Maintenance

DIAGRAMS
GC/GLC040-065RG/TG/ZG [E187]

PART NO. 524158910 8000 YRM 807

 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 Diagram (Early Models) ......................................................... 2
Figure 2. GM 3.0L Gasoline Engine Wiring Diagram (Late Models) .......................................................... 6
Figure 3. GM 3.0L LPG Engine With MSTS Wiring Diagram (Early Models) ............................................. 10
Figure 4. GM 3.0L LPG Engine With MSTS Wiring Diagram - IMPCO System ......................................... 12
Figure 5. GM 3.0L LPG Engine With MSTS Wiring Diagram - Aisan System ............................................ 14
Figure 6. GM 3.0L LPG Engine Without MSTS Wiring Diagram (Early Models) ........................................ 16
Figure 7. GM 3.0L LPG Engine Without MSTS Wiring Diagram - IMPCO System .................................... 18
Figure 8. GM 3.0L LPG Engine Without MSTS - Aisan System................................................................. 20
Figure 9. GM 3.0L LPG Engine Wiring Diagram ........................................................................................ 22
Figure 10. GM 3.0L LPG Engine Closed Loop ........................................................................................... 28
Figure 11. GM 3.0L Gas and LPG EPA Compliant Engine Electrical Schematic ....................................... 32
Figure 12. Mazda FE and F2 Gasoline Engine Wiring Diagram................................................................. 36
Figure 13. Mazda FE and F2 LPG Engine Wiring Diagram - IMPCO Closed-Loop ................................... 38
Figure 14. Mazda FE and F2 Gasoline and LPG Engine Wiring Diagram ................................................. 40
Figure 15. Mazda FE and F2 LPG Engine Wiring Diagram - Aisan Open-Loop ........................................ 44
Figure 16. Mazda FE and F2 LPG Engine Wiring Diagram - Aisan Closed-Loop ...................................... 46
Figure 17. Mazda FE and F2 Engine With Dual Fuel System Wiring Diagram .......................................... 48
Figure 18. Mazda FE and F2 Engine Wiring Diagram - Powertrain Protection .......................................... 50
Figure 19. GM 3.0L Engine With Dual Fuel System Wiring Diagram (Late Models) .................................. 52
Figure 20. GM 3.0L Gasoline Engine Electrical Schematic (Late Models)................................................. 56
Figure 21. GM 3.0L LPG Engine Electrical Schematic (Late Models)........................................................ 60
Figure 22. Mazda FE and F2 Gasoline Engine Electrical Schematic (Late Models) .................................. 66
Figure 23. Mazda FE and F2 LPG Engine Electrical Schematic - Aisan System....................................... 68
Figure 24. Mazda FE and F2 Gasoline and LPG Engine Electrical Schematic (Late Models)................... 70
Figure 25. Chassis Wiring Diagram (Late Models)..................................................................................... 74
Figure 26. UL Safety Classification Wiring Diagram................................................................................... 76
Figure 27. Lights Wiring Diagram (Early Models)....................................................................................... 78
Figure 28. Wiring Diagram Chassis and Cluster (Late Models) ................................................................. 80
Figure 29. Hydraulic System Schematic..................................................................................................... 88
Figure 30. Hydraulic System Arrangement................................................................................................. 89
Figure 31. Hydraulic Schematic for Transmission (Neutral)........................................................................ 90

This section is for the following models:

GC/GLC040-065RG/TG/ZG [E187]

©2005 Yale Materials Handling Corp. i

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NOTES

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Figure 1. GM 3.0L Gasoline Engine Wiring Diagram (Early Models) (Sheet 1 of 2)

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Figure 1. GM 3.0L Gasoline Engine Wiring Diagram (Early Models) (Sheet 2 of 2)

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Figure 2. GM 3.0L Gasoline Engine Wiring Diagram (Late Models) (Sheet 1 of 2)

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Figure 2. GM 3.0L Gasoline Engine Wiring Diagram (Late Models) (Sheet 2 of 2)

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

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Figure 4. GM 3.0L LPG Engine With MSTS Wiring Diagram - IMPCO System

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Figure 5. GM 3.0L LPG Engine With MSTS Wiring Diagram - Aisan System

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Figure 6. GM 3.0L LPG Engine Without MSTS Wiring Diagram (Early Models)

