4
STARTER
AUX
PUMP
M4
M3
12
34 GROUND BN
5 FUEL PUMP BL/WH
87
N.C.H.O.
30
AB15
R6
11
30
FUEL PUMP
M2
Y57
Y55
Y50 LPG
G6 ENGINE HOURMETER
M2 AUXILIARY PUMP
M4 FUEL PUMP
GROUND
M3 STARTER MOTOR
K1 STARTER RELAY
H2 AUTOMOTIVE-STYLE HORN
B1 12 VOLT BATTERY
OSCILLATING AXLE
(OPTION)
(AVAILABLE AFTER SERIAL NUMBER 41618)
6 - 44
ES7163B
Section 6 Schematics
July 2007
Electrical Schematic
ANSI Models with Ford Power
(from serial number GS9003-41523 to GS9004-41693)
Part 2 of 3
REV D
AB1
AB3
AB3
OIL COOLER
(GS-5390)
(OPTION)
PLAT
DOWN
LIMIT
SWITCH
CB7
20A
86
AB4
LS6
30
85
LS5
WH
SW4
HYDRAULIC
OIL TEMP
N.C.
AB1
J2-C12
CD13
N.C.
PLAT
UP
LIMIT
SWITCH
RD
LS5A
87
CR17
87A
N.C.
LEVEL SENSOR
CIRCUIT BOARD
HYDRAULIC
OIL COOLER
N.C.
PLAT
UP
LIMIT
SWITCH
FAN
S7 LEVEL
SENSOR
M1
FAN MOTOR
MODELS WITHOUT
OUTRIGGERS
AB2
BK
J2-B10
J2-A6
J2-B2
J2-A3
J2-A5
J2-C12
J2-A1
J2-A2
J2-B11
J2-B8
J2-B7
J2-A4
J2-C5
J2-C6
J2-C1/C3
U5
BN23
BN91
AUXILIARY DOWN
J1-B3
J1-B2
J1-C8
J1-A12
J1-A11
J1-B4
J1-A4
J1-A10
J1-A1
J1-A2
J1-C9
J1-A9
J1-A3
J1-C7
J2-C10
J2-B9
J1-B12
AB12
Y4
Y9
Y1
Y49A
FWD
REV
AB9
Y51
EDC
M5
SW1
Y7
Y8
Y49
SW2
M5 HYDRAULIC PUMP
Y51 FORWARD/REVERSE COIL
S7 LEVEL SENSOR
Y2 BRAKE RELEASE
ES7163B
Y2
Y1 TWO SPEED MOTOR STROKE
Y3 STEER RIGHT
Y4 STEER LEFT
Y7 PLATFORM DOWN
Y8 PLATFORM UP
Y3
6 - 45
Section 6 Schematics
July 2007
Electrical Schematic
ANSI Models with Ford Power
(from serial number GS9003-41523 to GS9004-41693)
Part 3 of 3
REV D
P2
QD3
QD4
WH/RD
BK
POWER TO PLATFORM
POWER TO GROUND
EMERGENCY
STOP
BK
RD
RD/WH
RD
BL
WH
GROUND
WH
BK
BL
BL
OR
OR
OR
J5 PIN1
J5 PIN4
J5 PIN5
OUTRIGGERS
(STANDARD ON GS-5390)
(OPTION ON GS-3390, GS-4390)
J5 PIN2
CD11
CD11
CD12
D7
U3
CD12
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
WH
JC1
JOYSTICK
CONTROLLER
BN
BL
PP
J2 PIN4
J5 PIN3
GY
SW5
OR
FUNCTION ENABLE
BK
J2 PIN6
RIGHT
J2 PIN5
LEFT
BK
YL
BL
RD
GROUND
N.O.
ROLL
N.O.
J2 PIN13
HALL EFFECT
GENERATOR
YL
J2 PIN3
PITCH
N.O.
J2 PIN2
J2 PIN12
POWER
N.O.
S8
5V DC
GY
J2 PIN1
2 AXIS
TILT LEVEL
SENSOR
12V DC
SW6
STEER
LEFT/ RIGHT
RD
J2 PIN7
J2 PIN8
J2-A12
J2-A11
J2-A10
J2-B2
J2-B3
J2-B1
J2-B10
J1-C4
J1-C6
J1-C3
J1-C5
J2 PIN14
POUT1
PIN5
PIN6
GENERATOR BN7
PIN7
PIN8
PIN9
PIN10
PIN11
PIN12
J2-C7
PIN4
J2-C11
HORN BN5
PIN3
J1-B1
PIN2
J2-B12
J1-B7
J1-B6
J1-B10
J1-B11
J1-B9
J1-B5
U5
ELECTRONIC CONTROL MODULE
CD1
Y36
Y34
Y35
Y29
Y40
Y33
H5 FB1
Y39
ECM GROUND
H5 ALARM
PIN13
PIN14
PIN15
BL
J1 PIN3
RD
J1 PIN1
BK
J3 PIN1
- NOTE -
6 - 46
YL
J1 PIN4
J1 PIN5
WH/BL
J3 PIN2
ES7163B
RD
BK
H1
ALARM
PLATFORM
CONTROLS
Part No. 72863
July 2007
Section 6 Schematics
6 - 47
Section 6 Schematics
July 2007
Electrical Schematic
ANSI Models with Ford Power
(from serial number GS9004-41694 to GS9005-42143)
Part 1 of 3
P1
REV D
EMERGENCY STOP
PLATFORM
CONTROL
4
3
GROUND
CONTROL
CB2 20A
AB7
CR41
CR42
CONTROL
SYSTEM
(ESTOP 1)
POWER
(ESTOP 2)
CR5
CR8
HORN
IGNITION
CR1
CR23
CR84
CR85
ENGINE
START
AUXILIARY
DOWN
OSCILLATE
STOWED
OSCILLATE
RAISED
AB1
86
85
86
87A
85
30
87
86
87A
85
30
87
30
87
86
87A
85
30
87
86
87A
85
86
87A
85
30
87
30
87
86
87A
85
G6
FUSE
LINK
H2
A
S
I
D1
510 W
6
1
24
9
SW20
B1
86
87
87A
85
87A
N.C.H.O.
LS23
LS22
LEFT
OSCILLATE
LIMIT SWITCH
RIGHT
OSCILLATE
LIMIT SWITCH
MALFUNCTION LED BL
KEY ON WH
KEEP ALIVE POWER WH
VPWR RD
CD2
CD3
CD4
Y54
34 GROUND BN
5 FUEL PUMP BL/WH
CD5
Y56
Y50
FORD
ENGINE HARNESS
M4
STARTER
AUX
PUMP
M4
M3
12
87
N.C.H.O.
30
AB15
R6
11
30
FUEL PUMP
M2
Y57
Y55
Y50 LPG
G6 ENGINE HOURMETER
M2 AUXILIARY PUMP
M4 FUEL PUMP
GROUND
M3 STARTER MOTOR
K1 STARTER RELAY
H2 AUTOMOTIVE-STYLE HORN
B1 12 VOLT BATTERY
OSCILLATING AXLE
(OPTION)
(AVAILABLE AFTER SERIAL NUMBER 41618)
6 - 48
ES7163C
Section 6 Schematics
July 2007
Electrical Schematic
ANSI Models with Ford Power
(from serial number GS9004-41694 to GS9005-42143)
Part 2 of 3
REV D
AB1
AB3
AB3
OIL COOLER
(GS-5390)
(OPTION)
PLAT
DOWN
LIMIT
SWITCH
CB7
20A
86
AB4
LS6
30
85
LS5
WH
SW4
HYDRAULIC
OIL TEMP
N.C.
AB1
J2-C12
CD13
N.C.
PLAT
UP
LIMIT
SWITCH
RD
LS5A
87
CR17
87A
HYDRAULIC
OIL COOLER
N.C.
LEVEL SENSOR
CIRCUIT BOARD
N.C.
PLAT
UP
LIMIT
SWITCH
FAN
M1
FAN MOTOR
BATTERY 12V (-)
AB2
S7 LEVEL
SENSOR
MODELS WITHOUT
OUTRIGGERS
BK
J2-B10
J2-A6
J2-B2
J2-A3
J2-A5
J2-C12
J2-A1
J2-A2
J2-B11
J2-B8
J2-B7
J2-A4
J2-C5
J2-C6
J2-C1/C3
U5
BN23
BN91
AUXILIARY DOWN
J1-B3
J1-B2
J1-C8
J1-B4
J1-A4
J1-A10
J1-A1
J1-A2
J1-C9
J1-A9
J1-A3
J1-C7
J2-C10
J2-B9
J1-B12
AB12
Y4
Y9
Y1
FWD
REV
AB9
Y51
EDC
M5
SW1
Y7
Y8
Y3
M5 HYDRAULIC PUMP
Y51 FORWARD/REVERSE COIL
S7 LEVEL SENSOR
Y2 BRAKE RELEASE
Y3 STEER RIGHT
Y4 STEER LEFT
Y7 PLATFORM DOWN
Y8 PLATFORM UP
ES7163C
SW2
Y2
6 - 49
Section 6 Schematics
July 2007
Electrical Schematic
ANSI Models with Ford Power
(from serial number GS9004-41694 to GS9005-42143)
Part 3 of 3
REV D
P2
QD3
QD4
WH/RD
BK
POWER TO PLATFORM
POWER TO GROUND
EMERGENCY
STOP
BK
RD
RD/WH
RD
BL
WH
GROUND
WH
BK
BL
BL
OR
OR
OR
J5 PIN1
J5 PIN4
J5 PIN5
OUTRIGGERS
(STANDARD ON GS-5390)
(OPTION ON GS-3390, GS-4390)
J5 PIN2
CD11
CD11
CD12
D7
U3
CD12
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
WH
JC1
JOYSTICK
CONTROLLER
BN
BL
PP
J2 PIN4
J5 PIN3
GY
SW5
OR
FUNCTION ENABLE
BK
J2 PIN6
RIGHT
J2 PIN5
LEFT
BK
YL
BL
RD
GROUND
N.O.
ROLL
N.O.
J2 PIN13
HALL EFFECT
GENERATOR
YL
J2 PIN3
PITCH
N.O.
J2 PIN2
J2 PIN12
POWER
N.O.
S8
5V DC
GY
J2 PIN1
2 AXIS
TILT LEVEL
SENSOR
12V DC
SW6
STEER
LEFT/ RIGHT
RD
J2 PIN7
J2 PIN8
J2-A12
J2-A11
J2-A10
J2-B2
J2-B3
J2-B1
J2-B10
J1-C4
J1-C6
J1-C3
J1-C5
J2 PIN14
POUT1
PIN5
PIN6
GENERATOR BN7
PIN7
PIN8
PIN9
PIN10
PIN11
PIN12
J2-C7
PIN4
J2-C11
HORN BN5
PIN3
J1-B1
PIN2
J2-B12
J1-B7
J1-B6
J1-B10
J1-B11
J1-B9
J1-B5
U5
ELECTRONIC CONTROL MODULE
CD1
Y36
Y34
Y35
Y29
Y40
Y33
H5 FB1
Y39
ECM GROUND
H5 ALARM
PIN13
PIN14
PIN15
BL
J1 PIN3
RD
J1 PIN1
BK
J3 PIN1
- NOTE -
6 - 50
YL
J1 PIN4
J1 PIN5
WH/BL
J3 PIN2
ES7163C
RD
BK
H1
ALARM
PLATFORM
CONTROLS
Part No. 72863
July 2007
Section 6 Schematics
6 - 51
Section 6 Schematics
July 2007
Electrical Schematic
ANSI Models with Ford Power
(from serial number GS9005-42144 to GS9005-42203)
Part 1 of 3
F9 5A FUSE
KS1 KEY SWITCH
REV C
P1EMERGENCY STOP
B1
PLATFORM
CONTROL
4
B
3
GROUND
CONTROL
CB2 20A
AB7
CR41
CR42
CONTROL
SYSTEM
(ESTOP 1)
POWER
(ESTOP 2)
CR5
CR8
HORN
IGNITION
CR1
CR23
CR84
CR85
ENGINE
START
AUXILIARY
DOWN
OSCILLATE
STOWED
OSCILLATE
RAISED
AB1
86
85
86
87A
85
30
87
86
87A
85
30
87
30
87
86
87A
85
30
87
86
87A
85
86
87A
85
30
87
30
87
86
87A
85
G6
FUSE
LINK
H2
A
S
I
D1
510 W
6
1
24
9
SW20
B1
86
87
87A
85
87A
N.C.H.O.
LS23
LS22
LEFT
OSCILLATE
LIMIT SWITCH
RIGHT
OSCILLATE
LIMIT SWITCH
MALFUNCTION LED BL
KEY ON WH
KEEP ALIVE POWER WH
VPWR RD
CD2
CD3
CD4
Y54
34 GROUND BN
5 FUEL PUMP BL/WH
CD5
Y56
Y50
FORD
ENGINE HARNESS
M4
STARTER
AUX
PUMP
M4
M3
12
87
N.C.H.O.
30
AB15
R6
11
30
FUEL PUMP
M2
Y57
Y55
Y50 LPG
G6 ENGINE HOURMETER
M2 AUXILIARY PUMP
M4 FUEL PUMP
GROUND
M3 STARTER MOTOR
K1 STARTER RELAY
H2 AUTOMOTIVE-STYLE HORN
B1 12 VOLT BATTERY
OSCILLATING AXLE
(OPTION)
(AVAILABLE AFTER SERIAL NUMBER 41618)
6 - 52
ES7163E
Section 6 Schematics
July 2007
Electrical Schematic
ANSI Models with Ford Power
(from serial number GS9005-42144 to GS9005-42203)
Part 2 of 3
REV C
AB1
AB3
AB3
OIL COOLER
(GS-5390)
(OPTION)
PLAT
DOWN
LIMIT
SWITCH
CB7
20A
86
AB4
LS6
30
85
LS5
WH
SW4
HYDRAULIC
OIL TEMP
N.C.
AB1
J2-C12
CD13
N.C.
PLAT
UP
LIMIT
SWITCH
RD
LS5A
87
CR17
87A
HYDRAULIC
OIL COOLER
N.C.
