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Maintenance
OPERATORS CABGLP/GDP3.5-5.5LJ/MJ
(GP/GLP/GDP70-120LJ/MJ) [C813, E813]
PART NO. 524173801 100 YRM 778
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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!
CAUTIONIndicates a condition that can cause property damage!
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Operators Cab Table of Contents
TABLE OF CONTENTS
General................................................................................................................................................................
Cab Repair.......................................................................................................................................................... 2
Remove ........................................................................................................................................................... 2
Install............................................................................................................................................................... 3
Switch Panel........................................................................................................................................................ 3
Window Wipers Replacement ............................................................................................................................. 4
Front Wiper Assembly ..................................................................................................................................... 4
Rear Wiper Assembly ..................................................................................................................................... 4
Door Handle Assembly........................................................................................................................................ 6
Fuse Panel .......................................................................................................................................................... 7
Heater Assembly ................................................................................................................................................. 7
Remove ........................................................................................................................................................... 7
Install............................................................................................................................................................... 7
Window Replacement.......................................................................................................................................... 9
Options ................................................................................................................................................................ 1
Rear Strobe Lights .......................................................................................................................................... 1
Heavy-Duty Air Cleaner.................................................................................................................................. 1Label Replacement.............................................................................................................................................. 12
Electrical Schematics .......................................................................................................................................... 12
This section is for the following models:
GLP/GDP3.5-5.5LJ/MJ (GP/GLP/GDP70-120LJ/MJ) [C813, E813]
2004 Yale Materials Handling Corp.
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100 YRM 778 Genera
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 oper-ator 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 sep
arate unit and can be removed as a complete unit from
the module and frame of the lift truck.
Figure 1. Operator Cab
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Cab Repair 100 YRM 778
Cab Repair
REMOVE
To remove the operator cab from the frame, do the fol-
lowing:
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 har-
ness connection to the windshield wipers.
5. Disconnect the air filter hose from the lower left cor-
ner of the cab frame.
6. Disconnect the water hoses to the heater and dis-
connect the heater wire harness.
7. Remove the cab front attaching hardware. See Fig-
ure 2.
1. CAPSCREW (2)2. WASHER (4)
3. SHIM (ASREQUIRED)
4. LEFT FRONT LEG
Figure 2. Front Attaching Hardware
8. Remove the cab rear attaching hardware (1, 2, and
3, Figure 3).
1. FLAT WASHER2. LOCKWASHER3. CAPSCREW4. CAPSCREW5. LOCKWASHER
6. FLAT WASHER7. RING WASHER8. ISOLATOR9. ISOLATOR10. ISOLATOR CUP
Figure 3. Rear Attaching Hardware
9. Remove the rear isolator hardware and inspect for
wear or damage. Replace if necessary. See Fig-
ure 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 ca-
pacity to lift 500 kg (1100 lb).
11. Connect a lifting device to a spreader bar or liftstrap, that is through the door openings at the top of
the operator cab (under the overhead guard struc-
ture). 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.
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100 YRM 778 Switch Pane
CAUTION
Lift the operator cab carefully. Check that all elec-
trical wires and attachments are disconnected cor-
rectly and are not damaged.
12. Carefully lift the cab away from the lift truck. Setthe 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 replace-
ment, 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 struc-
ture). Put material that will be a cushion at the top
of the door openings to prevent damage. Operatethe 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.
5. Install the rear attaching hardware to the frame an
tighten finger-tight only.
6. Install the front attaching hardware. Install th
shims as required and bend the tabs as necessary
Tighten finger-tight only.
7. Connect the wiring harnesses andwires to the com
ponents 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 har
ness connection to the windshield wipers.
12. Connect the main wiring harness and the front and
rear light harness between the lift truck and the op
erator cab.
13. Install the cowl cover.
14. Install the dash over the cowl cover and install the
retaining screws.
15. Install the cab doors.
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/WASHER2. REAR WIPER/WASHER3. HEATER FAN
Figure 4. Cab Switches
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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.
FRONT WIPER ASSEMBLY
1. To replace the front motor assembly, remove the re-
taining 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.
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 har-
ness.
