Section 6 Schematics June 2007

Electrical Schematic REV B

ANSI, CSA and Australia Models
(after serial number GS6805-44698)
A B C D E F G H I J K L M N

1
CB2 P1 KS1
7A CIRCUIT EMERGENCY QD4
BREAKER GN/BK STOP KEY SWITCH
WH
BK 4 4
B
RD 3 3

GN/BK
3 OR K1 WH 1 1
1 30 86
CR48 BL 2 2
B1 POWER
F10 OR 5 5
2 RELAY 87 85
5A FUSE 4 2 GN/BK TO U5

TERMINAL STRIP 3
TERMINAL STRIP 1
TERMINAL STRIP 2
TERMINAL STRIP 4
INVERTER

YL
(OPTION) RD/BK
N.C.

K4 BN44
30 86
CR101 FUNCTION
INVERTER ENABLE H5 LS6
87 85 RELAY BN92 MULTI- DOWN

RD
3 AUXILIARY
FUNCTION LIMIT
ALARM SWITCH
DOWN
SWITCH

TERMINAL STRIP 5
GN/BK
RD
CR79
RD

BN84 BN83
WH

U13 PLATFORM PLATFORM POTHOLE

RELAY K3
INVERTER DOWN UP 30 86

- + N.O.
87A 87 85
WH
LEVEL
4 SENSOR
CIRCUIT
BOARD
F9
80A

TERMINAL STRIP 10
TERMINAL STRIP 12
TERMINAL STRIP 9
TERMINAL STRIP 8

FUSE S7
Y10 Y11 LEVEL
AUXILIARY BK AUXILIARY SENSOR

RD
DOWN DOWN
2 (GS-3268 ONLY) BN

RD
OR
OR

BK/RD
GN/BK

U4

WH/BK
WH/BK
WH/BK
WH/BK

5 48V TO 26V
DC-DC
WH CONVERTER A12 B12 A11 A4 B11 C2 B9 B10 C12 A2 B1 C1 C11 A5
1 3 IN IN IN IN IN IN OUT IN IN IN IN IN IN OUT
RD
A9 OUT

BN
QD1 (+) F6
275A FUSE WH/BK
- A8 OUT U5
GN/BK ELECTRONIC CONTROL MODULE
B8 OUT

+
B5
6 8-6V A1 OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT
-
BATTERY C8 C9 C7 B7 A7 C6 A6 B6 B3

+
D1
L30
- WORK LIGHT
M5 (OPTION)
BL
RD

OR

+
GND

RD
BL/BK
RD/BK

OR/BK

GN/BK
RD/WH

G5 M5

TERMINAL STRIP 7
K2
AMMETER A1 MOTOR
-
30 86
CR5

+
TERMINAL STRIP 11

HORN RELAY FB
(H2 OPTION) 87 85
7 -

GN
M- B+

+
RD
GN

- A2 3
GN/BK

WH/BK
FB

+
B- 1
U9 Y9
-
BATTERY
H2 FB Y1 Y1A Y2 Y3 Y4 Y5 Y6 Y8 Y7 PLATFORM
CHARGER
U6 MOTOR AUTOMOTIVE-STYLE FLASHING PARALLEL HIGH SPEED BRAKE STEER STEER DRIVE DRIVE PLATFORM PLATFORM DOWN
CONTROLLER HORN BEACONS BYPASS RELEASE RIGHT LEFT REVERSE FORWARD UP DOWN (GS-3268 ONLY)

+
(OPTION) (OPTION)
8 - AC INPUT

G6

+
HOUR
QD1 (-) METER
GND GND

ES7150G

6 - 66 GS-2668 DC GS-3268 DC Part No. 65248

 June 2007 Section 6 Schematics

REV B Electrical Schematic

ANSI, CSA and Australia Models
(after serial number GS6805-44698)
N M L K J I H G F E D C B A

P2 1
EMERGENCY
QD3 STOP
BK
C C BK POWER TO PLATFORM
RD
A A RD POWER TO GROUND

B B WH GROUND PIO3
PIO2
D D BL DATA LINK (HIGH) PIO4

E E OR DATA LINK (LOW) PIO5

2
24V DC

5V DC
U3 D7
PLATFORM CONTROLS VOLTAGE
PRINTED CIRCUIT BOARD REGULATOR

BN
JC1 3
HALL JOYSTICK ABBREVIATION LEGEND ABBREVIATION LEGEND
GY GENERATOR CONTROLLER
Item Description Item Description
GN B5 Battery Main power LS6 Limit switch platform down
WH BN Button M5 Hydraulic power unit
BN5 = Horn N.C. Normally closed
BN6 = High torque N.O. Normally open
BL
BN8 = Drive enable P Power
SW5 SW6 BN9 = Lift enable P1 = Emergency stop button at ground controls
PP FUNCTION ENABLE STEER BN44 = Function enable P2 = Emergency stop button at platform controls
LEFT/ RIGHT BN83 = Platform up
4
QD Quick disconnect
WH/BL BN84 = Platform down QD1 = Battery quick disconnect
PIN9
BN92 = Auxiliary down QD3 = Control cable to ground