LEVEL SENSOR
CIRCUIT BOARD
N.C.
PLAT
UP
LIMIT
SWITCH
FAN
M1
FAN MOTOR
BATTERY 12V (-)
AB2
S7 LEVEL
SENSOR
MODELS WITHOUT
OUTRIGGERS
BK
J2-B10
J2-A6
J2-B2
J2-A3
J2-A5
J2-C12
J2-A1
J2-A2
J2-B11
J2-B8
J2-B7
J2-A4
J2-C5
J2-C6
J2-C1/C3
U5
BN23
BN91
AUXILIARY DOWN
J1-B3
J1-B2
J1-C8
J1-B4
J1-A4
J1-A10
J1-A1
J1-A2
J1-C9
J1-A9
J1-A3
J1-C7
J2-C10
J2-B9
J1-B12
AB12
Y4
Y9
Y1
FWD
REV
AB9
Y51
EDC
M5
SW1
Y7
Y8
Y3
M5 HYDRAULIC PUMP
Y51 FORWARD/REVERSE COIL
S7 LEVEL SENSOR
Y2 BRAKE RELEASE
Y3 STEER RIGHT
Y4 STEER LEFT
Y7 PLATFORM DOWN
Y8 PLATFORM UP
ES7163E
SW2
Y2
6 - 53
Section 6 Schematics
July 2007
Electrical Schematic
ANSI Models with Ford Power
(from serial number GS9005-42144 to GS9005-42203)
Part 3 of 3
REV C
P2
QD3
QD4
WH/RD
BK
POWER TO PLATFORM
POWER TO GROUND
EMERGENCY
STOP
BK
RD
RD/WH
RD
BL
WH
GROUND
WH
BK
BL
BL
OR
OR
OR
J5 PIN1
J5 PIN4
J5 PIN5
OUTRIGGERS
(STANDARD ON GS-5390)
(OPTION ON GS-3390, GS-4390)
J5 PIN2
CD11
CD11
CD12
D7
U3
CD12
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
WH
JC1
JOYSTICK
CONTROLLER
BN
BL
PP
J2 PIN4
J5 PIN3
GY
SW5
OR
FUNCTION ENABLE
BK
J2 PIN6
RIGHT
J2 PIN5
LEFT
BK
YL
BL
RD
GROUND
N.O.
ROLL
N.O.
J2 PIN13
HALL EFFECT
GENERATOR
YL
J2 PIN3
PITCH
N.O.
J2 PIN2
J2 PIN12
POWER
N.O.
S8
5V DC
GY
J2 PIN1
2 AXIS
TILT LEVEL
SENSOR
12V DC
SW6
STEER
LEFT/ RIGHT
RD
J2 PIN7
J2 PIN8
J2-A12
J2-A11
J2-A10
J2-B2
J2-B3
J2-B1
J2-B10
J1-C4
J1-C6
J1-C3
J1-C5
J2 PIN14
POUT1
PIN5
PIN6
GENERATOR BN7
PIN7
PIN8
PIN9
PIN10
PIN11
PIN12
J2-C7
PIN4
J2-C11
HORN BN5
PIN3
J1-B1
PIN2
J2-B12
J1-B7
J1-B6
J1-B10
J1-B11
J1-B9
J1-B5
U5
ELECTRONIC CONTROL MODULE
CD1
Y36
Y34
Y35
Y29
Y40
Y33
H5 FB1
Y39
ECM GROUND
H5 ALARM
PIN13
PIN14
PIN15
BL
J1 PIN3
RD
J1 PIN1
BK
J3 PIN1
- NOTE -
6 - 54
YL
J1 PIN4
J1 PIN5
WH/BL
J3 PIN2
ES7163E
RD
BK
H1
ALARM
PLATFORM
CONTROLS
Part No. 72863
July 2007
Section 6 Schematics
6 - 55
Section 6 Schematics
July 2007
Electrical Schematic
ANSI Models with Ford Power
(from serial number GS9005-42204 to GS9005-42685)
Part 1 of 3
F9 5A FUSE
KS1 KEY SWITCH
REV B
P1EMERGENCY STOP
B1
PLATFORM
CONTROL
4
B
3
GROUND
CONTROL
CB2 20A
AB7
CR41
CR42
CONTROL
SYSTEM
(ESTOP 1)
POWER
(ESTOP 2)
CR5
CR8
HORN
IGNITION
CR1
CR23
CR84
CR85
ENGINE
START
AUXILIARY
DOWN
OSCILLATE
STOWED
OSCILLATE
RAISED
AB1
86
85
86
87A
85
30
87
86
87A
85
30
87
30
87
86
87A
85
30
87
86
87A
85
86
87A
85
30
87
30
87
86
87A
85
G6
FUSE
LINK
H2
A
S
I
D1
510 W
6
1
24
9
SW20
B1
86
87
87A
85
87A
N.C.H.O.
LS23
LS22
LEFT
OSCILLATE
LIMIT SWITCH
RIGHT
OSCILLATE
LIMIT SWITCH
MALFUNCTION LED BL
KEY ON WH
KEEP ALIVE POWER WH
VPWR RD
CD2
CD3
CD4
Y54
34 GROUND BN
5 FUEL PUMP BL/WH
CD5
Y56
Y50
FORD
ENGINE HARNESS
M4
STARTER
AUX
PUMP
M4
M3
12
87
N.C.H.O.
30
AB15
R6
11
30
FUEL PUMP
M2
Y57
Y55
Y50 LPG
G6 ENGINE HOURMETER
M2 AUXILIARY PUMP
M4 FUEL PUMP
GROUND
K1 STARTER RELAY
M3 STARTER MOTOR
H2 AUTOMOTIVE-STYLE HORN
B1 12 VOLT BATTERY
OSCILLATING AXLE
(OPTION)
(AVAILABLE AFTER SERIAL NUMBER 41618)
6 - 56
ES7163F
Section 6 Schematics
July 2007
Electrical Schematic
ANSI Models with Ford Power
(from serial number GS9005-42204 to GS9005-42685)
Part 2 of 3
REV B
AB1
AB3
AB3
OIL COOLER
(GS-5390)
(OPTION)
PLAT
DOWN
LIMIT
SWITCH
CB7
20A
86
AB4
LS6
30
85
LS5
WH
SW4
HYDRAULIC
OIL TEMP
N.C.
AB1
J2-C12
CD13
N.C.
PLAT
UP
LIMIT
SWITCH
RD
LS5A
87
CR17
87A
HYDRAULIC
OIL COOLER
N.C.
LEVEL SENSOR
CIRCUIT BOARD
N.C.
PLAT
UP
LIMIT
SWITCH
FAN
M1
FAN MOTOR
BATTERY 12V (-)
AB2
S7 LEVEL
SENSOR
MODELS WITHOUT
OUTRIGGERS
BK
J2-B10
J2-A6
J2-B2
J2-A3
J2-A5
J2-C12
J2-A1
J2-A2
J2-B11
J2-B8
J2-B7
J2-A4
J2-C5
J2-C6
J2-C1/C3
U5
BN23
BN91
AUXILIARY DOWN
J1-B3
J1-B2
J1-C8
J1-B4
J1-A4
J1-A10
J1-A1
J1-A2
J1-C9
J1-A9
J1-A3
J1-C7
J2-C10
J2-B9
J1-B12
AB12
Y4
Y9
Y1
FWD
REV
AB9
Y51
EDC
M5
SW1
Y7
Y8
Y3
M5 HYDRAULIC PUMP
Y51 FORWARD/REVERSE COIL
S7 LEVEL SENSOR
Y2 BRAKE RELEASE
Y3 STEER RIGHT
Y4 STEER LEFT
Y7 PLATFORM DOWN
Y8 PLATFORM UP
ES7163F
SW2
Y2
6 - 57
Section 6 Schematics
July 2007
Electrical Schematic
ANSI Models with Ford Power
(from serial number GS9005-42204 to GS9005-42685)
Part 3 of 3
REV B
P2
QD3
QD4
WH/RD
BK
POWER TO PLATFORM
POWER TO GROUND
EMERGENCY
STOP
BK
RD
RD/WH
RD
BL
WH
GROUND
WH
BK
BL
BL
OR
OR
OR
J5 PIN1
J5 PIN4
J5 PIN5
OUTRIGGERS
(STANDARD ON GS-5390)
(OPTION ON GS-3390, GS-4390)
J5 PIN2
CD11
CD11
CD12
D7
U3
CD12
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
WH
JC1
JOYSTICK
CONTROLLER
BN
BL
PP
J2 PIN4
J5 PIN3
GY
SW5
OR
FUNCTION ENABLE
BK
J2 PIN6
RIGHT
J2 PIN5
LEFT
BK
YL
BL
RD
GROUND
N.O.
ROLL
N.O.
J2 PIN13
HALL EFFECT
GENERATOR
YL
J2 PIN3
PITCH
N.O.
J2 PIN2
J2 PIN12
POWER
N.O.
S8
5V DC
GY
J2 PIN1
2 AXIS
TILT LEVEL
SENSOR
12V DC
SW6
STEER
LEFT/ RIGHT
RD
J2 PIN7
J2 PIN8
J2-A12
J2-A11
J2-A10
J2-B2
J2-B3
J2-B1
J2-B10
J1-C4
J1-C6
J1-C3
J1-C5
J2 PIN14
POUT1
PIN5
PIN6
GENERATOR BN7
PIN7
PIN8
PIN9
PIN10
PIN11
PIN12
J2-C7
PIN4
J2-C11
HORN BN5
PIN3
J1-B1
PIN2
J2-B12
J1-B7
J1-B6
J1-B10
J1-B11
J1-B9
J1-B5
U5
ELECTRONIC CONTROL MODULE
CD1
Y36
Y34
Y35
Y29
Y40
Y33
H5 FB1
Y39
ECM GROUND
H5 ALARM
PIN13
PIN14
PIN15
BL
J1 PIN3
RD
J1 PIN1
BK
J3 PIN1
- NOTE -
6 - 58
YL
J1 PIN4
J1 PIN5
WH/BL
J3 PIN2
ES7163F
RD
BK
H1
ALARM
PLATFORM
CONTROLS
Part No. 72863
July 2007
Section 6 Schematics
6 - 59
Section 6 Schematics
June 2008
Electrical Schematic
CE Models with Ford Power
(from serial number GS9003-41523 to GS9004-41693)
Part 1 of 3
6 - 60
REV D
Section 6 Schematics
June 2008
Electrical Schematic
REV D
6 - 61
Section 6 Schematics
June 2008
Electrical Schematic
CE Models with Ford Power
(from serial number GS9003-41523 to GS9004-41693)
Part 3 of 3
6 - 62
REV D
June 2008
Section 6 Schematics
6 - 63
Section 6 Schematics
June 2008
Electrical Schematic
CE Models with Ford Power
(from serial number GS9004-41694 to GS9005-42143)
Part 1 of 3
6 - 64
REV D
Section 6 Schematics
June 2008
Electrical Schematic
REV D
6 - 65
Section 6 Schematics
June 2008
Electrical Schematic
CE Models with Ford Power
(from serial number GS9004-41694 to GS9005-42143)
Part 3 of 3
6 - 66
REV D
June 2008
Section 6 Schematics
6 - 67
Section 6 Schematics
June 2008
Electrical Schematic
CE Models with Ford Power
(from serial number GS9005-42144 to GS9005-42203)
Part 1 of 3
6 - 68
REV D
Section 6 Schematics
June 2008
Electrical Schematic
REV D
6 - 69
Section 6 Schematics
June 2008
Electrical Schematic
CE Models with Ford Power
(from serial number GS9005-42144 to GS9005-42203)
Part 3 of 3
6 - 70
REV D
June 2008
Section 6 Schematics
6 - 71
Section 6 Schematics
June 2008
Electrical Schematic
CE Models with Ford Power
(from serial number GS9005-42204 to GS9005-42411)
Part 1 of 3
6 - 72
REV C
Section 6 Schematics
June 2008
Electrical Schematic
REV C
6 - 73
Section 6 Schematics
June 2008
Electrical Schematic
CE Models with Ford Power
(from serial number GS9005-42204 to GS9005-42411)
Part 3 of 3
6 - 74
REV C
June 2008
Section 6 Schematics
6 - 75
Section 6 Schematics
June 2008
Electrical Schematic
CE Models with Ford Power
(from serial number GS9005-42412 to GS9005-42685)
Part 1 of 3
6 - 76
REV C
Section 6 Schematics
June 2008
Electrical Schematic
REV C
6 - 77
Section 6 Schematics
June 2008
Electrical Schematic
CE Models with Ford Power
(from serial number GS9005-42412 to GS9005-42685)
Part 3 of 3
6 - 78
REV C
June 2008
Section 6 Schematics
6 - 79
Section 6 Schematics
July 2007
Electrical Schematic
Deutz Models (before serial number 40428)
Part 1 of 3
REV D
P1
EMERGENCY STOP
B
PLATFORM
CONTROL
B
T
GROUND
CONTROL
CB2
20A
CR41
CR42
CONTROL
SYSTEM
(ESTOP 1)
86
85
30
87
POWER
(ESTOP 2)
K5
86
87A
85
30
K6
86
87A
85
87
CR5
CR8
CR1
CR58
HORN
IGNITION
ENGINE START
FWD/REV
30
87
K4
86
87A
85
30
87
K2
86
87A
85
30
87
K1
86
87A
85
87A
J2-A5
J1-A3
J1-A2
87
J1-C11,C12
J2-B11
30
Y51
EDC
FWD
85
REV
86
J1-A9
AUXILIARY
FUNCTION ENABLE
STARTING
AID
U30
J4-C4
TS69
J1-B2
J4-A5
J4-C3
J4-B4
CR15
SOLENOID
CONTROL
MODULE
U5
AUX(+)
BATT(+)
BATT(-)
B1
D1
J4-B5
J2-B9
J1-C1-C4
G6
K3
J1-B3
30
87
TS70
AUXILIARY
PLATFORM DOWN
87A
Y4
STARTER
RD
BK
WH
M5
M3
U32
Q8
FUEL
SHUT OFF
H2
AUX
PUMP
GLOW
PLUG
(OPTION)
M2
Y7
Y8
Y8 PLATFORM UP
Y4 STEER LEFT
Y7 PLATFORM DOWN
M2 AUXILIARY PUMP
M5 HYDRAULIC PUMP
Y51 FORWARD/REVERSE COIL
G6 ENGINE HOURMETER
M3 STARTER MOTOR
K1 STARTER RELAY
D1 ALTERNATOR
H2 AUTOMOTIVE-STYLE
HORN
B1 12 VOLT BATTERY
6 - 80
ES7142A
Section 6 Schematics
July 2007
Electrical Schematic
Deutz Models (before serial number 40428)
Part 2 of 3
REV D
QD4
WH/RD
RD/WH
BL
BK
OR
WH
RD
TS67
FUNCTION
ENABLE
OUTRIGGERS
(STANDARD ON GS-5390)
(OPTION ON GS-3390, GS-4390)
TS54
TS66
ENGINE
START
ENGINE
HIGH IDLE
PLATFORM
UP/DOWN
PLAT
UP
LIMIT
SWITCH
(GS-5390)
PLAT
DOWN
LIMIT
SWITCH
PLATFORM
OVERLOAD
PRESSURE
SWITCH
(OPTION)
N.O.
