Maintenance

DIAGRAMS
GP/GLP/GDP2.00-3.00RF/TF
(GP/GLP/GDP040-060RG/TG/ZG) [A875]

PART NO. 524158902 8000 YRM 709

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas-
tened, and that the load being lifted is balanced. Make sure the crane, cables, and chains
have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on

electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE
LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use YALE APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using
force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or
if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels
and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away
from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Diagrams Table of Contents

TABLE OF CONTENTS

Diagrams, Schematics, or Arrangements ............................................................................................................ 1

Figure 1. GM 3.0L Gasoline Engine Wiring Schematic (Early Models) ...................................................... 2
Figure 2. GM 3.0L Gasoline Engine Wiring Schematic (Late Models) ....................................................... 4
Figure 3. GM 3.0L LPG Engine With MSTS Wiring Schematic (Early Models).......................................... 6
Figure 4. GM 3.0 LPG Engine With MSTS Wiring Schematic (Late Models) ............................................. 8
Figure 5. GM 3.0L LPG Engine Without MSTS Wiring Schematic (Late Models) ...................................... 10
Figure 6. GM 3.0L Engine Wiring Harness LPG Closed Loop ................................................................... 12
Figure 7. GM 3.0L Gas and LPG EPA Compliant Engine Electrical Schematic ......................................... 16
Figure 8. Mazda EGI Gas EPA Compliant Engine Wiring Diagram ........................................................... 20
Figure 9. Mazda Gasoline or LPG Engine Wiring Schematic (Early Models) ............................................ 22
Figure 10. Mazda Gasoline or LPG Engine Wiring Schematic (Late Models)............................................ 23
Figure 11. Mazda FE and F2 LPG Engine Wiring Schematic - Aisan Closed-Loop................................... 24
Figure 12. Mazda Diesel Engine Wiring Schematic ................................................................................... 26
Figure 13. Dual Fuel Option on GM 3.0L Engine Electrical Schematic ...................................................... 28
Figure 14. Dual Fuel Option on Mazda FE and F2 Engine Electrical Schematic ....................................... 28
Figure 15. UL Safety Classification Wiring Schematic ............................................................................... 29
Figure 16. Chassis Wiring Schematic (Early Models) ................................................................................ 30
Figure 17. GM 3.0L Engine Chassis Wiring Schematic (Early Models) ..................................................... 32
Figure 18. Cab Wiring Schematic............................................................................................................... 34
Figure 19. Lights Wiring Schematic (Early Models) ................................................................................... 36
Figure 20. Lights Wiring Schematic (Late Models)..................................................................................... 38
Figure 21. Chassis and Lights Wiring Schematic - Late Models ................................................................ 40
Figure 22. Chassis, Instruments, and Cowl Wiring Diagram, Mazda HA/XA Diesel Engine ...................... 44
Figure 23. Instrument Cluster Harness (Later Models) .............................................................................. 51
Figure 24. Instrument Cluster Wiring Schematic ........................................................................................ 52
Figure 25. Hydraulic System Schematic..................................................................................................... 53
Figure 26. Hydraulic System Arrangement................................................................................................. 54
Figure 27. Transmission Control Lever Schematic ..................................................................................... 55
Figure 28. Powershift Transmission (Neutral) Hydraulic Schematic ........................................................... 56
Figure 29. Hydraulic Schematic for Hydrostatic Drive System ................................................................... 57
Figure 30. Electrical Schematic for Hydrostatic Transmission .................................................................... 58
Figure 31. Hydrostatic Transmission Throttle Up Wiring Diagram .............................................................. 59

This section is for the following models:

GP/GLP/GDP2.00-3.00RF/TF (GP/GLP/GDP040-060RG/TG/ZG) [A875]

©2004 Yale Materials Handling Corp. i

8000 YRM 709 Diagrams, Schematics, or Arrangements

NOTES

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Figure 1. GM 3.0L Gasoline Engine Wiring Schematic (Early Models)

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8000 YRM 709 Diagrams, Schematics, or Arrangements

Figure 2. GM 3.0L Gasoline Engine Wiring Schematic (Late Models)

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Figure 3. GM 3.0L LPG Engine With MSTS Wiring Schematic (Early Models)

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Figure 4. GM 3.0 LPG Engine With MSTS Wiring Schematic (Late Models)

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Figure 5. GM 3.0L LPG Engine Without MSTS Wiring Schematic (Late Models)

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Figure 6. GM 3.0L Engine Wiring Harness LPG Closed Loop (Sheet 1 of 2)

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Figure 6. GM 3.0L Engine Wiring Harness LPG Closed Loop (Sheet 2 of 2)

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Figure 7. GM 3.0L Gas and LPG EPA Compliant Engine Electrical Schematic (Sheet 1 of 4)

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Figure 7. GM 3.0L Gas and LPG EPA Compliant Engine Electrical Schematic (Sheet 2 of 4)

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Figure 7. GM 3.0L Gas and LPG EPA Compliant Engine Electrical Schematic (Sheet 3 of 4)

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Figure 7. GM 3.0L Gas and LPG EPA Compliant Engine Electrical Schematic (Sheet 4 of 4)

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Figure 8. Mazda EGI Gas EPA Compliant Engine Wiring Diagram (Sheet 1 of 2)

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Figure 8. Mazda EGI Gas EPA Compliant Engine Wiring Diagram (Sheet 2 of 2)

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Figure 9. Mazda Gasoline or LPG Engine Wiring Schematic (Early Models)