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. WIPER ARM (2)2. RETAINING NUT (2)3. LOCKWASHER (2)4. NUT (2)5. LOCK NUT (2)
6. FLAT WASHER (2)7. WIPER MOTOR8. ELECTRICAL CONNECTOR9. WATER TUBE10. HEATER
11. COVER12. CHECK VALVE13. GROMMET
Figure 5. Front Window Wiper System
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100 YRM 778 Window Wipers Replacemen
1. MOUNTING STUD2. WASHER (2)
3. GROMMET (2)4. GLASS5. WIPER MOTOR6. WASHER (2)7. NUT (2)8. COVER9. WATER TUBE10. CONNECTOR
11. RESERVOIR12. SPRAY NOZZLE MOUNTING STUD
13. GROMMET14. WASHER15. RETAINER16. NUT17. HARDWARE COVER18. NUT19. WASHER20. WIPER ARM
Figure 6. Rear Window Wiper System
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Door Handle Assembly 100 YRM 778
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.
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 noz-
zle 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 com-
ponents: an outside handle with lock, an inside lever-
type 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 holesfrom 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 mecha-
nism 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 FRAME2. INSIDE HANDLE3. COVER
4. STRIKERHARDWARE5. SEAL6. OUTSIDE HANDLE
Figure 7. Door Handle Assembly
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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. WIPERFRONT/REAR
2. DOMELIGHT
3. FAN/RADIO4. HEATER/BLOWER
Figure 8. Fuse Panel
Heater Assembly
REMOVE
WARNINGIf 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.
CAUTIONWhen 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 num-
ber 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.
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.
INSTALL
1. Attach the heater assembly to the mounting bracke
with four screws and washers. See Figure 9.
2. Attach the heater duct to the mounting bracket wit
two screws and washers. Make sure that the duc
mates with the heater input opening.
3. Make sure that the seal on the door side of the duc
is installed correctly.
4. Connect the heater electrical connector.
5. Connect the two preformed heater hoses to th
heater. See Figure 9.
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Heater Assembly 100 YRM 778
1. HEAT DUCT2. SEAL3. HEATER4. BRACKET5. SCREW (4)
6. WASHER (4)7. HEATER HOSE CONNECTIONS8. PREFORMED HEATER HOSE (RETURN)9. PREFORMED HEATER HOSE (SUPPLY)
Figure 9. Heater Assembly
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100 YRM 778 Window Replacemen
Window Replacement
WARNING
All windows installed in the cab are made of tem-
pered 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 window
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 damag
to any of the cab windows, it is recommended that a
windows be repaired or replaced by your Yale dealer o
other qualified glazier.
Table 1. Material Specifications for Cab Windows
ThicknessLocation of
Window
Yale Part
NumberMaterial Specification
mm inch
Front 580014760 5.9 to 7.5 0.23 to 0.29
Rear 580014770
Tinted Tempered Safety Glass per ANSI
Z26.1 AS1 Requirements 5.6 to 6.8 0.22 to 0.27
Doors
Upper RH 580014007
Upper LH 580014006
Tinted Tempered Safety Glass per ANSI
Z26.1 AS2 Requirements
4.5 to 5.0 0.18 to 0.2
Lower, R/L 524140139 Tinted Tempered Safety Glass per ANSI
Z26.1 AS2 Requirements
4.5 to 5.0 0.18 to 0.2
Top 580025892 Tinted Lexan MR 5004-310351 3.0 0.12
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Window Replacement 100 YRM 778
1. FRONT WINDOW2. SEAL3. ATTACHING HARDWARE4. CLAMP WITH HARDWARE
5. SKYLIGHT6. REAR WINDOW7. LOWER DOOR WINDOW8. UPPER DOOR WINDOW
Figure 10. Operator Cab Assembly Glass
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100 YRM 778 Options
Options
There are several options available for the cab. See
your Yale dealer for the full range of available options.
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 Fig-
ure 11. The strobe light is normally configured to op-
erate continuously. It can be optionally configured to
activate when the lift truck is put into reverse gear. See
Figure 12.
HEAVY-DUTY AIR CLEANER
In environments with very dirty conditions, the lift truc
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 neces
sary. Inspect the canister, the hose, and the molde
port for excessive wear, cracks, or damage.
1. LOW MOUNT OR HIGH MOUNT STROBE2. HEAVY-DUTY AIR CLEANER3. ADDITIONAL MIRROR
Figure 11. Operator Cab Options
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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 differ-
ent 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 Fig-
ure 13. Refer to Diagrams 8000 YRM 757 for the lift truck electrical schematics.
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100 YRM 778 Electrical Schematics
Figure 12. Cab Light Options Electrical Schematic
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Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011
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