N.O.
N.O.
N.O.
MODELS WITHOUT
OUTRIGGERS
BN
G8
DIAGNOSTIC
DISPLAY
J2-C1/C10
J2-B10
J2-A6
J3-B5
J3-A6
J2-A10
J2-A8
J4-B3
J3-A2
J3-A1
J2-A2
J2-A7
J4-A4
J2-A1
J3-A5
S5
J3-A4
LS6
LS5
N.C.
J3-B4
N.O.
N.C.
S7 LEVEL
SENSOR
LF
RF
LR
RR
O-RIG
O-RIG
O-RIG
O-RIG
LIMIT
LIMIT
LIMIT
LIMIT
SWITCH SWITCH SWITCH SWITCH
UP
N.C.
LEVEL SENSOR
CIRCUIT BOARD
DOWN
TS52
U5
Y40
S8
J4-B2
Y34
J4-B1
Y36
YL
H5
BL
Y49A
J2-B1
RD
Y29
Y1
J2-B3
J1-B7
J2-B10
J1-B6
J3-B6
J4-C2
J1-A12
J1-B5
J2-B12
J1-B1
J1-A11
J4-B6
J1-B4
J1-A10
J1-A1
J1-A4
Y2
J1-C7, C8
SW3
2 AXIS
TILT LEVEL
SENSOR
BK
SW2
FB1
Y9
Y3
Y49
Y35
Y33
Y39
U5 ECM GROUND
H5 ALARM
Y3 STEER RIGHT
Y2 BRAKE RELEASE
ES7142A
6 - 81
Section 6 Schematics
July 2007
Electrical Schematic
Deutz Models (before serial number 40428)
Part 3 of 3
REV D
P2
C
P2
EMERGENCY
STOP
QD3
BK
POWER TO PLATFORM
BK
RD
RD
WH
GROUND
PIO3
BL
PIO4
YL
PIO5
POWER TO GROUND
EMERGENCY
STOP
QD3
PIO2
BK
BK
POWER TO PLATFORM
RD
POWER TO GROUND
WH
GROUND
PIO3
BL
PIO4
YL
PIO5
RD
PIO2
12V DC
OR
R15
PP
5K
POTENTIOMETER
WH/YL
PIN18
PIN15
PLATFORM CONTROLS
MEMBRANE DECAL
POUT2
PP
5K
POTENTIOMETER
POUT3
WH/BL
JOYSTICK
CONTROLLER
WH/YL
SW6 STEER
LEFT/ RIGHT
SW5
PIN14
BK
R15
FUNCTION ENABLE
WH/RD
RIGHT
WH
JC1
BN
LEFT
RIGHT
WH/RD
OR
WH/BK
LEFT
PIN15
PIN14
FUNCTION ENABLE
1
2
3
4
5
6
7
8
WH
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POUT3
POUT4
POUT4
POUT5
POUT5
POUT6
POUT6
POUT8
POUT8
PIN5
PIN5
PIN6
PIN6
PIN10
PIN10
PIN19
HORN BN5
PIN19
PIN23
PIN23
PIN24
GENERATOR BN7
PIN24
RR OUTRIGGER BN24
PIN25
PIN13
PIN29
PIN25
PIN25
PIN29
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
UP
PLATFORM UP/DOWN TS20
YL
PIN3
DOWN
PIN4
POUT1
PIN11
6 - 82
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
SW6 STEER
LEFT/ RIGHT
SW5
WH/BL
JOYSTICK
CONTROLLER
D7
U3
SW25
DIP
SWITCH
JC1
BN
WH/BK
PIN18
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
DIP
SWITCH
1
2
3
4
5
6
7
8
D7
U3
SW25
12V DC
RD
BK
POUT1
H1
ALARM
PIN11
BL
RD
UP
YL
DOWN
RD
BK
H1
ALARM
PLATFORM CONTROLS
PLATFORM CONTROLS
July 2007
Section 6 Schematics
6 - 83
Section 6 Schematics
July 2007
Electrical Schematic
Deutz Models (from serial number 40428 to 40737)
Part 1 of 3
REV E
P1
EMERGENCY STOP
B
PLATFORM
CONTROL
B
T
GROUND
CONTROL
CB2
20A
CR41
CR42
CONTROL
SYSTEM
(ESTOP 1)
86
85
30
87
POWER
(ESTOP 2)
K5
86
87A
85
30
87
K6
86
87A
85
CR5
CR8
CR1
CR58
HORN
IGNITION
ENGINE START
FWD/REV
30
87
K4
86
87A
85
30
87
K2
86
87A
85
30
87
K3
87A
J1-C11,C12
J1-A3
J1-A2
J1-A9
TS70
AUXILIARY
PLATFORM DOWN
87
87A
M3
GLOW
PLUG
(OPTION)
Y4
M5
STARTER
U32
FUEL
SHUT OFF
J1-B2
EDC
30
Q8
Y51
FWD
RD
BK
WH
85
AUXILIARY
FUNCTION ENABLE
REV
86
J2-A5
U5
J4-A5
J4-C3
J4-B4
STARTING
AID
U30
J2-B11
85
J4-C4
86
87
J4-B5
30
J2-B9
POWER
SUPPLY 87A
TO STARTER
J1-C1-C4
CR1A
CR15
SOLENOID
CONTROL
MODULE
85
TS69
AUX(+)
BATT(+)
BATT(-)
B1
D1
86
87A
J1-B3
H2
K1
G6
30
87
AUX
PUMP
M2
Y7
Y8
Y8 PLATFORM UP
Y4 STEER LEFT
Y7 PLATFORM DOWN
M2 AUXILIARY PUMP
M5 HYDRAULIC PUMP
Y51 FORWARD/REVERSE COIL
K1 STARTER RELAY
M3 STARTER MOTOR
G6 ENGINE HOURMETER
D1 ALTERNATOR
H2 AUTOMOTIVE-STYLE
HORN
B1 12 VOLT BATTERY
6 - 84
Section 6 Schematics
July 2007
Electrical Schematic
Deutz Models (from serial number 40428 to 40737)
Part 2 of 3
REV E
QD4
WH/RD
RD/WH
BL
BK
OR
WH
RD
TS67
FUNCTION
ENABLE
OUTRIGGERS
(STANDARD ON GS-5390)
(OPTION ON GS-3390, GS-4390)
TS54
TS66
ENGINE
START
ENGINE
HIGH IDLE
PLATFORM
UP/DOWN
PLAT
UP
LIMIT
SWITCH
(GS-5390)
PLAT
DOWN
LIMIT
SWITCH
PLATFORM
OVERLOAD
PRESSURE
SWITCH
(OPTION)
N.O.
N.O.
N.O.
N.O.
MODELS WITHOUT
OUTRIGGERS
BN
G8
DIAGNOSTIC
DISPLAY
J2-C1/C10
J2-B10
J2-A6
J3-B5
J3-A6
J2-A10
J2-A8
J4-B3
J3-A2
J3-A1
J2-A2
J2-A7
J4-A4
J2-A1
J3-A5
S5
J3-A4
LS6
LS5
N.C.
J3-B4
N.O.
N.C.
S7 LEVEL
SENSOR
LF
RF
LR
RR
O-RIG
O-RIG
O-RIG
O-RIG
LIMIT
LIMIT
LIMIT
LIMIT
SWITCH SWITCH SWITCH SWITCH
UP
N.C.
LEVEL SENSOR
CIRCUIT BOARD
DOWN
TS52
U5
Y40
S8
J4-B2
Y34
J4-B1
Y36
YL
H5
BL
Y49A
J2-B1
RD
Y29
Y1
J2-B3
J1-B7
J2-B10
J1-B6
J3-B6
J4-C2
J1-A12
J1-B5
J2-B12
J1-B1
J1-A11
J4-B6
J1-B4
J1-A10
J1-A1
J1-A4
Y2
J1-C7, C8
SW3
2 AXIS
TILT LEVEL
SENSOR
BK
SW2
FB1
Y9
Y3
Y49
Y35
Y33
Y39
U5 ECM GROUND
H5 ALARM
Y3 STEER RIGHT
Y2 BRAKE RELEASE
6 - 85
Section 6 Schematics
July 2007
Electrical Schematic
Deutz Models (from serial number 40428 to 40737)
Part 3 of 3
REV E
P2
C
P2
EMERGENCY
STOP
QD3
BK
POWER TO PLATFORM
BK
RD
RD
WH
GROUND
PIO3
BL
PIO4
YL
PIO5
POWER TO GROUND
EMERGENCY
STOP
QD3
PIO2
BK
BK
POWER TO PLATFORM
RD
POWER TO GROUND
WH
GROUND
PIO3
BL
PIO4
YL
PIO5
RD
PIO2
12V DC
OR
R15
PP
5K
POTENTIOMETER
WH/YL
PIN18
PIN15
PLATFORM CONTROLS
MEMBRANE DECAL
POUT2
PP
5K
POTENTIOMETER
POUT3
WH/BL
JOYSTICK
CONTROLLER
WH/YL
SW6 STEER
LEFT/ RIGHT
SW5
PIN14
BK
R15
FUNCTION ENABLE
WH/RD
RIGHT
WH
JC1
BN
LEFT
RIGHT
WH/RD
OR
WH/BK
LEFT
PIN15
PIN14
FUNCTION ENABLE
1
2
3
4
5
6
7
8
WH
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POUT3
POUT4
POUT4
POUT5
POUT5
POUT6
POUT6
POUT8
POUT8
PIN5
PIN5
PIN6
PIN6
PIN10
PIN10
PIN19
HORN BN5
PIN19
PIN23
PIN23
PIN24
GENERATOR BN7
PIN24
RR OUTRIGGER BN24
PIN25
PIN13
PIN29
PIN25
PIN25
PIN29
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
UP
PLATFORM UP/DOWN TS20
YL
PIN3
DOWN
PIN4
POUT1
PIN11
6 - 86
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
SW6 STEER
LEFT/ RIGHT
SW5
WH/BL
JOYSTICK
CONTROLLER
D7
U3
SW25
DIP
SWITCH
JC1
BN
WH/BK
PIN18
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
DIP
SWITCH
1
2
3
4
5
6
7
8
D7
U3
SW25
12V DC
RD
BK
POUT1
H1
ALARM
PIN11
BL
RD
UP
YL
DOWN
RD
BK
H1
ALARM
PLATFORM CONTROLS
PLATFORM CONTROLS
July 2007
Section 6 Schematics
6 - 87
Section 6 Schematics
July 2007
Electrical Schematic
Deutz Models (from serial number 40738 to 40941)
Part 1 of 3
REV F
P1
EMERGENCY STOP
B
PLATFORM
CONTROL
B
T
GROUND
CONTROL
CB2
20A
CR41
CR42
CONTROL
SYSTEM
(ESTOP 1)
86
85
30
87
POWER
(ESTOP 2)
K5
86
87A
85
30
87
K6
86
87A
85
CR1
CR5
CR8
HORN
IGNITION
30
87
K4
86
87A
85
30
87
CR58
ENGINE
START
K2
86
87A
85
30
87
FWD/REV
K1
86
87A
85
30
87
K3
87A
J2-A5
J1-C11,C12
J1-A3
J1-A2
87A
M3
GLOW
PLUG
(OPTION)
Y4
M5
STARTER
U32
FUEL
SHUT OFF
TS70
AUXILIARY
PLATFORM DOWN
87
J2-B11
EDC
30
Q8
J1-A9
RD
BK
WH
85
Y51
FWD
REV
STARTING
AID
86
J4-C4
AUXILIARY
FUNCTION ENABLE
CR15
U30
J1-B2
J4-A5
J4-C3
J4-B4
TS69
SOLENOID
CONTROL
MODULE
U5
AUX(+)
BATT(+)
BATT(-)
B1
D1
J4-B5
H2
J2-B9
G6
J1-B3
J1-C1-C4
AUX
PUMP
M2
Y7
Y8
Y8 PLATFORM UP
Y4 STEER LEFT
Y7 PLATFORM DOWN
M2 AUXILIARY PUMP
M5 HYDRAULIC PUMP
Y51 FORWARD/REVERSE COIL
M3 STARTER MOTOR
K1 STARTER RELAY
G6 ENGINE HOURMETER
D1 ALTERNATOR
H2 AUTOMOTIVE-STYLE HORN
B1 12 VOLT BATTERY
6 - 88
ES7142B
Section 6 Schematics
July 2007
Electrical Schematic
Deutz Models (from serial number 40738 to 40941)
Part 2 of 3
REV F
QD4
WH/RD
RD/WH
BL
BK
OR
WH
RD
TS54
TS66
ENGINE
START
ENGINE
HIGH IDLE
PLATFORM
UP/DOWN
PLAT
UP
LIMIT
SWITCH
(GS-5390)
PLAT
DOWN
LIMIT
SWITCH
PLATFORM
OVERLOAD
PRESSURE
SWITCH
(OPTION)
N.O.
