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Maintenance

OPERATORS CAB
GLP/GDP3.5-5.5LJ/MJ (GP/GLP/GDP70-120LJ/MJ) [C813, E813]

PART NO. 524173801

100 YRM 778

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR


When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, 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!

Operators Cab

Table of Contents

TABLE OF CONTENTS
General................................................................................................................................................................ Cab Repair .......................................................................................................................................................... Remove ........................................................................................................................................................... Install............................................................................................................................................................... Switch Panel........................................................................................................................................................ Window Wipers Replacement ............................................................................................................................. Front Wiper Assembly ..................................................................................................................................... Rear Wiper Assembly ..................................................................................................................................... Door Handle Assembly........................................................................................................................................ Fuse Panel .......................................................................................................................................................... Heater Assembly ................................................................................................................................................. Remove ........................................................................................................................................................... Install............................................................................................................................................................... Window Replacement.......................................................................................................................................... Options ................................................................................................................................................................ Rear Strobe Lights .......................................................................................................................................... Heavy-Duty Air Cleaner .................................................................................................................................. Label Replacement.............................................................................................................................................. Electrical Schematics .......................................................................................................................................... This section is for the following models: GLP/GDP3.5-5.5LJ/MJ (GP/GLP/GDP70-120LJ/MJ) [C813, E813] 1 2 2 3 3 4 4 4 6 7 7 7 7 9 11 11 11 12 12

2004 Yale Materials Handling Corp.

100 YRM 778

General

General
A fully-enclosed operator cab can be installed on the lift truck as an option. See Figure 1. When installed, the cab has doors, windows, window wipers, heater system, and an optional circulation fan. The overhead guard is an integral part of the operator cab. The operator cab is installed on a platform above the main frame members. Step plates on both sides of the lift truck give access to the operator cab. The operator cab is a separate unit and can be removed as a complete unit from the module and frame of the lift truck.

Figure 1. Operator Cab

Cab Repair

100 YRM 778

Cab Repair
REMOVE
To remove the operator cab from the frame, do the following: 1. Remove the retaining screws from the dash and the cowl panel. 2. Lift up the dash and remove the cowl panel. 3. Disconnect the main wiring harness, the front light harness, and the rear light harness between the lift truck and the operator cab. Stow front light harness in the cab leg before removing the cab from the lift truck. 4. Disconnect the water tube and the wiper motor harness connection to the windshield wipers. 5. Disconnect the air filter hose from the lower left corner of the cab frame. 6. Disconnect the water hoses to the heater and disconnect the heater wire harness. 7. Remove the cab front attaching hardware. See Figure 2. 1. 2. 3. 4. 5. FLAT WASHER LOCKWASHER CAPSCREW CAPSCREW LOCKWASHER 6. 7. 8. 9. 10. FLAT WASHER RING WASHER ISOLATOR ISOLATOR ISOLATOR CUP 8. Remove the cab rear attaching hardware (1, 2, and 3, Figure 3).

Figure 3. Rear Attaching Hardware 9. Remove the rear isolator hardware and inspect for wear or damage. Replace if necessary. See Figure 3. 10. To prevent damage to the cab doors, remove them before attaching a lifting device.

WARNING
Make sure that the lifting device has a minimum capacity to lift 500 kg (1100 lb). 11. Connect a lifting device to a spreader bar or lift strap, that is through the door openings at the top of the operator cab (under the overhead guard structure). Put material that will be a cushion at the top of the door openings to prevent damage. Operate the lifting device just enough to correctly position the spreader bar or lift strap on the operator cab.

1. CAPSCREW (2) 2. WASHER (4)

3. SHIM (AS REQUIRED) 4. LEFT FRONT LEG

Figure 2. Front Attaching Hardware

100 YRM 778

Switch Panel 5. Install the rear attaching hardware to the frame and tighten finger-tight only. 6. Install the front attaching hardware. Install the shims as required and bend the tabs as necessary. Tighten finger-tight only. 7. Connect the wiring harnesses and wires to the components in the operator cab. 8. Connect the wiring harness to the heater. 9. Connect the air filter hose to the left rear leg of the cab frame. 10. Tighten the cab mounting bolts as follows: a. Front bolts - 90 Nm (66 lbf) b. Rear bolts - 90 Nm (66 lbf) 11. Connect the water tube and the wiper motor harness connection to the windshield wipers. 12. Connect the main wiring harness and the front and rear light harness between the lift truck and the operator cab. 13. Install the cowl cover. 14. Install the dash over the cowl cover and install the retaining screws. 15. Install the cab doors.

CAUTION
Lift the operator cab carefully. Check that all electrical wires and attachments are disconnected correctly and are not damaged. 12. Carefully lift the cab away from the lift truck. Set the cab assembly in a suitable storage area and put blocks under the unit to make it stable and prevent damage to parts still attached.

