cabina del operador

7/29/2019 Cabina Del Operador

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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

cabina del operador

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