N.O.
N.O.
N.O.
MODELS WITHOUT
OUTRIGGERS
BN
G8
DIAGNOSTIC
DISPLAY
J2-C1/C10
J2-B10
J2-A6
J3-B5
J3-A6
J2-A10
J2-A8
J4-B3
J3-A2
J3-A1
J2-A2
J2-A7
J4-A4
J2-A1
J3-A5
S5
J3-A4
LS6
LS5
N.C.
J3-B4
N.O.
N.C.
S7 LEVEL
SENSOR
LF
RF
LR
RR
O-RIG
O-RIG
O-RIG
O-RIG
LIMIT
LIMIT
LIMIT
LIMIT
SWITCH SWITCH SWITCH SWITCH
UP
N.C.
LEVEL SENSOR
CIRCUIT BOARD
DOWN
TS52
U5
Y40
S8
J4-B2
Y34
J4-B1
Y36
YL
H5
BL
Y49A
J2-B1
RD
Y29
Y1
J2-B3
J1-B7
J2-B10
J1-B6
J3-B6
J4-C2
J1-A12
J1-B5
J2-B12
J1-B1
J1-A11
J4-B6
J1-B4
J1-A10
J1-A1
J1-A4
Y2
J1-C7, C8
SW3
2 AXIS
TILT LEVEL
SENSOR
BK
SW2
FB1
Y9
Y3
Y49
Y35
Y33
Y39
U5 ECM GROUND
H5 ALARM
Y3 STEER RIGHT
Y2 BRAKE RELEASE
ES7142B
6 - 89
Section 6 Schematics
July 2007
Electrical Schematic
Deutz Models (from serial number 40738 to 40941)
Part 3 of 3
REV F
P2
C
P2
EMERGENCY
STOP
QD3
BK
POWER TO PLATFORM
BK
RD
RD
WH
GROUND
PIO3
BL
PIO4
YL
PIO5
POWER TO GROUND
EMERGENCY
STOP
QD3
PIO2
BK
BK
POWER TO PLATFORM
RD
POWER TO GROUND
WH
GROUND
PIO3
BL
PIO4
YL
PIO5
RD
PIO2
12V DC
OR
R15
PP
5K
POTENTIOMETER
WH/YL
PIN18
PIN15
PLATFORM CONTROLS
MEMBRANE DECAL
POUT2
PP
5K
POTENTIOMETER
POUT3
WH/BL
JOYSTICK
CONTROLLER
WH/YL
SW6 STEER
LEFT/ RIGHT
SW5
PIN14
BK
R15
FUNCTION ENABLE
WH/RD
RIGHT
WH
JC1
BN
LEFT
RIGHT
WH/RD
OR
WH/BK
LEFT
PIN15
PIN14
FUNCTION ENABLE
1
2
3
4
5
6
7
8
WH
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POUT3
POUT4
POUT4
POUT5
POUT5
POUT6
POUT6
POUT8
POUT8
PIN5
PIN5
PIN6
PIN6
PIN10
PIN10
PIN19
HORN BN5
PIN19
PIN23
PIN23
PIN24
GENERATOR BN7
PIN24
RR OUTRIGGER BN24
PIN25
PIN13
PIN29
PIN25
PIN25
PIN29
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
UP
PLATFORM UP/DOWN TS20
YL
PIN3
DOWN
PIN4
POUT1
PIN11
6 - 90
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
SW6 STEER
LEFT/ RIGHT
SW5
WH/BL
JOYSTICK
CONTROLLER
D7
U3
SW25
DIP
SWITCH
JC1
BN
WH/BK
PIN18
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
DIP
SWITCH
1
2
3
4
5
6
7
8
D7
U3
SW25
12V DC
RD
BK
POUT1
H1
ALARM
PIN11
BL
RD
UP
YL
DOWN
RD
BK
H1
ALARM
PLATFORM CONTROLS
PLATFORM CONTROLS
July 2007
Section 6 Schematics
6 - 91
Section 6 Schematics
July 2007
Electrical Schematic
Deutz Models (from serial number 40942 to 41065)
Part 1 of 3
REV C
P1
EMERGENCY STOP
B
PLATFORM
CONTROL
B
T
GROUND
CONTROL
CB2
20A
CR41
CR42
CONTROL
SYSTEM
(ESTOP 1)
86
85
30
87
POWER
(ESTOP 2)
K5
86
87A
85
30
87
K6
86
87A
85
CR1
CR5
CR8
HORN
IGNITION
30
87
K4
86
87A
85
30
87
CR58
ENGINE
START
K2
86
87A
85
30
87
FWD/REV
K1
86
87A
85
30
87
K3
87A
87A
F17
87A
J1-A3
87
J2-A5
85
87
J1-C11,C12
M3
EDC
AUXILIARY
FUNCTION ENABLE
TS70
85
30
J1-A2
86
Y51
FWD
REV
STARTER
30
J1-A9
TS69
HIGH IDLE
86
J1-B2
J4-A5
J4-C3
J4-B4
CR15
STARTING
AID
J2-B11
U5
CR4
B1
J4-C4
J4-B5
D1
J2-B9
H2
J1-C1-C4
J1-B3
G6
M5
Y4
AUXILIARY
PLATFORM DOWN
15A FUSE
U32
Q8
GLOW
PLUG
(OPTION)
FUEL
SHUT OFF
AUX
PUMP
Q3
M2
HIGH IDLE
SOLENOID
Y7
Y8
Y8 PLATFORM UP
Y4 STEER LEFT
Y7 PLATFORM DOWN
M2 AUXILIARY PUMP
M5 HYDRAULIC PUMP
Y51 FORWARD/REVERSE COIL
G6 ENGINE HOURMETER
D1 ALTERNATOR
K1 STARTER RELAY
M3 STARTER MOTOR
H2 AUTOMOTIVE-STYLE HORN
B1 12 VOLT BATTERY
6 - 92
ES7142C
Section 6 Schematics
July 2007
Electrical Schematic
Deutz Models (from serial number 40942 to 41065)
Part 2 of 3
REV C
QD4
WH/RD
RD/WH
BL
BK
OR
WH
RD
TS67 FUNCTION
ENABLE
OUTRIGGERS
(STANDARD ON GS-5390)
(OPTION ON GS-3390, GS-4390)
TS54
TS66
ENGINE
START
ENGINE
HIGH IDLE
PLATFORM
UP/DOWN
PLAT
UP
LIMIT
SWITCH
(GS-5390)
PLAT
DOWN
LIMIT
SWITCH
PLATFORM
OVERLOAD
PRESSURE
SWITCH
(OPTION)
N.O.
N.O.
N.O.
N.O.
MODELS WITHOUT
OUTRIGGERS
BN
G8
DIAGNOSTIC
DISPLAY
J2-C1/C10
J2-B10
J2-A6
J3-B5
J3-A6
J2-A10
J2-A8
J4-B3
J3-A2
J3-A1
J2-A2
J2-A7
J4-A4
J2-A1
J3-A5
S5
J3-A4
LS6
LS5
N.C.
J3-B4
N.O.
N.C.
S7 LEVEL
SENSOR
LF
RF
LR
RR
O-RIG
O-RIG
O-RIG
O-RIG
LIMIT
LIMIT
LIMIT
LIMIT
SWITCH SWITCH SWITCH SWITCH
UP
N.C.
LEVEL SENSOR
CIRCUIT BOARD
DOWN
TS52
U5
Y40
S8
J4-B2
Y34
J4-B1
Y36
YL
H5
BL
Y49A
J2-B1
RD
Y29
Y1
J2-B3
J1-B7
J2-B10
J1-B6
J3-B6
J4-C2
J1-A12
J1-B5
J2-B12
J1-B1
J1-A11
J4-B6
J1-B4
J1-A10
J1-A1
J1-A4
Y2
J1-C7, C8
SW3
2 AXIS
TILT LEVEL
SENSOR
BK
SW2
FB1
Y9
Y3
Y49
Y35
Y33
Y39
U5 ECM GROUND
H5 ALARM
Y3 STEER RIGHT
Y2 BRAKE RELEASE
ES7142C
6 - 93
Section 6 Schematics
July 2007
Electrical Schematic
Deutz Models (from serial number 40942 to 41065)
Part 3 of 3
REV C
P2
C
P2
EMERGENCY
STOP
QD3
BK
POWER TO PLATFORM
BK
RD
RD
WH
GROUND
PIO3
BL
PIO4
YL
PIO5
POWER TO GROUND
EMERGENCY
STOP
QD3
PIO2
BK
BK
POWER TO PLATFORM
RD
POWER TO GROUND
WH
GROUND
PIO3
BL
PIO4
YL
PIO5
RD
PIO2
12V DC
OR
R15
PP
5K
POTENTIOMETER
WH/YL
PIN18
PIN15
PLATFORM CONTROLS
MEMBRANE DECAL
POUT2
PP
5K
POTENTIOMETER
POUT3
WH/BL
JOYSTICK
CONTROLLER
WH/YL
SW6 STEER
LEFT/ RIGHT
SW5
PIN14
BK
R15
FUNCTION ENABLE
WH/RD
RIGHT
WH
JC1
BN
LEFT
RIGHT
WH/RD
OR
WH/BK
LEFT
PIN15
PIN14
FUNCTION ENABLE
1
2
3
4
5
6
7
8
WH
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POUT3
POUT4
POUT4
POUT5
POUT5
POUT6
POUT6
POUT8
POUT8
PIN5
PIN5
PIN6
PIN6
PIN10
PIN10
PIN19
HORN BN5
PIN19
PIN23
PIN23
PIN24
GENERATOR BN7
PIN24
RR OUTRIGGER BN24
PIN25
PIN13
PIN29
PIN25
PIN25
PIN29
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
UP
PLATFORM UP/DOWN TS20
YL
PIN3
DOWN
PIN4
POUT1
PIN11
6 - 94
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
SW6 STEER
LEFT/ RIGHT
SW5
WH/BL
JOYSTICK
CONTROLLER
D7
U3
SW25
DIP
SWITCH
JC1
BN
WH/BK
PIN18
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
DIP
SWITCH
1
2
3
4
5
6
7
8
D7
U3
SW25
12V DC
RD
BK
POUT1
H1
ALARM
PIN11
BL
RD
UP
YL
DOWN
RD
BK
H1
ALARM
PLATFORM CONTROLS
PLATFORM CONTROLS
July 2007
Section 6 Schematics
6 - 95
Section 6 Schematics
July 2007
Electrical Schematic
Deutz Models (from serial number 41066 to GS9003-41350)
Part 1 of 3
REV B
P1
EMERGENCY STOP
B
PLATFORM
CONTROL
B
T
GROUND
CONTROL
CB2
20A
CR41
CR42
CONTROL
SYSTEM
(ESTOP 1)
86
85
30
87
POWER
(ESTOP 2)
K5
86
87A
85
30
87
K6
86
87A
85
CR1
CR5
CR8
HORN
IGNITION
30
87
K4
86
87A
85
30
87
CR58
ENGINE
START
K2
86
87A
85
30
87
FWD/REV
K1
86
87A
85
30
87
K3
87A
86
M3
85
86
EDC
AUXILIARY
FUNCTION ENABLE
TS70
85
30
87
30
87
87A
F17
87A
J1-A3
STARTER
J2-A5
STARTING
AID
Y51
FWD
REV
B1
J1-C11,C12
TS69
HIGH IDLE
CR15
J1-A2
J1-B2
CR4
J1-A9
U5
J4-A5
ELECTRONIC CONTROL MODULE
J4-C3
J4-B4
J1-C11,C12
H2
J2-B11
J4-C4
G6
J4-B5
J2-B9
D1
J1-C1-C4
J1-B3
M5
Y4
AUXILIARY
PLATFORM DOWN
15A FUSE
U32
Q8
GLOW
PLUG
(OPTION)
FUEL
SHUT OFF
AUX
PUMP
Q3
M2
HIGH IDLE
SOLENOID
Y7
Y8
Y8 PLATFORM UP
Y4 STEER LEFT
Y7 PLATFORM DOWN
M2 AUXILIARY PUMP
M5 HYDRAULIC PUMP
Y51 FORWARD/REVERSE COIL
G6 ENGINE HOURMETER
D1 ALTERNATOR
K1 STARTER RELAY
M3 STARTER MOTOR
H2 AUTOMOTIVE-STYLE HORN
B1 12 VOLT BATTERY
6 - 96
ES7142D
Section 6 Schematics
July 2007
Electrical Schematic
Deutz Models (from serial number 41066 to GS9003-41350)
Part 2 of 3
REV B
QD4
WH/RD
RD/WH
BL
BK
OR
PLAT
UP
LIMIT
SWITCH
(GS-5390)
ENABLE
TS54
TS66
ENGINE
START
ENGINE
HIGH IDLE
PLATFORM
UP/DOWN
OUTRIGGERS
(STANDARD ON GS-5390)
(OPTION ON GS-3390, GS-4390)
N.C.
LEVEL SENSOR
CIRCUIT BOARD
PLAT
UP
LIMIT
SWITCH
(GS-5390)
PLAT
DOWN
LIMIT
SWITCH
PLATFORM
OVERLOAD
PRESSURE
SWITCH
(OPTION)
N.O.
N.O.
N.O.
N.O.
MODELS WITHOUT
OUTRIGGERS
BN
G8
DIAGNOSTIC
DISPLAY
J2-C1/C10
J2-B10
J2-A6
J3-B5
J3-A6
J2-A10
J2-A8
J4-B3
J3-A2
J3-A1
J2-A2
J2-A7
J4-A4
J2-A1
J3-A5
S5
J3-A4
LS6
LS5
N.C.
J3-B4
N.O.
N.C.
S7 LEVEL
SENSOR
LF
RF
LR
RR
O-RIG
O-RIG
O-RIG
O-RIG
LIMIT
LIMIT
LIMIT
LIMIT
SWITCH SWITCH SWITCH SWITCH
UP
N.C.