INSTALL
If the operator cab was removed for repair or replacement, install it as follows: 1. Connect a lifting device to a spreader bar or lift strap, that is through the door openings at the top of the operator cab (under the overhead guard structure). Put material that will be a cushion at the top of the door openings to prevent damage. Operate the lifting device just enough to correctly position the spreader bar or lift strap on the operator cab. 2. Make sure that the bottom half of the isolators are in place. 3. Install the operator cab on the mounts making sure that the isolator is correctly positioned through the hole in the cab frame mount. See Figure 3. 4. Install the rubber isolators, washers, nuts, and bolts for the mounts. Make sure that the isolators are correctly positioned.

Switch Panel
The switch panel for the front and rear window wipers and the heater fan is located in the upper right rear of the cab. See Figure 4. Gauges and switches that are not an integral part of the cab are covered in Instrument Panel Indicators and Senders 2200 YRM 756.

1. FRONT WIPER/WASHER 2. REAR WIPER/WASHER 3. HEATER FAN Figure 4. Cab Switches

Window Wipers Replacement

100 YRM 778

Window Wipers Replacement


Two window wiper motor assemblies are installed in the operator cab. The front window motor assembly has two wiper arms connected to a single wiper blade. The rear window has a wiper motor assembly that has one wiper arm attached to a single wiper blade. 3. Remove the water tube and disconnect the wiring harness. 4. Repair or replace defective parts and install the front wiper assembly as shown in Figure 5. 5. Install the water tube and connect the wiring harness.

FRONT WIPER ASSEMBLY


1. To replace the front motor assembly, remove the retaining nuts and lockwashers from the wiper arms. Remove the wiper arm and blade from the outside. See Figure 5. 2. Remove the nuts, lockwashers, and flat washers from the two threaded shafts that pass through the metal frame (cowl) of the operator cab.

REAR WIPER ASSEMBLY


1. To replace the rear motor assembly, remove the retaining nut and lockwasher from the wiper arm. Remove the wiper arm and blade from the outside. See Figure 6.

1. 2. 3. 4. 5.

WIPER ARM (2) RETAINING NUT (2) LOCKWASHER (2) NUT (2) LOCK NUT (2)

6. 7. 8. 9. 10.

FLAT WASHER (2) WIPER MOTOR ELECTRICAL CONNECTOR WATER TUBE HEATER

11. COVER 12. CHECK VALVE 13. GROMMET

Figure 5. Front Window Wiper System

100 YRM 778

Window Wipers Replacement

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

MOUNTING STUD WASHER (2) GROMMET (2) GLASS WIPER MOTOR WASHER (2) NUT (2) COVER WATER TUBE CONNECTOR

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

RESERVOIR SPRAY NOZZLE MOUNTING STUD GROMMET WASHER RETAINER NUT HARDWARE COVER NUT WASHER WIPER ARM

Figure 6. Rear Window Wiper System

Door Handle Assembly 2. Remove the hardware covers, nuts, retainers, and flat washers from the threaded shafts that pass through the glass of the operator cab. 3. Remove the wiper motor cover by pulling backward. The cover is held in place by plastic tabs on the inside of the cover. 4. Remove the water tube and disconnect the wiring harness connector.

100 YRM 778 5. From inside the cab, on the wiper motor, remove the nuts and washers from the mounting studs that pass through the glass from the back side. 6. Repair or replace any defective parts and install the rear wiper assembly as shown in Figure 6. NOTE: One of the mounting studs is also the spray nozzle for the window washer. 7. Install the water tubes and connect the electrical wires harness.

Door Handle Assembly


The door handle assemblies are made up of three components: an outside handle with lock, an inside levertype handle and latch mechanism, and the striker. See Figure 7. The outside door handle is fastened to the door by three screws installed through access holes from the inside of the door. The inside door handle is fastened to the door by a capscrew and washer at the bottom end of the handle and attaching hardware at the mechanism. The handle assembly has a latch mechanism that contacts the striker. The striker is threaded and is installed on the forward door post. Adjust the striker so that it mates with the latch mechanism.

1. DOOR FRAME 2. INSIDE HANDLE 3. COVER

4. STRIKER HARDWARE 5. SEAL 6. OUTSIDE HANDLE

Figure 7. Door Handle Assembly

100 YRM 778

Heater Assembly

Fuse Panel
The fuse panel with the fuses for the window wipers, lights, fan, and heater system are inside the operator cab. This fuse panel is located in the upper right rear corner of the cab. The fuse arrangement is shown in Figure 8. The fuse panel can be pulled away or removed from the mount by loosening two capscrews, then disconnecting the fuse panel from the wire harness.

1. WIPER FRONT/REAR 2. DOMELIGHT

3. FAN/RADIO 4. HEATER/BLOWER

Figure 8. Fuse Panel

Heater Assembly
REMOVE WARNING
If the truck has been run for awhile, the heater hoses will be hot and the water can cause severe burns. Make sure that the hoses are cool before removal. 2. Disconnect the heater electrical connector. 3. Open the right-hand cab door and remove the two screws that fasten the heater duct to the bracket. 4. Remove the four screws that fasten the heater to the bracket and remove the heater assembly.