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Figure 10. Mazda Gasoline or LPG Engine Wiring Schematic (Late Models)

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Figure 11. Mazda FE and F2 LPG Engine Wiring Schematic - Aisan Closed-Loop

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 NOTES

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Figure 12. Mazda Diesel Engine Wiring Schematic

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Figure 13. Dual Fuel Option on GM 3.0L Engine Electrical Schematic

Figure 14. Dual Fuel Option on Mazda FE and F2 Engine Electrical Schematic

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Figure 15. UL Safety Classification Wiring Schematic

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Figure 16. Chassis Wiring Schematic (Early Models)

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Figure 17. GM 3.0L Engine Chassis Wiring Schematic (Early Models)

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Figure 18. Cab Wiring Schematic

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Figure 19. Lights Wiring Schematic (Early Models)

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Figure 20. Lights Wiring Schematic (Late Models)

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Figure 21. Chassis and Lights Wiring Schematic - Late Models (Sheet 1 of 2)

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Figure 21. Chassis and Lights Wiring Schematic - Late Models (Sheet 2 of 2)

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Figure 22. Chassis, Instruments, and Cowl Wiring Diagram, Mazda HA/XA Diesel Engine (Sheet 1 of 4)

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Figure 22. Chassis, Instruments, and Cowl Wiring Diagram, Mazda HA/XA Diesel Engine (Sheet 2 of 4)

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Figure 22. Chassis, Instruments, and Cowl Wiring Diagram, Mazda HA/XA Diesel Engine (Sheet 3 of 4)

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Figure 22. Chassis, Instruments, and Cowl Wiring Diagram, Mazda HA/XA Diesel Engine (Sheet 4 of 4)

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Figure 23. Instrument Cluster Harness (Later Models)

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Figure 24. Instrument Cluster Wiring Schematic

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8000 YRM 709 Diagrams, Schematics, or Arrangements

1. HYDRAULIC PUMP 11. TILT SPOOL

2. FLOW CONTROL VALVE 12. AUXILIARY FUNCTION SPOOL
3. RELIEF VALVE (STEERING SYSTEM) 13. RELIEF VALVE (TILT AND AUXILIARY CIRCUITS)
4. CHECK PORT (STEERING SYSTEM) 14. TILT CYLINDER
5. STEERING CONTROL UNIT 15. LIFT CYLINDER
6. STEERING CYLINDER 16. LOWERING CONTROL VALVE (INSIDE
7. MAIN CONTROL VALVE CYLINDER)
8. FILTER 17. LOWERING CONTROL VALVE (OUTSIDE
9. RELIEF VALVE (LIFT CIRCUIT) CYLINDER)
10. LIFT/LOWER SPOOL 18. CHECK PORT (LIFT AND TILT CIRCUITS)

Figure 25. Hydraulic System Schematic

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1. HYDRAULIC TANK 7. TO LIFT CYLINDERS

2. BREATHER 8. TILT CYLINDER
3. RETURN LINE 9. STEERING CONTROL UNIT
4. MAIN CONTROL VALVE 10. HYDRAULIC PUMP
5. TILT BACKWARD LINE 11. FILTER
6. TILT FORWARD LINE 12. STEERING CYLINDER

Figure 26. Hydraulic System Arrangement

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COLOR CODES: Y = WHITE, W = GREEN, X = RED, CB = LIGHT GREEN (REV SOLENOID), CC =

ORANGE/BLACK (FWD SOLENOID)
1. REVERSE CONTROL SWITCH 3. FORWARD CONTROL SWITCH
2. NEUTRAL START SWITCH 4. CONNECTOR-TO-COWL WIRING HARNESS

Figure 27. Transmission Control Lever Schematic

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1. SCREEN 13. MODULATOR REGULATOR

2. PUMP 14. INCHING SPOOL
3. PUMP RELIEF VALVE 15. DIRECTION SPOOL
4. FILTER 16. REVERSE SOLENOID
5. CHECK PORT FOR TORQUE CONVERTER 17. FORWARD SOLENOID
6. TORQUE CONVERTER 18. CHECK PORT FOR FORWARD CLUTCH
7. TORQUE CONVERTER REGULATOR PRESSURE
8. OIL COOLER 19. CHECK PORT FOR REVERSE CLUTCH
9. CHECK PORT FOR LUBRICATION CIRCUIT PRESSURE
10. CLUTCH PRESSURE REGULATOR 20. REVERSE CLUTCH
11. CHECK PORT FOR MODULATOR PRESSURE 21. FORWARD CLUTCH
12. MODULATOR CONTROL VALVE 22. CHECK PORT FOR PUMP PRESSURE

Figure 28. Powershift Transmission (Neutral) Hydraulic Schematic

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1. THROTTLE CONTROL 6. SCREEN

2. TRANSMISSION FILTER 7. TRANSMISSION RESERVOIR
3. DIRECTION CONTROL VALVE 8. OIL COOLER
4. BRAKE INCHING VALVE 9. WHEEL MOTORS
5. HYDROSTATIC TRANSMISSION PUMP

Figure 29. Hydraulic Schematic for Hydrostatic Drive System

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Figure 30. Electrical Schematic for Hydrostatic Transmission

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Figure 31. Hydrostatic Transmission Throttle Up Wiring Diagram

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 NOTES

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 Yale Europe Materials Handling Limited
Flagship House, Reading Road North, Fleet, Hampshire GU138 HR United Kingdom

8000 YRM 709 10/04 (12/03)(12/02)(2/02) Printed in the United Kingdom