DOWN
TS52
U5
S8
J4-B2
Y40
J4-B1
Y34
YL
Y36
BL
H5
J2-B1
RD
Y49A
J2-B3
J1-B7
J2-B10
J1-B6
J3-B6
J4-C2
J1-A12
J1-B5
J2-B12
J1-B1
J1-A11
J4-B6
J1-B4
J1-A10
J1-A1
J1-A4
Y29
Y1
J1-C7, C8
Y2
WH
RD
LS5A
TS67 FUNCTION
SW3
2 AXIS
TILT LEVEL
SENSOR
BK
SW2
FB1
Y9
Y3
Y49
Y35
Y33
Y39
U5 ECM GROUND
H5 ALARM
Y3 STEER RIGHT
Y2 BRAKE RELEASE
ES7142D
6 - 97
Section 6 Schematics
July 2007
Electrical Schematic
Deutz Models (from serial number 41066 to GS9003-41350)
Part 3 of 3
REV B
P2
C
P2
EMERGENCY
STOP
QD3
BK
POWER TO PLATFORM
BK
RD
RD
WH
GROUND
PIO3
BL
PIO4
YL
PIO5
POWER TO GROUND
EMERGENCY
STOP
QD3
PIO2
BK
BK
POWER TO PLATFORM
RD
POWER TO GROUND
WH
GROUND
PIO3
BL
PIO4
YL
PIO5
RD
PIO2
12V DC
OR
R15
PP
5K
POTENTIOMETER
WH/YL
PIN18
PIN15
PLATFORM CONTROLS
MEMBRANE DECAL
POUT2
PP
5K
POTENTIOMETER
POUT3
WH/BL
JOYSTICK
CONTROLLER
WH/YL
SW6 STEER
LEFT/ RIGHT
SW5
PIN14
BK
R15
FUNCTION ENABLE
WH/RD
RIGHT
WH
JC1
BN
LEFT
RIGHT
WH/RD
OR
WH/BK
LEFT
PIN15
PIN14
FUNCTION ENABLE
1
2
3
4
5
6
7
8
WH
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POUT3
POUT4
POUT4
POUT5
POUT5
POUT6
POUT6
POUT8
POUT8
PIN5
PIN5
PIN6
PIN6
PIN10
PIN10
PIN19
HORN BN5
PIN19
PIN23
PIN23
PIN24
GENERATOR BN7
PIN24
RR OUTRIGGER BN24
PIN25
PIN13
PIN29
PIN25
PIN25
PIN29
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
UP
PLATFORM UP/DOWN TS20
YL
PIN3
DOWN
PIN4
POUT1
PIN11
6 - 98
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
SW6 STEER
LEFT/ RIGHT
SW5
WH/BL
JOYSTICK
CONTROLLER
D7
U3
SW25
DIP
SWITCH
JC1
BN
WH/BK
PIN18
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
DIP
SWITCH
1
2
3
4
5
6
7
8
D7
U3
SW25
12V DC
RD
BK
POUT1
H1
ALARM
PIN11
BL
RD
UP
YL
DOWN
RD
BK
H1
ALARM
PLATFORM CONTROLS
PLATFORM CONTROLS
July 2007
Section 6 Schematics
6 - 99
Section 6 Schematics
July 2007
Electrical Schematic
Deutz Models (from serial number GS9003-41351 to 41522)
Part 1 of 3
P1
EMERGENCY STOP
B1
REV B
PLATFORM
CONTROL
3
GROUND
CONTROL
CB2
20A
CR41
CR42
CONTROL
SYSTEM
(ESTOP 1)
86
85
30
87
POWER
(ESTOP 2)
K5
86
87A
85
30
87
K6
86
87A
85
CR1
CR5
CR8
HORN
IGNITION
30
87
K4
86
87A
85
30
87
CR58
ENGINE
START
K2
86
87A
85
30
87
FWD/REV
K1
86
87A
85
30
87
K3
87A
87A
M5
F17
87A
J1-A3
87
J2-A5
85
87
J1-C11,C12
M3
EDC
AUXILIARY
FUNCTION ENABLE
TS70
85
30
J1-A2
86
30
Y51
FWD
REV
STARTER
J2-B11
TS69
HIGH IDLE
CR15
86
J1-A9
J1-B2
CR4
STARTING
AID
J4-C4
U5
J4-A5
ELECTRONIC CONTROL MODULE
J4-C3
J4-B4
J1-C11,C12
B1
J4-B5
G6
H2
J2-B9
D1
J1-C1-C4
J1-B3
Y4
AUXILIARY
PLATFORM DOWN
15A FUSE
U32
Q8
GLOW
PLUG
(OPTION)
FUEL
SHUT OFF
AUX
PUMP
Q3
M2
HIGH IDLE
SOLENOID
Y7
Y8
Y8 PLATFORM UP
Y4 STEER LEFT
Y7 PLATFORM DOWN
M2 AUXILIARY PUMP
M5 HYDRAULIC PUMP
Y51 FORWARD/REVERSE COIL
G6 ENGINE HOURMETER
D1 ALTERNATOR
K1 STARTER RELAY
M3 STARTER MOTOR
H2 AUTOMOTIVE-STYLE HORN
B1 12 VOLT BATTERY
6 - 100
ES7142E
Section 6 Schematics
July 2007
Electrical Schematic
Deutz Models (from serial number GS9003-41351 to 41522)
Part 2 of 3
REV B
QD4
WH/RD
RD/WH
BL
BK
OR
PLAT
UP
LIMIT
SWITCH
(GS-5390)
ENABLE
TS54
TS66
ENGINE
START
ENGINE
HIGH IDLE
PLATFORM
UP/DOWN
OUTRIGGERS
(STANDARD ON GS-5390)
(OPTION ON GS-3390, GS-4390)
N.C.
LEVEL SENSOR
CIRCUIT BOARD
PLAT
UP
LIMIT
SWITCH
(GS-5390)
PLAT
DOWN
LIMIT
SWITCH
PLATFORM
OVERLOAD
PRESSURE
SWITCH
(OPTION)
N.O.
N.O.
N.O.
N.O.
MODELS WITHOUT
OUTRIGGERS
BN
G8
DIAGNOSTIC
DISPLAY
J2-C1/C10
J2-B10
J2-A6
J3-B5
J3-A6
J2-A10
J2-A8
J4-B3
J3-A2
J3-A1
J2-A2
J2-A7
J4-A4
J2-A1
J3-A5
S5
J3-A4
LS6
LS5
N.C.
J3-B4
N.O.
N.C.
S7 LEVEL
SENSOR
LF
RF
LR
RR
O-RIG
O-RIG
O-RIG
O-RIG
LIMIT
LIMIT
LIMIT
LIMIT
SWITCH SWITCH SWITCH SWITCH
UP
N.C.
DOWN
TS52
U5
S8
J4-B2
Y40
J4-B1
Y34
YL
Y36
BL
H5
J2-B1
RD
Y49A
J2-B3
J1-B7
J2-B10
J1-B6
J3-B6
J4-C2
J1-A12
J1-B5
J2-B12
J1-B1
J1-A11
J4-B6
J1-B4
J1-A10
J1-A1
J1-A4
Y29
Y1
J1-C7, C8
Y2
WH
RD
LS5A
TS67 FUNCTION
SW3
2 AXIS
TILT LEVEL
SENSOR
BK
SW2
FB1
Y9
Y3
Y49
Y35
Y33
Y39
U5 ECM GROUND
H5 ALARM
Y3 STEER RIGHT
Y2 BRAKE RELEASE
ES7142E
6 - 101
Section 6 Schematics
July 2007
Electrical Schematic
Deutz Models (from serial number GS9003-41351 to 41522)
Part 3 of 3
REV B
P2
C
P2
EMERGENCY
STOP
QD3
BK
POWER TO PLATFORM
BK
RD
RD
WH
GROUND
PIO3
BL
PIO4
YL
PIO5
POWER TO GROUND
EMERGENCY
STOP
QD3
PIO2
BK
BK
POWER TO PLATFORM
RD
POWER TO GROUND
WH
GROUND
PIO3
BL
PIO4
YL
PIO5
RD
PIO2
12V DC
OR
R15
PP
5K
POTENTIOMETER
WH/YL
PIN18
PIN15
PLATFORM CONTROLS
MEMBRANE DECAL
POUT2
PP
5K
POTENTIOMETER
POUT3
WH/BL
JOYSTICK
CONTROLLER
WH/YL
SW6 STEER
LEFT/ RIGHT
SW5
PIN14
BK
R15
FUNCTION ENABLE
WH/RD
RIGHT
WH
JC1
BN
LEFT
RIGHT
WH/RD
OR
WH/BK
LEFT
PIN15
PIN14
FUNCTION ENABLE
1
2
3
4
5
6
7
8
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
SW6 STEER
LEFT/ RIGHT
SW5
WH/BL
JOYSTICK
CONTROLLER
D7
U3
SW25
DIP
SWITCH
JC1
BN
WH/BK
PIN18
5V DC
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
DIP
SWITCH
1
2
3
4
5
6
7
8
D7
U3
SW25
12V DC
WH
PLATFORM CONTROLS
MEMBRANE DECAL
BK
POUT2
POUT3
POUT4
POUT4
POUT5
POUT5
POUT6
POUT6
POUT8
POUT8
PIN5
PIN5
PIN6
PIN6
PIN10
PIN10
PIN19
HORN BN5
PIN19
PIN23
PIN23
PIN24
GENERATOR BN7
PIN24
RR OUTRIGGER BN24
PIN25
PIN13
PIN29
PIN25
PIN25
PIN29
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
UP
PLATFORM UP/DOWN TS20
YL
PIN3
DOWN
PIN4
POUT1
PIN11
RD
BK
POUT1
H1
ALARM
PIN11
BL
RD
UP
YL
DOWN
RD
BK
H1
ALARM
PLATFORM CONTROLS
PLATFORM CONTROLS
6 - 102
July 2007
Section 6 Schematics
6 - 103
Section 6 Schematics
July 2007
Electrical Schematic
ANSI Models with Deutz Power
(from serial number GS9003-41523 to GS9005-42143)
Part 1 of 3
KS1 KEY SWITCH
REV D
P1
EMERGENCY STOP
B1
PLATFORM
CONTROL
4
B
3
GROUND
CONTROL
CB2 20A
AB7
CR41
CR42
CONTROL
SYSTEM
(ESTOP 1)
POWER
(ESTOP 2)
CR5
CR8
HORN
IGNITION
CR1
CR23
CR84
CR85
ENGINE
START
AUXILIARY
DOWN
OSCILLATE
STOWED
OSCILLATE
RAISED
AB1
86
85
30
87
86
87A
85
86
87A
85
30
87
86
87A
85
30
87
30
87
86
87A
85
86
87A
85
30
87
30
87
86
87A
85
D1
G6
H2
11
86
87A
85
30
87
30
87
11
87A
N.C.H.O.
N.C.H.O.
LS23
LS22
LEFT
OSCILLATE
LIMIT SWITCH
RIGHT
OSCILLATE
LIMIT SWITCH
AB15
CR4
HIGH IDLE
CR15
B1
STARTER
CD2
STARTING
AID
86
M3
85
86
85
30
87
CD3
30
87
CD4
Y54
87A
CD5
Y56
F17
87A
15A FUSE
U32
Q8
GLOW
PLUG
(OPTION)
FUEL
SHUT OFF
Q3
AUX
PUMP
M2
HIGH IDLE
SOLENOID
Y57
Y55
Y55 OSC ENABLE
G6 ENGINE HOURMETER
M2 AUXILIARY PUMP
D1 ALTERNATOR
K1 STARTER RELAY
M3 STARTER MOTOR
H2 AUTOMOTIVE-STYLE HORN
B1 12 VOLT BATTERY
OSCILLATING AXLE
(OPTION)
(AVAILABLE AFTER SERIAL NUMBER 41618)
6 - 104
ES7164C
Section 6 Schematics
July 2007
Electrical Schematic
ANSI Models with Deutz Power
(from serial number GS9003-41523 to GS9005-42143)
Part 2 of 3
REV D
AB1
AB3
AB3
OIL COOLER
(GS-5390)
(OPTION)
PLAT
DOWN
LIMIT
SWITCH
CB7
20A
86
AB4
LS6
30
85
LS5
WH
SW4
HYDRAULIC
OIL TEMP
N.C.
AB1
J2-C12
CD13
N.C.
PLAT
UP
LIMIT
SWITCH
RD
LS5A
87
87A
CR17
N.C.
LEVEL SENSOR
CIRCUIT BOARD
HYDRAULIC
OIL COOLER
N.C.
PLAT
UP
LIMIT
SWITCH
FAN
S7 LEVEL
SENSOR
M1
FAN MOTOR
MODELS WITHOUT
OUTRIGGERS
AB2
BK
J2-B10
J2-A6
J2-B2
J2-A3
J2-A5
J2-C12
J2-A1
J2-A2
J2-B11
J2-B8
J2-B7
J2-A4
J2-C5
J2-C6
J2-C1/C3
U5
BN23
BN91
AUXILIARY DOWN
J1-B3
J1-B2
J1-C8
J1-A12
J1-A11
J1-B4
J1-A4
J1-A10
J1-A1
J1-A2
J1-C9
J1-A9
J1-A3
J1-C7
J2-C4
J2-C10
J2-B9
AB12
Y4
Y9
Y1
Y49A
FWD
REV
AB9
Y51
EDC
M5
SW3
Y7
Y8
Y2
Y49
SW2
M5 HYDRAULIC PUMP
Y51 FORWARD/REVERSE COIL
S7 LEVEL SENSOR
Y2 BRAKE RELEASE
Y3 STEER RIGHT
Y4 STEER LEFT
Y7 PLATFORM DOWN
Y8 PLATFORM UP
Y3
ES7164C
6 - 105
Section 6 Schematics
July 2007
Electrical Schematic
ANSI Models with Deutz Power
(from serial number GS9003-41523 to GS9005-42143)
Part 3 of 3
REV D
P2
QD3
QD4
WH/RD
BK
POWER TO PLATFORM
POWER TO GROUND
EMERGENCY
STOP
BK
RD
RD/WH
RD
BL
WH
GROUND
WH
BK
BL
BL
OR
OR
OR
J5 PIN1
J5 PIN4
J5 PIN5
OUTRIGGERS
(STANDARD ON GS-5390)
(OPTION ON GS-3390, GS-4390)
J5 PIN2
CD11
CD11
CD12
D7
U3
CD12
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
WH
JC1
JOYSTICK
CONTROLLER
BN
J2 PIN13
BL
PP
J2 PIN4
J5 PIN3
GY
SW5
OR
FUNCTION ENABLE
BK
J2 PIN6
RIGHT
J2 PIN5
LEFT
BK
YL
BL
RD
ROLL
N.O.