CAUTION
When the engine heater hoses must be replaced in the cab, make sure to use heater hoses of the correct material and size. Order Yale part number 504323758 for the engine supply hose and 504323755 for the return hose. All hoses must conform to SAE Specification 20R3 Class C or 20R3 Class D-2. NOTE: If the heater fails, replace the heater assembly as a complete unit. 1. Disconnect the two preformed heater hoses from the heater. See Figure 9.

INSTALL
1. Attach the heater assembly to the mounting bracket with four screws and washers. See Figure 9. 2. Attach the heater duct to the mounting bracket with two screws and washers. Make sure that the duct mates with the heater input opening. 3. Make sure that the seal on the door side of the duct is installed correctly. 4. Connect the heater electrical connector. 5. Connect the two preformed heater hoses to the heater. See Figure 9.

Heater Assembly

100 YRM 778

1. 2. 3. 4. 5.

HEAT DUCT SEAL HEATER BRACKET SCREW (4)

6. 7. 8. 9.

WASHER (4) HEATER HOSE CONNECTIONS PREFORMED HEATER HOSE (RETURN) PREFORMED HEATER HOSE (SUPPLY)

Figure 9. Heater Assembly

100 YRM 778

Window Replacement

Window Replacement
WARNING
All windows installed in the cab are made of tempered glass. The overhead skylight is made of Lexan. All replacement windows must be made of the correct material and thickness as the windows furnished with the lift truck. See Table 1 for window specifications. The front window is a single unit held in place by screws through the glass. See Figure 10. The rear and lower door windows are replaced as single units held in the window openings by a rubber seal. The slider windows and frames in the doors must be replaced as a unit. The top window is a single piece of curved Lexan and is fastened by an adhesive. In the event of breakage, cracking, or other damage to any of the cab windows, it is recommended that all windows be repaired or replaced by your Yale dealer or other qualified glazier.

Table 1. Material Specifications for Cab Windows Location of Window Front Rear Doors Upper RH Upper LH Lower, R/L Top 580014007 580014006 524140139 580025892 Tinted Tempered Safety Glass per ANSI Z26.1 AS2 Requirements Tinted Tempered Safety Glass per ANSI Z26.1 AS2 Requirements Tinted Lexan MR 5004-310351 4.5 to 5.0 0.18 to 0.2 Yale Part Number 580014760 580014770 Material Specification mm Tinted Tempered Safety Glass per ANSI Z26.1 AS1 Requirements 5.9 to 7.5 5.6 to 6.8 Thickness inch 0.23 to 0.29 0.22 to 0.27

4.5 to 5.0 3.0

0.18 to 0.2 0.12

Window Replacement

100 YRM 778

1. 2. 3. 4.

FRONT WINDOW SEAL ATTACHING HARDWARE CLAMP WITH HARDWARE

5. 6. 7. 8.

SKYLIGHT REAR WINDOW LOWER DOOR WINDOW UPPER DOOR WINDOW

Figure 10. Operator Cab Assembly Glass

10

100 YRM 778

Options

Options
There are several options available for the cab. See your Yale dealer for the full range of available options.

HEAVY-DUTY AIR CLEANER


In environments with very dirty conditions, the lift truck can be equipped with a heavy-duty air cleaner which precleans the air before it enters the standard air filter. This precleaner is mounted on the rear of the cab in place of the air vent. See Figure 11. Clean or replace the heavy-duty precleaner as necessary. Inspect the canister, the hose, and the molded port for excessive wear, cracks, or damage.

REAR STROBE LIGHTS


In addition to the standard overhead driving lights, the cab can be equipped with a rear-mounted strobe light with either a high or low mounting fixture. See Figure 11. The strobe light is normally configured to operate continuously. It can be optionally configured to activate when the lift truck is put into reverse gear. See Figure 12.

1. LOW MOUNT OR HIGH MOUNT STROBE 2. HEAVY-DUTY AIR CLEANER 3. ADDITIONAL MIRROR Figure 11. Operator Cab Options

11

Electrical Schematics

100 YRM 778

Label Replacement
WARNING
Labels that have WARNINGS or CAUTIONS must be replaced if they are damaged. If a mast of a different size or an accessory carriage is installed, the capacity rating can change. Changes in drive tires can change the capacity rating. See a Yale lift trucks dealer for a replacement nameplate. The nameplate information is a safety item and must be correct for the equipment and configuration of the lift truck. Refer to Frame 100 YRM 726 for label placement.

Electrical Schematics
The electrical schematic for the cab is included in this manual for the users convenience. See Figure 12 and Figure 13. Refer to Diagrams 8000 YRM 757 for the lift truck electrical schematics.

12

100 YRM 778

Electrical Schematics

Figure 12. Cab Light Options Electrical Schematic

13

Electrical Schematics

100 YRM 778

Figure 13. Operator Cab Wiring Schematic

14

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

100 YRM 778

6/04 (9/03)(8/02) Printed in U.S.A.