Maintenance

ELECTRICAL SYSTEM
GDP/GLP80-120DB
(GDP/GLP170-280DB) [D876];
GDP/GLP130-160EB
(GDP/GLP300-360EB) [D877]

PART NO. 524300814 2200 YRM 1351

 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!
Electrical System Table of Contents

TABLE OF CONTENTS

Description .......................................................................................................................................................... 1
Warning Devices ................................................................................................................................................. 6
General ........................................................................................................................................................... 6
Description ...................................................................................................................................................... 7
Operator-Controlled Horn ........................................................................................................................... 7
Reverse Warning Horns/Lights ................................................................................................................... 7
Warning Lights ............................................................................................................................................ 7
Strobe Light ............................................................................................................................................ 7
Brake Lights............................................................................................................................................ 9
Hazard Lights ......................................................................................................................................... 9
Replace....................................................................................................................................................... 9
General................................................................................................................................................... 9
Horns ...................................................................................................................................................... 9
Horn Relay.............................................................................................................................................. 9
Light Assemblies .................................................................................................................................... 9
Flashing Unit........................................................................................................................................... 10
Meters, Senders, and Switches........................................................................................................................... 10
General ........................................................................................................................................................... 10
Diagrams, Schematics, or Arrangements ............................................................................................................ 10
Figure 6. Diesel Main Wire Harness (D876)............................................................................................... 12
Figure 7. Diesel Main Wire Harness (D877)............................................................................................... 14
Figure 8. LPG Main Wire Harness (D876) ................................................................................................. 16
Figure 9. LPG Main Wire Harness (D877) ................................................................................................. 18

This section is for the following models:

GDP/GLP80-120DB (GDP/GLP170-280DB) [D876];

GDP/GLP130-160EB (GDP/GLP300-360EB) [D877]

©2007 Yale Materials Handling Corp. i

2200 YRM 1351 Description

Description
The main part of the electrical system is the one-piece, See Figure 1 and Figure 2 and the section Instrument
main electrical wire harness. The batteries provide the Panel Indicators and Senders 2200 YRM 1105 for fur-
main electrical wire harness with electricity and then ther information regarding senders and indicator func-
the main electrical wire harness transmits the electricity tions.
to several components (senders, warning lights, etc.).

Figure 1. Main Electrical Wire Harness (Diesel)

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Description 2200 YRM 1351

Legend for Figure 1

Item No. Connector Description

Main Wiring Harness
1 C390 Reverse Alarm
2 C380 LH Rear Lamp
3 C100 Backup Diode
4 C280 Alternator Signs
5 C270 Alternator +
6 C290 Alternator Ground
7 C105 Ground
8 C420 Pre-excitation Diode
9 C70 +24V
10 C415 Grid Heater Relay
11 C110 Starter Solenoid
12 C115 +24V
13 C425 Fuse
14 C85 Starter Relay
15 C80 Valve
16 C90 Drum Speed
17 C470 Fuel Filter to Filter
18 C150 Engine Speed
19 C82 Cab Tilt Power
20 C60 Fuel Sender
21 C350 Low
22 C120 Output Speed
23 C370 Tilt
24 C360 Aux
25 C25 LH Hub Brake Temp
26 C30 Tilt
27 C20 Front Lamps
28 C40 Aux
29 C50 Lift
30 C310 Park Brake Solenoid
31 C450 Accelerator Pedal
32 C15 RH Hub Brake Temp (wet brake option)
Hydraulic Tank Temp (dry brake option)

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2200 YRM 1351 Description

Item No. Connector Description

33 C10 Front End
34 C130 Battery
35 C340 Turbine Speed
36 C330 Conv Out Temp Sensor
37 C146 Cab Supplies
38 C144 Cab Signals
39 C175 Air Dryer
40 C75 Park Brake and Air Dryer Diode
41 C460 Fuel Filter to Engine
42 C170 Engine Oil Pressure
43 C405 Terminating Resistor
44 C401 Engine Supply
45 C300 Diagnostics
46 C400 ECM
47 C220 Air Filter
48 C148 Grid Heater
49 C305 AC
50 C210 RH Rear Lamp
51 C215 Coolant Level

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Description 2200 YRM 1351

Figure 2. Main Electrical Wire Harness (LPG)

Legend for Figure 2

Item No. Connector Description

Main Wiring Harness
1 C390 Reverse Alarm
2 C380 LH Rear Lamp
3 C100 Backup Diode
4 C270 Alternator +
5 C280 Alternator Signs
6 C290 Alternator Ground