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Figure 7. GM 3.0L LPG Engine Without MSTS Wiring Diagram - IMPCO System

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Figure 8. GM 3.0L LPG Engine Without MSTS - Aisan System

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Figure 9. GM 3.0L LPG Engine Wiring Diagram (Sheet 1 of 3)

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Figure 9. GM 3.0L LPG Engine Wiring Diagram (Sheet 2 of 3)

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Figure 9. GM 3.0L LPG Engine Wiring Diagram (Sheet 3 of 3)

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Figure 10. GM 3.0L LPG Engine Closed Loop (Sheet 1 of 2)

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Figure 10. GM 3.0L LPG Engine Closed Loop (Sheet 2 of 2)

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Figure 11. GM 3.0L Gas and LPG EPA Compliant Engine Electrical Schematic (Sheet 1 of 4)

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Figure 11. GM 3.0L Gas and LPG EPA Compliant Engine Electrical Schematic (Sheet 2 of 4)

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Figure 11. GM 3.0L Gas and LPG EPA Compliant Engine Electrical Schematic (Sheet 3 of 4)

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Figure 11. GM 3.0L Gas and LPG EPA Compliant Engine Electrical Schematic (Sheet 4 of 4)

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Figure 12. Mazda FE and F2 Gasoline Engine Wiring Diagram

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Figure 13. Mazda FE and F2 LPG Engine Wiring Diagram - IMPCO Closed-Loop

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Figure 14. Mazda FE and F2 Gasoline and LPG Engine Wiring Diagram (Sheet 1 of 2)

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Figure 14. Mazda FE and F2 Gasoline and LPG Engine Wiring Diagram (Sheet 2 of 2)

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Figure 15. Mazda FE and F2 LPG Engine Wiring Diagram - Aisan Open-Loop

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Figure 16. Mazda FE and F2 LPG Engine Wiring Diagram - Aisan Closed-Loop

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Figure 17. Mazda FE and F2 Engine With Dual Fuel System Wiring Diagram

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Figure 18. Mazda FE and F2 Engine Wiring Diagram - Powertrain Protection

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Figure 19. GM 3.0L Engine With Dual Fuel System Wiring Diagram (Late Models) (Sheet 1 of 2)

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Figure 19. GM 3.0L Engine With Dual Fuel System Wiring Diagram (Late Models) (Sheet 2 of 2)

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Figure 20. GM 3.0L Gasoline Engine Electrical Schematic (Late Models) (Sheet 1 of 2)

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Figure 20. GM 3.0L Gasoline Engine Electrical Schematic (Late Models) (Sheet 2 of 2)

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Figure 21. GM 3.0L LPG Engine Electrical Schematic (Late Models) (Sheet 1 of 3)

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Figure 21. GM 3.0L LPG Engine Electrical Schematic (Late Models) (Sheet 2 of 3)

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Figure 21. GM 3.0L LPG Engine Electrical Schematic (Late Models) (Sheet 3 of 3)

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Figure 22. Mazda FE and F2 Gasoline Engine Electrical Schematic (Late Models)

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Figure 23. Mazda FE and F2 LPG Engine Electrical Schematic - Aisan System

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Figure 24. Mazda FE and F2 Gasoline and LPG Engine Electrical Schematic (Late Models) (Sheet 1 of 2)

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Figure 24. Mazda FE and F2 Gasoline and LPG Engine Electrical Schematic (Late Models) (Sheet 2 of 2)

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Figure 25. Chassis Wiring Diagram (Late Models)

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Figure 26. UL Safety Classification Wiring Diagram

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Figure 27. Lights Wiring Diagram (Early Models)

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Figure 28. Wiring Diagram Chassis and Cluster (Late Models) (Sheet 1 of 4)

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Figure 28. Wiring Diagram Chassis and Cluster (Late Models) (Sheet 2 of 4)

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Figure 28. Wiring Diagram Chassis and Cluster (Late Models) (Sheet 3 of 4)

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Figure 28. Wiring Diagram Chassis and Cluster (Late Models) (Sheet 4 of 4)

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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 29. 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 30. Hydraulic System Arrangement

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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 31. Hydraulic Schematic for Transmission (Neutral)

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 Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011

8000 YRM 807 9/05 (12/03)(9/03)(4/03)(2/02) Printed in U.S.A.