GROUND
N.O.
HALL EFFECT
GENERATOR
YL
J2 PIN3
PITCH
N.O.
J2 PIN2
J2 PIN12
POWER
N.O.
S8
5V DC
GY
J2 PIN1
2 AXIS
TILT LEVEL
SENSOR
12V DC
SW6
STEER
LEFT/ RIGHT
RD
J2 PIN7
J2 PIN8
J2-A12
J2-A11
J2-A10
J2-B2
J2-B3
J2-B1
J2-B10
J1-C4
J1-C6
J1-C3
J1-C5
J2 PIN14
POUT1
PIN5
PIN6
GENERATOR BN7
PIN7
PIN8
PIN9
PIN10
PIN11
PIN12
J2-C7
PIN4
J2-C11
HORN BN5
PIN3
J1-B1
PIN2
J2-B12
J1-B7
J1-B6
J1-B10
J1-B11
J1-B9
J1-B5
U5
ELECTRONIC CONTROL MODULE
CD1
Y36
Y34
Y35
Y29
Y40
Y33
H5 FB1
Y39
WH/BL
ECM GROUND
H5 ALARM
PIN13
PIN14
PIN15
J1 PIN4
J1 PIN3
J1 PIN1
J1 PIN5
J3 PIN1
6 - 106
J3 PIN2
ES7164C
YL
PLATFORM UP/DOWN TS20
-ORPLATFORM & OUTRIGGER
UP/DOWN
Ts21
BL
RD
BK
RD
BK
H1
ALARM
PLATFORM
CONTROLS
Part No. 72863
July 2007
Section 6 Schematics
6 - 107
Section 6 Schematics
July 2007
Electrical Schematic
ANSI Models with Deutz Power
(from serial number GS9005-42144 to GS9005-42685)
Part 1 of 3
F9 5A FUSE
KS1 KEY SWITCH
REV C
P1EMERGENCY STOP
B1
PLATFORM
CONTROL
4
B
3
GROUND
CONTROL
CB2 20A
AB7
CR41
CR42
CONTROL
SYSTEM
(ESTOP 1)
POWER
(ESTOP 2)
CR5
CR8
HORN
IGNITION
CR1
CR23
CR84
CR85
ENGINE
START
AUXILIARY
DOWN
OSCILLATE
STOWED
OSCILLATE
RAISED
AB1
86
85
30
87
86
87A
85
86
87A
85
30
87
86
87A
85
30
87
30
87
86
87A
85
30
87
86
87A
85
30
87
86
87A
85
D1
G6
H2
11
86
87A
85
30
87
30
87
12
87A
N.C.H.O.
N.C.H.O.
LS23
LS22
LEFT
OSCILLATE
LIMIT SWITCH
RIGHT
OSCILLATE
LIMIT SWITCH
AB15
30
CR4
50
HIGH IDLE
45
CR15
B1
STARTING
AID
STARTER
86
M3
85
CD2
86
85
30
87
CD3
30
87
CD4
Y54
87A
CD5
Y56
F17
87A
15A FUSE
U32
Q8
GLOW
PLUG
(OPTION)
FUEL
SHUT OFF
Q3
AUX
PUMP
M2
HIGH IDLE
SOLENOID
Y57
Y55
Y55 OSC ENABLE
G6 ENGINE HOURMETER
M2 AUXILIARY PUMP
D1 ALTERNATOR
K1 STARTER RELAY
M3 STARTER MOTOR
H2 AUTOMOTIVE-STYLE HORN
B1 12 VOLT BATTERY
OSCILLATING AXLE
(OPTION)
6 - 108
ES7164G
Section 6 Schematics
July 2007
Electrical Schematic
ANSI Models with Deutz Power
(from serial number GS9005-42144 to GS9005-42685)
Part 2 of 3
REV C
AB1
AB3
AB3
OIL COOLER
(GS-5390)
(OPTION)
PLAT
DOWN
LIMIT
SWITCH
CB7
20A
86
AB4
LS6
30
85
LS5
WH
SW4
HYDRAULIC
OIL TEMP
N.C.
AB1
J2-C12
CD13
N.C.
PLAT
UP
LIMIT
SWITCH
RD
LS5A
87
87A
CR17
HYDRAULIC
OIL COOLER
N.C.
LEVEL SENSOR
CIRCUIT BOARD
N.C.
PLAT
UP
LIMIT
SWITCH
FAN
M1
FAN MOTOR
BATTERY 12V (-)
AB2
S7 LEVEL
SENSOR
MODELS WITHOUT
OUTRIGGERS
BK
J2-B10
J2-A6
J2-B2
J2-A3
J2-A5
J2-C12
J2-A1
J2-A2
J2-B11
J2-B8
J2-B7
J2-A4
J2-C5
J2-C6
J2-C1/C3
U5
BN23
BN91
AUXILIARY DOWN
J1-B3
J1-B2
J1-C8
J1-B4
J1-A4
J1-A10
J1-A1
J1-A2
J1-C9
J1-A9
J1-A3
J1-C7
J2-C4
J2-C10
J2-B9
AB12
Y4
Y9
Y1
FWD
REV
AB9
Y51
EDC
M5
SW3
Y7
Y8
Y3
SW2
Y2
M5 HYDRAULIC PUMP
Y51 FORWARD/REVERSE COIL
S7 LEVEL SENSOR
Y2 BRAKE RELEASE
Y3 STEER RIGHT
Y4 STEER LEFT
Y7 PLATFORM DOWN
Y8 PLATFORM UP
ES7164G
6 - 109
Section 6 Schematics
July 2007
Electrical Schematic
ANSI Models with Deutz Power
(from serial number GS9005-42144 to GS9005-42685)
Part 3 of 3
REV C
P2
QD3
QD4
WH/RD
BK
POWER TO PLATFORM
POWER TO GROUND
EMERGENCY
STOP
BK
RD
RD/WH
RD
BL
WH
GROUND
WH
BK
BL
BL
OR
OR
OR
J5 PIN1
J5 PIN4
J5 PIN5
OUTRIGGERS
(STANDARD ON GS-5390)
(OPTION ON GS-3390, GS-4390)
J5 PIN2
CD11
CD11
CD12
D7
U3
CD12
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
WH
JC1
JOYSTICK
CONTROLLER
BN
J2 PIN13
BL
PP
J2 PIN4
J5 PIN3
GY
SW5
OR
FUNCTION ENABLE
BK
J2 PIN6
RIGHT
J2 PIN5
LEFT
BK
YL
BL
RD
ROLL
N.O.
GROUND
N.O.
HALL EFFECT
GENERATOR
YL
J2 PIN3
PITCH
N.O.
J2 PIN2
J2 PIN12
POWER
N.O.
S8
5V DC
GY
J2 PIN1
2 AXIS
TILT LEVEL
SENSOR
12V DC
SW6
STEER
LEFT/ RIGHT
RD
J2 PIN7
J2 PIN8
J2-A12
J2-A11
J2-A10
J2-B2
J2-B3
J2-B1
J2-B10
J1-C4
J1-C6
J1-C3
J1-C5
J2 PIN14
POUT1
PIN5
PIN6
GENERATOR BN7
PIN7
PIN8
PIN9
PIN10
PIN11
PIN12
J2-C7
PIN4
J2-C11
HORN BN5
PIN3
J1-B1
PIN2
J2-B12
J1-B7
J1-B6
J1-B10
J1-B11
J1-B9
J1-B5
U5
ELECTRONIC CONTROL MODULE
CD1
Y36
Y34
Y35
Y29
Y40
Y33
H5 FB1
Y39
WH/BL
ECM GROUND
H5 ALARM
PIN13
PIN14
PIN15
J1 PIN4
J1 PIN3
J1 PIN1
J1 PIN5
J3 PIN1
6 - 110
J3 PIN2
ES7164G
YL
PLATFORM UP/DOWN TS20
-ORPLATFORM & OUTRIGGER
UP/DOWN
Ts21
BL
RD
BK
RD
BK
H1
ALARM
PLATFORM
CONTROLS
Part No. 72863
July 2007
Section 6 Schematics
6 - 111
Section 6 Schematics
July 2007
Electrical Schematic
CE Models with Deutz Power
(from serial number GS9003-41523 to GS9005-42143)
Part 1 of 3
KS1 KEY SWITCH
REV D
P1
EMERGENCY STOP
B1
PLATFORM
CONTROL
3
GROUND
CONTROL
CB2 20A
AB7
PS2
PLATFORM
OVERLOAD
PRESSURE
SWITCH
CR41
CR42
CONTROL
SYSTEM
(ESTOP 1)
POWER
(ESTOP 2)
CR5
CR8
HORN
IGNITION
CR1
CR23
CR84
CR85
ENGINE
START
AUXILIARY
DOWN
OSCILLATE
STOWED
OSCILLATE
RAISED
AB1
86
85
30
87
86
87A
85
86
87A
85
30
87
86
87A
85
30
87
30
87
86
87A
85
30
87
86
87A
85
30
87
86
87A
85
D1
G6
H2
11
86
87A
85
30
87
30
87
12
87A
N.C.H.O.
N.C.H.O.
LS23
LS22
LEFT
OSCILLATE
LIMIT SWITCH
RIGHT
OSCILLATE
LIMIT SWITCH
AB15
CR4
HIGH IDLE
CR15
B1
STARTER
CD2
STARTING
AID
86
M3
85
86
85
30
87
CD3
30
87
CD4
Y54
87A
CD5
Y56
F17
87A
15A FUSE
U32
Q8
GLOW
PLUG
(OPTION)
FUEL
SHUT OFF
Q3
AUX
PUMP
M2
HIGH IDLE
SOLENOID
Y57
Y55
Y55 OSC ENABLE
G6 ENGINE HOURMETER
M2 AUXILIARY PUMP
D1 ALTERNATOR
K1 STARTER RELAY
M3 STARTER MOTOR
H2 AUTOMOTIVE-STYLE HORN
B1 12 VOLT BATTERY
OSCILLATING AXLE
(OPTION)
(AVAILABLE AFTER SERIAL NUMBER 41618)
6 - 112
ES7175A
Section 6 Schematics
July 2007
Electrical Schematic
CE Models with Deutz Power
(from serial number GS9003-41523 to GS9005-42143)
Part 2 of 3
REV D
(GS-5390 ONLY)
CD6
AB3
LS12A
(OPTION)
CD10
BK
J2-B10
J2-A6
J2-B2
J2-A3
J2-A5
J2-C12
J2-A1
J2-A2
J1-C2
J2-B11
J2-B8
J2-B7
J2-A4
J2-C5
J2-C6
J2-C1/C3
U5
BN91
J1-A9
J1-A3
J1-B3
J1-B2
J1-C8
J1-A12
J1-A11
J1-B4
J1-A4
J1-A10
J1-A1
J1-A2
J1-C9
N.C.
87A
86
85
30
87
10
87A
LS24
MAX
HEIGHT
LIMIT
SWITCH
DOWN
ENABLE
86
85
30
87
87A
LS25
LOAD
SENSE
DELAY
LIMIT
SWITCH
Y4
Y9
Y1
Y49A
FWD
87
REV
85
(GS-5390 ONLY)
LIFT
ENABLE
N.C.
MODELS WITHOUT
OUTRIGGERS
CR77
LIFT
ENABLE
CR82A
S7 LEVEL
SENSOR
M1
BATTERY 12V (-)
AB5
AB12
87A
N.C.
LEVEL SENSOR
CIRCUIT BOARD
HYDRAULIC
OIL COOLER
FAN MOTOR
AB13
30
87
FAN
AB9
86
CR17
LS5
PLAT
UP
LIMIT
SWITCH
CD10
CR82
30
85
LOWER
RR O-RIG
LIMIT SWITCH
AUXILIARY DOWN
20A
86
CD9
N.C.
BN23
J1-C7
J2-C4
J2-C10
J2-B9
CB7
HYDRAULIC
OIL TEMP
N.C.
LS15A
AB2
SW4
WH
PLAT
DOWN
LIMIT
SWITCH
LS5A
PLAT
UP
LIMIT
N.C. SWITCH
LOWER
LR O-RIG
LIMIT SWITCH
RD
AB1
CD13
CD8
LS14A
J2-C12
N.C.
N.C.
LOWER
RF O-RIG
LIMIT SWITCH
LS6
OIL COOLER
CD7
LS13A
N.C.
AB3
N.C.
LOWER
LF O-RIG
LIMIT SWITCH
Y51
EDC
A10
AB14
B10
IF GS-5390,
B10 BECOMES AB11
AB8
NOT USED
ON GS-5390
Y8
M5
Y7
C5
SW3
Y3
4700 uF
Y49
SW2
M5 HYDRAULIC PUMP
Y51 FORWARD/REVERSE COIL
S7 LEVEL SENSOR
Y2 BRAKE RELEASE
Y3 STEER RIGHT
Y4 STEER LEFT
Y7 PLATFORM DOWN
Y8 PLATFORM UP
Y2
ES7175A
6 - 113
Section 6 Schematics
July 2007
Electrical Schematic
CE Models with Deutz Power
(from serial number GS9003-41523 to GS9005-42143)
Part 3 of 3
REV D
P2
QD3
QD4
WH/RD
BK
POWER TO PLATFORM
POWER TO GROUND
EMERGENCY
STOP
BK
RD
RD/WH
RD
BL
WH
GROUND
WH
BK
BL
BL
OR
OR
OR
J5 PIN1
J5 PIN4
J5 PIN5
OUTRIGGERS
(STANDARD ON GS-5390)
(OPTION ON GS-3390, GS-4390)
J5 PIN2
CD11
CD11
CD12
D7
U3
CD12
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
WH
JC1
JOYSTICK
CONTROLLER
BN
J2 PIN13
BL
PP
J2 PIN4
J5 PIN3
GY
SW5
OR
FUNCTION ENABLE
BK
J2 PIN6
RIGHT
J2 PIN5
LEFT
BK
YL
BL
RD
ROLL
N.O.