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2200 YRM 1351 Description

Item No. Connector Description

7 C105 Ground
8 C70 +24V
9 C115 +24V
10 C110 Starter Solenoid
11 C425 Fuse
12 C85 Starter Relay
13 C480 LPG Relay
14 C490 Fuse Box 1
15 C500 Fuse Box 2
16 C510 Fuse Box 3
17 C440 LPG Solenoid
18 C460 Low Pressure Switch
19 C82 Cab Tilt Power
20 C520 Resistor
21 C470 DC/DC Converter
22 C150 Engine Speed
23 C80 Valve
24 C90 Drum Speed
25 C35 Hydraulic Cooler
26 C350 Low
27 C120 Output Speed
28 C370 Tilt
29 C360 Aux
30 C25 LH Hub Brake Temp
31 C30 Tilt
32 C20 Front Lamps
33 C40 Aux
34 C50 Lift
35 C310 Park Brake Solenoid
36 C450 Acc Pedal
37 C15 RH Hub Brake Temp (wet brake option)
Hydraulic Tank Temp (dry brake option)
38 C10 Front End
39 C130 Battery
40 C340 Turbine Speed

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Warning Devices 2200 YRM 1351

Item No. Connector Description

41 C330 Conv Out Temp Sensor
42 C146 Cab Supplies
43 C144 Cab Signals
44 C175 Air Dryer
45 C410 Engine
46 C400 ECM
C405 Terminating Resistor
47 C430 Can Connector
48 C75 Park Brake and Air Dryer Diode
49 C86 Pressure Switch
50 C170 Engine Oil Pressure
51 C220 Air Filter
52 C210 RH Rear Lamp
53 C305 AC
54 C215 Coolant Level

Warning Devices
GENERAL energizing a buzzer to sound. A reverse warning horn
automatically sounds a warning that the equipment is
Electrical warning devices used on the lift truck are as moving in the reverse direction. Warning lights auto-
follows: matically illuminate to warn personnel that the equip-
• Operator-controlled air horn ment is operating in a special way. Warning lights are
• Reverse warning horn/lights also used to warn personnel that the equipment is near.
• Warning lights Some of these warning devices need to be energized
and de-energized at a fast rate. A separate flashing de-
Operator-controlled horns permit the operator to warn
vice does this. Most equipment does not need each of
personnel that the equipment is near. System warn-
these warning devices.
ing lights and buzzers make an important system con-
dition known to the operator. They do this by illuminat-
ing an indicator that is not normally illuminated or by

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2200 YRM 1351 Warning Devices

DESCRIPTION
Operator-Controlled Horn
The operator-controlled horn has a horn switch, a relay,
and horn. See Figure 3. The horn switch energizes the
relay to close the power contacts and energize the horn.
This makes the horn sound. The lower sound level of
equipment operation results in a horn that is less loud
and uses less current. This horn current is directly con-
trolled by the switch. The horn switch is located at the
operator’s position. The horn is installed underneath
the cab. The horn relay is installed in the side console.

1. HORN
2. TRANSMISSION SHIFTER OR FOOT
DIRECTIONAL CONTROL PEDAL
3. RELAY
4. BASE

Figure 4. Reverse Warning Horn Components

Warning Lights
1. ELECTRICAL HORN
The following types of warning lights are attached to the
Figure 3. Operator-Controlled Horns lift truck:
• Strobe Light
Reverse Warning Horns/Lights • Brake Lights
• Hazard Lights
The reverse warning horn is operated by the foot direc-
tional control pedal or the shifter. See Figure 4. They Strobe Light
use a flashing device to make the sound of the horn
begin and end repeatedly. This flashing device is part These warning lights indicate a particular type of equip-
of the reverse warning horn. The switch is energized to ment operation. See Figure 5. They warn others that
the ON position when the equipment is set to operate in the equipment is in the area or that the operator’s view is
the reverse direction. The switch will then energize the limited by the particular operation. These lights can be
relay to energize the horn. The horn is most frequently flashing lights. A switch and a flashing device are used
located under the back of the equipment. The relay is to operate the flashing light. The flashing device is part
located in the side console. of the light assembly. The light can be connected to op-
erate when the key switch is in the ON position. They
can also be connected to operate with a particular op-
eration of the equipment such as: Equipment is set for
reverse operation. When connected in this way, a sep-
arate switch is operated automatically by the equipment
function.

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Warning Devices 2200 YRM 1351

Item No. Connector Description

1 N/A Working Light (Halogen or HID)
2 N/A Strobe Light
3 N/A Cab
4 C10 (black 8 way dt socket housing – DEUTSCH) Mate to connector on cab assembly.
5 C30 (4 mm socket terminal and 4 mm male bullet terminal – Strobe
SUMITOMO)
6 C20 (black 2 way dt socket housing – DEUTSCH) Rear Drive Light
7 C50 (black 2 way dt socket housing – DEUTSCH) Outer Front Flood Light
8 C40 (black 2 way dt socket housing – DEUTSCH) Inner Front Flood Light

Figure 5. Light Assemblies

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2200 YRM 1351 Warning Devices

Brake Lights 4. Remove the horn and install the replacement.