LEFT
WH/RD

RIGHT
PIN8 CB Circuit breaker QD4 = Control cable to platform
WH CB2 = 20 amp (before serial number 41200) S7 Tilt level sensor
PIN10
CB2 = 7 amp (after serial number 41199) SW Switch
CR Control relay SW5 = Function enable
PLATFORM CONTROLS CR5 = Horn SW6 = Steer left/right
MEMBRANE DECAL CR48 = Power U Electronic component
BK
CR79 = Pothole
U3 = Encoder printed circuit board 5
D7 Voltage regulator 24V DC to 5V DC U4 = Voltage converter
FB1 Flashing beacons (option) U5 = Electronic control module
POUT1 LIFT LED L16
F Fuse U6 = Motor controller
POUT2 DRIVE LED L17 F6 = 275A fuse U9 = Battery charger
POUT3 HIGH TORQUE LED L21 F10 = 5A fuse Y Valve coil
G Gauge Y1 = Drive parallel
G5 = Ammeter Y1A = Drive parallel (before serial number 41200)
G6 = Hour meter Y1A = High speed bypass (after s/n 41199)
POUT4
G8 G8 = Diagnostic display Y2 = Brake release
DIAGNOSTIC
DISPLAY GND Ground Y3 = Steer right 6
H Horn or alarm Y4 = Steer left
H1 = Horn Y5 = Drive reverse
H2 = Automotive-style horn Y6 = Drive forward
PIN1 HIGH TORQUE BN6 H5 = Multifunction alarm Y7 = Platform down
JC1 Joystick controller- drive, steer, platform up/down Y8 = Platform up
PIN2 HORN BN5
KS1 Key switch Y9 = Platform down (GS-3268 only)
PIN3 DRIVE ENABLE BN8 L LED or light Y10 = Auxiliary platform down (GS-3268 only)
L16 = Lift Y11 = Platform down (GS-3268 only)
PIN4 LIFT ENABLE BN9
L17 = Drive
RD L21 = High torque selected 7
POUT11 + L30 = Work light (option)
H1 PLATFORM
BK ALARM
PIN11 - CONTROLLER
WIRE COLOR LEGEND
Color Description Color Description
BL Blue OR/BK Orange/Black
BL/BK Blue/Black PP Purple
BK Black RD Red 8
BK/RD Black/Red RD/BK Red/Black
BN Brown RD/WH Red/White
GN Green WH White
GN/BK Green/Black WH/BK White/Black
GY Gray YL Yellow
OR Orange

Part No. 65248 GS-2668 DC GS-3268 DC 6 - 67

 June 2007 Section 6 Schematics

REV B Hydraulic Schematic

(after serial number GS6806-45257)
N M L K J I H G F E D C B A
LIFT CYLINDER
LOAD SENSE OPTION STEER CYLINDER
(After serial number 42450) 1
LIFT CYLINDER
(GS-3268 ONLY) 0.037 inch LEFT RIGHT
.94 mm BA BRAKE RELEASE BRAKE
Y9 Y11 PS2 Y7 Y10
HAND PUMP MANIFOLD
BA
AU LEFT RIGHT
MANUAL MOTOR MOTOR 2
RELEASE HAND
BB BB PUMP

0.059 inch 0.059 inch

1.5 mm 1.5 mm
BF BE

B1

LIFT S1 S2 BRAKE HP M1B M1A M2A M2B

3
10 psi
0.7 bar AK
AC
Y4 Y3
AO 0.050 inch
AB 1.27 mm
Y1

4
10 psi Y1A
AP
0.7 bar
AQ
AM
AE AJ
Y2

2100 psi
AA 145 bar 0.035 inch AR
AT 0.9 mm Y6 Y5
AS
TP AH 5
2 gpm
7.5 L/min

AF AL AN
100 psi
Y8 6.9 bar AI AG 2 psi 2 psi
GS-2668DC 3600 psi / 248 bar
GS-3268DC 2800 psi / 193 bar 4000 psi 0.14 bar 0.14 bar
AD 275.8 bar

3500 psi
241 bar 6
FUNCTION MANIFOLD
P T

8.3 gpm
17 L/min M

7
HS7041G
ABBREVIATION LEGEND ABBREVIATION LEGEND
Item Description
Item Description AK Check valve, anti intensification drive circuit
AA Priority flow regulator AL Check valve, anti cavitation drive circuit
AB 2 position, 2 way solenoid valve brake circuit AM Flow divider/combiner drive circuit
AC 3 position, 4 way solenoid valve steer left/right AN Check valve, anti cavitation drive circuit
AD Relief valve system AO Orifice drive circuit
AE Relief valve steer left/right AP 2 position, 4 way normally open solenoid valve
AF Relief valve platform up drive speed select circuit
8
ABBREVIATION LEGEND AG Relief valve drive circuit AQ Check valve steer circuit
Item Description AH Orifice brake circuit AR 3 position, 4 way directional valve directs oil flow to
BA 2 position, 2 way solenoid valve platform lowering AI Check valve prevents power unit from running the front wheel motors in both forward and reverse
Note: 'alpha' callouts refer to BB Orifice platform down circuit backward when on an incline and reversing direction AS 2 position, 4 way solenoid valve platform up
components shown in the BE Hand pump - manual brake release circuit of travel AT Diagnostic nipple test port
manifold illustrations. BF Needle valve manual brake release circuit AJ 2 position, 2 way solenoid valve high speed bypass AU Pressure switch, platform overload
Refer to the Repair Section.

Part No. 65248 GS-2668 DC GS-3268 DC 6 - 89