GROUND
N.O.
HALL EFFECT
GENERATOR
YL
J2 PIN3
PITCH
N.O.
J2 PIN2
J2 PIN12
POWER
N.O.
S8
5V DC
GY
J2 PIN1
2 AXIS
TILT LEVEL
SENSOR
12V DC
SW6
STEER
LEFT/ RIGHT
RD
J2 PIN7
J2 PIN8
J2-A12
J2-A11
J2-A10
J2-B2
J2-B3
J2-B1
J2-B10
J1-C4
J1-C6
J1-C3
J1-C5
J2 PIN14
POUT1
PIN5
PIN6
GENERATOR BN7
PIN7
PIN8
PIN9
PIN10
PIN11
PIN12
J2-C7
PIN4
J2-C11
HORN BN5
PIN3
J1-B1
PIN2
J2-B12
J1-B7
J1-B6
J1-B10
J1-B11
J1-B9
J1-B5
U5
ELECTRONIC CONTROL MODULE
CD1
Y36
Y34
Y35
Y29
Y40
Y33
H5 FB1
Y39
WH/BL
ECM GROUND
H5 ALARM
PIN13
PIN14
PIN15
J1 PIN4
J1 PIN3
J1 PIN1
J1 PIN5
J3 PIN1
6 - 114
J3 PIN2
ES7175A
YL
PLATFORM UP/DOWN TS20
-ORPLATFORM & OUTRIGGER
UP/DOWN
Ts21
BL
RD
BK
RD
BK
H1
ALARM
PLATFORM
CONTROLS
Part No. 72863
July 2007
Section 6 Schematics
6 - 115
Section 6 Schematics
July 2007
Electrical Schematic
CE Models with Deutz Power
(from serial number GS9005-42144 to GS9005-42411)
Part 1 of 3
F9 5A FUSE
KS1 KEY SWITCH
REV C
P1EMERGENCY STOP
B1
PLATFORM
CONTROL
3
GROUND
CONTROL
CB2 20A
AB7
PS2
PLATFORM
OVERLOAD
PRESSURE
SWITCH
CR41
CR42
CONTROL
SYSTEM
(ESTOP 1)
POWER
(ESTOP 2)
CR5
CR8
HORN
IGNITION
CR1
CR23
CR84
CR85
ENGINE
START
AUXILIARY
DOWN
OSCILLATE
STOWED
OSCILLATE
RAISED
AB1
86
85
30
87
86
87A
85
86
87A
85
30
87
86
87A
85
30
87
30
87
86
87A
85
30
87
86
87A
85
30
87
86
87A
85
D1
G6
H2
11
86
87A
85
30
87
30
87
12
87A
N.C.H.O.
N.C.H.O.
LS23
LS22
LEFT
OSCILLATE
LIMIT SWITCH
RIGHT
OSCILLATE
LIMIT SWITCH
AB15
30
CR4
50
HIGH IDLE
45
CR15
B1
STARTING
AID
STARTER
86
M3
85
CD2
86
85
30
87
CD3
30
87
CD4
Y54
87A
CD5
Y56
F17
87A
15A FUSE
U32
Q8
GLOW
PLUG
(OPTION)
FUEL
SHUT OFF
Q3
AUX
PUMP
M2
HIGH IDLE
SOLENOID
Y57
Y55
Y55 OSC ENABLE
G6 ENGINE HOURMETER
M2 AUXILIARY PUMP
D1 ALTERNATOR
K1 STARTER RELAY
M3 STARTER MOTOR
H2 AUTOMOTIVE-STYLE HORN
B1 12 VOLT BATTERY
OSCILLATING AXLE
(OPTION)
6 - 116
ES7175F
Section 6 Schematics
July 2007
Electrical Schematic
CE Models with Deutz Power
(from serial number GS9005-42144 to GS9005-42411)
Part 2 of 3
REV C
(GS-5390 ONLY)
CD6
AB3
LS12A
(OPTION)
CD10
S7 LEVEL
SENSOR
MODELS WITHOUT
OUTRIGGERS
BK
J2-B10
J2-A6
J2-B2
J2-A3
J2-A5
J2-C12
J2-A1
J2-A2
J1-C2
J2-B11
J2-B8
J2-B7
J2-A4
J2-C5
J2-C6
J2-C1/C3
U5
BN91
J1-A9
J1-A3
J1-B3
J1-B2
J1-C8
J1-B4
J1-A4
J1-A10
J1-A1
J1-A2
J1-C9
N.C.
87A
86
85
30
87
10
87A
LS24
MAX
HEIGHT
LIMIT
SWITCH
DOWN
ENABLE
86
85
30
87
87A
LS25
LOAD
SENSE
DELAY
LIMIT
SWITCH
Y4
Y9
Y1
FWD
87
REV
85
(GS-5390 ONLY)
LIFT
ENABLE
N.C.
N.C.
LEVEL SENSOR
CIRCUIT BOARD
CR77
LIFT
ENABLE
CR82A
M1
BATTERY 12V (-)
AB5
AB12
87A
HYDRAULIC
OIL COOLER
FAN MOTOR
AB13
30
87
FAN
AB9
86
CR17
LS5
PLAT
UP
LIMIT
SWITCH
CD10
CR82
30
85
LOWER
RR O-RIG
LIMIT SWITCH
AUXILIARY DOWN
20A
86
CD9
N.C.
BN23
J1-C7
J2-C4
J2-C10
J2-B9
CB7
HYDRAULIC
OIL TEMP
N.C.
LS15A
AB2
SW4
WH
PLAT
DOWN
LIMIT
SWITCH
LS5A
PLAT
UP
LIMIT
N.C. SWITCH
LOWER
LR O-RIG
LIMIT SWITCH
RD
AB1
CD13
CD8
LS14A
J2-C12
N.C.
N.C.
LOWER
RF O-RIG
LIMIT SWITCH
LS6
OIL COOLER
CD7
LS13A
N.C.
AB3
N.C.
LOWER
LF O-RIG
LIMIT SWITCH
Y51
EDC
A10
AB14
B10
IF GS-5390,
B10 BECOMES AB11
AB8
NOT USED
ON GS-5390
Y8
M5
Y7
C5
SW3
Y3
4700 uF
SW2
Y2
M5 HYDRAULIC PUMP
Y51 FORWARD/REVERSE COIL
S7 LEVEL SENSOR
Y2 BRAKE RELEASE
Y3 STEER RIGHT
Y4 STEER LEFT
Y7 PLATFORM DOWN
Y8 PLATFORM UP
ES7175F
6 - 117
Section 6 Schematics
July 2007
Electrical Schematic
CE Models with Deutz Power
(from serial number GS9005-42144 to GS9005-42411)
Part 3 of 3
REV C
P2
QD3
QD4
WH/RD
BK
POWER TO PLATFORM
POWER TO GROUND
EMERGENCY
STOP
BK
RD
RD/WH
RD
BL
WH
GROUND
WH
BK
BL
BL
OR
OR
OR
J5 PIN1
J5 PIN4
J5 PIN5
OUTRIGGERS
(STANDARD ON GS-5390)
(OPTION ON GS-3390, GS-4390)
J5 PIN2
CD11
CD11
CD12
D7
U3
CD12
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
WH
JC1
JOYSTICK
CONTROLLER
BN
J2 PIN13
BL
PP
J2 PIN4
J5 PIN3
GY
SW5
OR
FUNCTION ENABLE
BK
J2 PIN6
RIGHT
J2 PIN5
LEFT
BK
YL
BL
RD
ROLL
N.O.
GROUND
N.O.
HALL EFFECT
GENERATOR
YL
J2 PIN3
PITCH
N.O.
J2 PIN2
J2 PIN12
POWER
N.O.
S8
5V DC
GY
J2 PIN1
2 AXIS
TILT LEVEL
SENSOR
12V DC
SW6
STEER
LEFT/ RIGHT
RD
J2 PIN7
J2 PIN8
J2-A12
J2-A11
J2-A10
J2-B2
J2-B3
J2-B1
J2-B10
J1-C4
J1-C6
J1-C3
J1-C5
J2 PIN14
POUT1
PIN5
PIN6
GENERATOR BN7
PIN7
PIN8
PIN9
PIN10
PIN11
PIN12
J2-C7
PIN4
J2-C11
HORN BN5
PIN3
J1-B1
PIN2
J2-B12
J1-B7
J1-B6
J1-B10
J1-B11
J1-B9
J1-B5
U5
ELECTRONIC CONTROL MODULE
CD1
Y36
Y34
Y35
Y29
Y40
Y33
H5 FB1
Y39
WH/BL
ECM GROUND
H5 ALARM
PIN13
PIN14
PIN15
J1 PIN4
J1 PIN3
J1 PIN1
J1 PIN5
J3 PIN1
6 - 118
J3 PIN2
ES7175F
YL
PLATFORM UP/DOWN TS20
-ORPLATFORM & OUTRIGGER
UP/DOWN
Ts21
BL
RD
BK
RD
BK
H1
ALARM
PLATFORM
CONTROLS
Part No. 72863
July 2007
Section 6 Schematics
6 - 119
Section 6 Schematics
July 2007
Electrical Schematic
CE Models with Deutz Power
(from serial number GS9005-42412 to GS9005-42685)
Part 1 of 3
F9 5A FUSE
KS1 KEY SWITCH
REV B
P1EMERGENCY STOP
B1
AB7
PLATFORM
CONTROL
R25
LS26
5 OHM
DUAL PW
(GS-5390 ONLY)
GROUND
CONTROL
CR41
CR42
CONTROL
SYSTEM
(ESTOP 1)
POWER
(ESTOP 2)
CR5
CR8
HORN
IGNITION
CR1
CR23
CR84
CR85
ENGINE
START
AUXILIARY
DOWN
OSCILLATE
STOWED
OSCILLATE
RAISED
AB1
86
85
30
87
86
87A
85
86
87A
85
30
87
86
87A
85
30
87
30
87
86
87A
85
30
87
86
87A
85
30
87
86
87A
85
11
86
87A
85
30
87
30
87
12
87A
CB2
20A
D1
G6
H2
N.C.H.O.
N.C.H.O.
LS23
LS22
LEFT
OSCILLATE
LIMIT SWITCH
RIGHT
OSCILLATE
LIMIT SWITCH
AB15
30
CR4
50
HIGH IDLE
45
CR15
B1
STARTING
AID
STARTER
86
M3
85
CD2
86
85
30
87
CD3
30
87
CD4
Y54
87A
CD5
Y56
F17
87A
15A FUSE
U32
Q8
GLOW
PLUG
(OPTION)
FUEL
SHUT OFF
Q3
AUX
PUMP
M2
HIGH IDLE
SOLENOID
Y57
Y55
Y55 OSC ENABLE
G6 ENGINE HOURMETER
M2 AUXILIARY PUMP
D1 ALTERNATOR
K1 STARTER RELAY
M3 STARTER MOTOR
H2 AUTOMOTIVE-STYLE HORN
B1 12 VOLT BATTERY
OSCILLATING AXLE
(OPTION)
6 - 120
ES7175K
Section 6 Schematics
July 2007
Electrical Schematic
CE Models with Deutz Power
(from serial number GS9005-42412 to GS9005-42685)
Part 2 of 3
REV B
(GS-5390 ONLY)
CD6
AB3
LS12A
(OPTION)
CD10
S7 LEVEL
SENSOR
MODELS WITHOUT
OUTRIGGERS
BK
J2-B10
J2-A6
J2-B2
J2-A3
J2-A5
J2-C12
J2-A1
J2-A2
J1-C2
J2-B11
J2-B8
J2-B7
J2-A4
J2-C5
J2-C6
J2-C1/C3
U5
BN91
J1-A9
J1-A3
J1-B3
J1-B2
J1-C8
J1-B4
J1-A4
J1-A10
J1-A1
J1-A2
J1-C9
N.C.
87A
86
85
30
87
10
87A
LS24
MAX
HEIGHT
LIMIT
SWITCH
DOWN
ENABLE
86
85
30
87
87A
LS25
LOAD
SENSE
DELAY
LIMIT
SWITCH
Y4
Y9
Y1
FWD
87
REV
85
(GS-5390 ONLY)
LIFT
ENABLE
N.C.
N.C.
LEVEL SENSOR
CIRCUIT BOARD
CR77
LIFT
ENABLE
CR82A
M1
BATTERY 12V (-)
AB5
AB12
87A
HYDRAULIC
OIL COOLER
FAN MOTOR
AB13
30
87
FAN
AB9
86
CR17
LS5
PLAT
UP
LIMIT
SWITCH
CD10
CR82
30
85
LOWER
RR O-RIG
LIMIT SWITCH
AUXILIARY DOWN
20A
86
CD9
N.C.
BN23
J1-C7
J2-C4
J2-C10
J2-B9
CB7
HYDRAULIC
OIL TEMP
N.C.
LS15A
AB2
SW4
WH
PLAT
DOWN
LIMIT
SWITCH
LS5A
PLAT
UP
LIMIT
N.C. SWITCH
LOWER
LR O-RIG
LIMIT SWITCH
RD
AB1
CD13
CD8
LS14A
J2-C12
N.C.
N.C.
LOWER
RF O-RIG
LIMIT SWITCH
LS6
OIL COOLER
CD7
LS13A
N.C.
AB3
N.C.