These warning lights indicate that the speed of the lift 5. Tighten the screws, nuts, or other items fastening
truck will slow down. They warn others that the lift truck the horn to the equipment.
will stop or decrease the speed severely. These lights
are positioned on the backside of the lift truck and will 6. Connect the wires, as marked, to the electrical ter-
be activated by operating the brake pedal. minals.

Hazard Lights Horn Relay

These warning lights will be used when the lift truck has The horn relay is located in the side console in the cab.
problems with driving or when the lift truck is placed at If necessary, follow the horn electrical leads to find the
a dangerous location. relay. Replace the relay as follows:

1. Disconnect the battery or batteries to remove all

Replace
voltage from the terminals.
General
2. Mark the wires for reconnecting.
Horns, light assemblies, flashing devices, buzzers, and
3. Disconnect the wires.
switches are not repairable items. The most accurate
and usually easiest checks for proper operation of indi- 4. Remove the screws, nuts, or other items fastening
vidual items is direct replacement. However, the most the unit to the equipment.
common cause of failure are poor connections or de-
fective or improper wiring. Also, there are no adjust- 5. Remove the unit and install the replacement unit.
ments to perform. Therefore, only replacement proce-
dures are given. Before replacing an item, verify the 6. Tighten the screws, nuts, or other items fastening
following: the unit to the equipment.
• Other electrical circuits are operating correctly.
7. Connect the marked wires to the correct terminals
• Battery is fully charged and the cable terminals are
or connectors.
clean and correctly connected.
• Wiring and connections to device are tight and in Light Assemblies
good condition.
1. Disconnect the battery or batteries to remove all
Horns voltage from the terminals.

CAUTION NOTE: Do Step 4 before Step 2 and Step 3 if there is

no access to assembly wire terminals.
Audible alarms and horns have various levels of
output. Be certain that any replacement alarm or 2. Mark the wires for reconnecting.
horn has an output that can be heard in the area
where the lift truck will be used. 3. Disconnect the wires at the wire connectors or light
terminals.
1. Make sure the key switch is in the OFF position or
the battery is disconnected. 4. Remove the screws, nuts, or other items fastening
the assembly to the equipment.
2. Mark the horn wires for reconnecting and discon-
nect them. 5. Remove the assembly and put the new assembly in
the correct position.
3. Remove the screws, nuts, or other items fastening
the horn to the equipment.

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Diagrams, Schematics, or Arrangements 2200 YRM 1351

NOTE: Some assemblies have no access to the wire Flashing Unit

terminals after it is fastened to the equipment. If so, do
Step 7 before Step 6. Replace the flashing unit by holding the base and
pulling the unit until the pins are out of the base clips.
6. Install the screws, nuts, or other items to fasten the Align the replacement flashing unit pins. Push the unit
assembly to the equipment. into position on the base.

7. Connect the marked wires to the correct terminals

or connectors.

Meters, Senders, and Switches

GENERAL 2. Make sure that the battery is charged, correctly in-
stalled, and the cable terminals are clean and tight.
Meters, senders, and switches cannot be repaired. The
fan and wiper motors of the operator compartment also 3. Make sure that the wires and connections to the unit
cannot be repaired. These components are replaced are tight and in good condition.
when they are defective. The most common cause of
failure is a bad connection or defective wiring. There are NOTE: See your Cummins engine dealer for starter and
no adjustments. See the section for replacement pro- alternator repair.
cedures. Before a meter or sender is replaced, make
the following checks:

1. Make sure that the other meters and electrical cir-

cuits are operating correctly.

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 NOTES

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Diagrams, Schematics, or Arrangements 2200 YRM 1351

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2200 YRM 1351 Diagrams, Schematics, or Arrangements

Figure 6. Diesel Main Wire Harness (D876)

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Diagrams, Schematics, or Arrangements 2200 YRM 1351

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2200 YRM 1351 Diagrams, Schematics, or Arrangements

Figure 7. Diesel Main Wire Harness (D877)

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Diagrams, Schematics, or Arrangements 2200 YRM 1351

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2200 YRM 1351 Diagrams, Schematics, or Arrangements

Figure 8. LPG Main Wire Harness (D876)

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Diagrams, Schematics, or Arrangements 2200 YRM 1351

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2200 YRM 1351 Diagrams, Schematics, or Arrangements

Figure 9. LPG Main Wire Harness (D877)

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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

2200 YRM 1351 4/07 Printed in the United Kingdom