LOWER
LF O-RIG
LIMIT SWITCH
Y51
EDC
A10
AB14
B10
IF GS-5390,
B10 BECOMES AB11
AB8
NOT USED
ON GS-5390
Y8
M5
Y7
C5
SW3
Y3
4700 uF
SW2
Y2
M5 HYDRAULIC PUMP
Y51 FORWARD/REVERSE COIL
S7 LEVEL SENSOR
Y2 BRAKE RELEASE
Y3 STEER RIGHT
Y4 STEER LEFT
Y7 PLATFORM DOWN
Y8 PLATFORM UP
ES7175K
6 - 121
Section 6 Schematics
July 2007
Electrical Schematic
CE Models with Deutz Power
(from serial number GS9005-42412 to GS9005-42685)
Part 3 of 3
REV B
P2
QD3
QD4
WH/RD
BK
POWER TO PLATFORM
POWER TO GROUND
EMERGENCY
STOP
BK
RD
RD/WH
RD
BL
WH
GROUND
WH
BK
BL
BL
OR
OR
OR
J5 PIN1
J5 PIN4
J5 PIN5
OUTRIGGERS
(STANDARD ON GS-5390)
(OPTION ON GS-3390, GS-4390)
J5 PIN2
CD11
CD11
CD12
D7
U3
CD12
VOLTAGE
REGULATOR
PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
WH
JC1
JOYSTICK
CONTROLLER
BN
J2 PIN13
BL
PP
J2 PIN4
J5 PIN3
GY
SW5
OR
FUNCTION ENABLE
BK
J2 PIN6
RIGHT
J2 PIN5
LEFT
BK
YL
BL
RD
ROLL
N.O.
GROUND
N.O.
HALL EFFECT
GENERATOR
YL
J2 PIN3
PITCH
N.O.
J2 PIN2
J2 PIN12
POWER
N.O.
S8
5V DC
GY
J2 PIN1
2 AXIS
TILT LEVEL
SENSOR
12V DC
SW6
STEER
LEFT/ RIGHT
RD
J2 PIN7
J2 PIN8
J2-A12
J2-A11
J2-A10
J2-B2
J2-B3
J2-B1
J2-B10
J1-C4
J1-C6
J1-C3
J1-C5
J2 PIN14
POUT1
PIN5
PIN6
GENERATOR BN7
PIN7
PIN8
PIN9
PIN10
PIN11
PIN12
J2-C7
PIN4
J2-C11
HORN BN5
PIN3
J1-B1
PIN2
J2-B12
J1-B7
J1-B6
J1-B10
J1-B11
J1-B9
J1-B5
U5
ELECTRONIC CONTROL MODULE
CD1
Y36
Y34
Y35
Y29
Y40
Y33
H5 FB1
Y39
WH/BL
ECM GROUND
H5 ALARM
PIN13
PIN14
PIN15
J1 PIN4
J1 PIN3
J1 PIN1
J1 PIN5
J3 PIN1
6 - 122
J3 PIN2
ES7175K
YL
PLATFORM UP/DOWN TS20
-ORPLATFORM & OUTRIGGER
UP/DOWN
Ts21
BL
RD
BK
RD
BK
H1
ALARM
PLATFORM
CONTROLS
Part No. 72863
July 2007
Section 6 Schematics
6 - 123
Section 6 Schematics
July 2007
HYDRAULIC COMPONENT
LEGEND
Item
BA
BB
BC
BD
BE
BF
BG
BH
BI
BJ
BK
BL
BM
BN
BO
BP
BQ
6 - 124
Function
High speed bypass
High speed bypass
Balances fluid flow from flow
divider/combiner BO to non-steer end
drive motors
Balances fluid flow from flow
divider/combiner BP to steer end drive
motors
Charge pressure circuit that gets hot
oil out of low pressure side of drive
pump and allows low pressure flow
path for brake release and 2-motor
shift
Testing P1 pressure port
Testing P2 pressure port
Charge pressure circuit
Brake release circuit
2-speed motor shift circuit
Brake release circuit
2-speed motor shift circuit
2-speed motor shift circuit
Balances fluid flow from flow
divider/combiner valve BM to flow
divider/combiner valves BO and BP
Controls flow to non-steer end drive
motors in forward and reverse
Controls flow to steer end drive
motors in forward and reverse
Controls fluid flow to flow
divider/combiner valves BO and BP in
forward and reverse
HYDRAULIC COMPONENT
LEGEND
Item
Function
CA
CB
CC
CD
DA
DB
DC
DD
DE
DF
DG
Oscillate on
Oscillate system relief valve
Oscillate float relief valve
Flow regulator
Right oscillate cylinder
Left oscillate cylinder
Oscillate float
EA
EB
EC
ED
EE
EF
EG
EH
EI
EJ
EK
EL
EM
EN
Section 6 Schematics
July 2007
Brake
Relief valve
Filter
Check valve
Priority flow regulator
Fixed displacement
pump
Hot oil
shuttle valve
Accumulator
Y9
Bi-directional
variable speed motor
Orifice
M
Variable speed motor
Proportional
solenoid valve
Y8
Counterbalance
valve
Flow regulator
valve
50%
Y27
Y4
Solenoid operated
2 position 2 way valve,
normally closed with
manual over-ride
Y2
Y3
Solenoid operated
3 position 4 way
directional valve
Y49A
50%
Flow
divider/combiner
valve
Solenoid operated
3 position 4 way
directional valve
Solenoid operated
2 position 3 way
directional valve
Solenoid operated
2 position 2 way
directional valve
6 - 125
Section 6 Schematics
July 2007
Hydraulic Schematic
(before serial number 40519)
Part 1 of 2
REV F
RIGHT
FRONT
BF
TP1
RIGHT
REAR
M1B
M1A
Y1
Y2
2.5 gpm
9.5 L/min
0.045 in
1.1 mm BL
P1
0.035 in
0.9 mm
0.045 in BM
1.1 mm
M3B
M3A
BI
BJ
BN
BP
BK
BO
50%
50%
BQ
50%
50%
50%
50%
BH
BC 2 gpm
1.5 gpm
BD
5.7 L/min
7.6 L/min
BA
BB
DRIVE
MANIFOLD
300 psi
20.7 bar
Y49
BE
Y49A
P2
BG TP2
M2A
M2B
LEFT
FRONT
P1
M4A
M4B
LEFT
REAR
P2
3625 psi
250 bar
Y51
E
10.8 gpm
40.9 L/min
6.5 gpm
24.6 L/min
0 to 30 gpm
0 to 113.6 L/min
3625 psi
250 bar
OIL
COOLER
(OPTION)
360 psi
24.8 bar
DRIVE PUMP
25 psi
1.7 bar
HYDRAULIC TANK
6 - 126
HS7036C
Section 6 Schematics
July 2007
Hydraulic Schematic
(before serial number 40519)
Part 2 of 2
REV F
OUTRIGGERS
PLATFORM
OVERLOAD
(OPTION)
STEER
CYLINDERS
LIFT CYLINDER
(ALL MODELS)
PS2
Right
(STANDARD ON GS-5390)
(OPTION ON GS-3390 AND GS-4390)
LIFT CYLINDER
(GS-5390)
AP
2900 psi
200 bar
2900 psi
200 bar
RIGHT
FRONT
LEFT
FRONT
RIGHT
REAR
LEFT
REAR
CA
CB
CC
CD
Y36
Y35
Y34
Y33
AO
SF1
TP1
Y4
SF2
L2
Y3
Y7
LEV1
L1
Y8
E
5 psi
0.3 bar
Y9
FUNCTION
MANIFOLD
H
AUXP
(OPTION)
AL
Y39
GENERATOR
3000 psi
207 bar
Y40
2.5 gpm
9.5 L/min
3000 psi
207 bar
10 psi
0.7 bar
2000 psi
138 bar
LEV2
NOTE
SYSTEM RELIEF
VALVE PRESSURE
(SCHEMATIC ITEM D)
4.5 gpm
AM 17 L/min
Y29
AN
3000 psi
207 bar
2000 psi
137.9 bar
AUXILIARY
POWER
UNIT
HS7037B
6 - 127
Section 6 Schematics
July 2007
Hydraulic Schematic
(from serial number 40519 to GS9004-41690)
Part 1 of 2
REV J
RIGHT
FRONT
BF
TP1
RIGHT
REAR
M1B
M1A
Y1
Y2
2.5 gpm
9.5 L/min
0.045 in
1.1 mm BL
P1
0.035 in
0.9 mm
0.045 in BM
1.1 mm
M3B
M3A
BI
BJ
BN
BP
BK
BO
50%
50%
BQ
50%
50%
50%
50%
BH
BC 2 gpm
1.5 gpm
BD
5.7 L/min
7.6 L/min
BA
BB
DRIVE
MANIFOLD
300 psi
20.7 bar
Y49
BE
Y49A
P2
BG TP2
M2A
M2B
LEFT
FRONT
P1
M4A
M4B
LEFT
REAR
P2
3625 psi
250 bar
Y51
E
10.8 gpm
40.9 L/min
6.5 gpm
24.6 L/min
0 to 30 gpm
0 to 113.6 L/min
3625 psi
250 bar
OIL
COOLER
(OPTION)
360 psi
24.8 bar
DRIVE PUMP
25 psi
1.7 bar
HYDRAULIC TANK
6 - 128
HS7036C
Section 6 Schematics
July 2007
Hydraulic Schematic
(from serial number 40519 to GS9004-41690)
Part 2 of 2
REV J
OUTRIGGERS
PLATFORM
OVERLOAD
(OPTION)
PS2
(STANDARD ON GS-5390)
(OPTION ON GS-3390 AND GS-4390)
LIFT CYLINDER
(GS-5390)
LIFT CYLINDER
(ALL MODELS)
RIGHT
FRONT
LEFT
FRONT
RIGHT
REAR
LEFT
REAR
CA
CB
CC
CD
Y36
Y35
Y34
AP
Y33
AO
STEER CYLINDERS
AB
TP1
LEFT
L2
RIGHT
S1
L1
S2
LEV1
LEV2
AI
0.150 in
3.8 mm
AA
Y7
Y9
Y8
AK
AH
Y4
AD
Y3
Y40
Y39
AE
AG
TP2
2000 psi
138 bar
AF
AJ
AC
0.1 gpm
0.38 L/min
FUNCTION
MANIFOLD
AUXP
GENERATOR
NOTE
(OPTION)
SYSTEM RELIEF
VALVE PRESSURE
AL
AM 17 L/min
Y29
AN
3000 psi
207 bar
2000 psi
137.9 bar
AUXILIARY
POWER
UNIT
HS7037L
6 - 129
Section 6 Schematics
July 2007
Hydraulic Schematic
(from serial number GS9004-41691 to GS9005-42685)
Part 1 of 2
REV D
RIGHT
FRONT
2SPD
BRK
M1A
RIGHT
REAR
M1B
M3B
M3A
0.045 in
EH
1.1 mm
EF
Y2 EJ
Y1
0.035 in
0.9 mm
EM
EG
50%
0.090 in
2.3 mm
EL
EK
50%
P1
50%
50%
50%
50%
EE
EN TP1
EC TP2
280 psi
19.3 bar
DRIVE
MANIFOLD
EA
0.043 inch
1.1 mm
ED 0.046 inch
EB
1.2 mm
EI
P2
T
M2B
M2A
LEFT
FRONT
P1
M4A
M4B
LEFT
REAR
P2
3750 psi
258.6 bar
Y51
E
10.6 gpm
40.1 L/min
9.1 gpm
34.4 L/min
0 to 32.5 gpm
0 to 123 L/min
3750 psi
258.6 bar
OIL
COOLER
(OPTION)
325 psi
22.4 bar
DRIVE PUMP
25 psi
1.7 bar
HYDRAULIC TANK
6 - 130
HS7043C
Section 6 Schematics
July 2007
Hydraulic Schematic
(from serial number GS9004-41691 to GS9005-42685)
Part 2 of 2
REV D
OSCILLATING AXLE
OUTRIGGERS
(STANDARD ON GS-5390)
(OPTION ON GS-3390 AND GS-4390)
(OPTION)
PLATFORM
OVERLOAD
(OPTION)
LEFT
LIFT CYLINDER
(GS-5390)
LIFT CYLINDER
(ALL MODELS)
RIGHT
PS2
3800 psi
262 bar
4.5:1
RIGHT
FRONT
LEFT
FRONT
RIGHT
REAR
LEFT
REAR
CA
CB
CC
CD
Y36
Y35
Y34
AP
3800 psi
262 bar
4.5:1
Y33
AO
DF Y56
Y57
DE
DC
AB
900 psi
62 bar
STEER CYLINDERS
TP1
LEFT
L2
DG
RIGHT
S1
L1
S2
LEV1
LEV2
AI
Y54
0.150 in
3.8 mm
DB
AA
3500 psi
241.3 bar
1 gpm
3.8 L/min
Y7
DD
Y9
Y8
AK
AH
Y4
AD
Y3
Y40
Y39
AE
AG
TP2
OSCILLATE
MANIFOLD
2000 psi
138 bar
DA
AF
Y55
AJ
AC
0.1 gpm
0.38 L/min
FUNCTION
MANIFOLD
AUXP
GENERATOR
NOTE
(OPTION)
SYSTEM RELIEF
VALVE PRESSURE
AL
AM 17 L/min
Y29
AN
3000 psi
207 bar
2000 psi
137.9 bar
AUXILIARY
POWER
UNIT
HS7037L
6 - 131
Section 6 Schematics
July 2007
6 - 132
California Proposition 65
Warning
The exhaust from this product
contains chemicals known to
the State of California to
cause cancer, birth defects
or other reproductive harm.
Phone 425.881.1800
Toll Free USA and Canada
800.536.1800
Fax 425.883.3475
Genie Scandinavia
Phone +46 31 575100
Fax +46 31 579020
Genie China
Phone +86 21 53852570
Fax +86 21 53852569
Genie France
Phone +33 (0)2 37 26 09 99
Fax +33 (0)2 37 26 09 98
Genie Malaysia
Phone +65 98 480 775
Fax +65 67 533 544
Genie Iberica
Phone +34 93 579 5042
Fax +34 93 579 5059
Genie Japan
Phone +81 3 3453 6082
Fax +81 3 3453 6083
Genie Germany
Phone
Phone
Fax
Genie U.K.
Phone +44 (0)1476 584333
Fax +44 (0)1476 584334
Genie Korea
Phone +82 25 587 267
Fax +82 25 583 910
Genie Brasil
Phone +55 11 41 665 755
Fax +55 11 41 665 754
Genie Holland
Phone +31 183 581 102
Fax +31 183 581 566
Distributed By: