Yale e879 glc60vx lift truck service repair manual by 1630861

GLC/GDC60VX, GLC/GDC70VX (E879) SERVICE MANUAL CONTENTS SECTION FRAME............................................................................................................................ GM 4.3L V-6 ENGINES................................................................................................... KUBOTA ENGINE REPAIR............................................................................................ COOLING SYSTEM........................................................................................................ LPG FUEL SYSTEM GM 4.3L ENGINE WITH PSI........................................................ THREE-SPEED POWERSHIFT TRANSMISSION REPAIR........................................... TRANSMISSION REPAIR (DANA SPICER) 2X2........................................................... DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR (WET BRAKE)................... STEERING AXLE............................................................................................................ BRAKE SYSTEM............................................................................................................ HYDRAULIC GEAR PUMP............................................................................................. HYDRAULIC CLEANLINESS PROCEDURES............................................................... MAIN CONTROL VALVE................................................................................................ CYLINDER REPAIR (MAST S/N A513, A514, A613, A614, B513, B514)..................... HIGH VOLTAGE SWITCH (HVS) IGNITION.................................................................. WIRE HARNESS REPAIR.............................................................................................. USER INTERFACE......................................................................................................... USER INTERFACE......................................................................................................... ELECTRICAL SYSTEM.................................................................................................. MAST REPAIRS (S/N A513, A514, A613, A614, A702, A703, A704, A705, A706, A707, A751, A752, B513, B514, B586, B587, B588, B589, B590, B591, B749, B750, B751, B752, B753, B754)................................................................................ METRIC AND INCH (SAE) FASTENERS....................................................................... CALIBRATION PROCEDURES...................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... DIAGRAMS AND SCHEMATICS.................................................................................... DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................

PART NUMBER

YRM NUMBER

REV DATE

524288189 524265337 550048607 524223757 550043871 524288194 524294873 524288199 524223764 524262279 524223766 550073240 524223767 524294878 524208014 524223769 524223770 524223771 524223772

0100 YRM 1316 0600 YRM 1251 0600 YRM 1557 0700 YRM 1123 0900 YRM 1556 1300 YRM 1317 1300 YRM 1343 1400 YRM 1318 1600 YRM 1133 1800 YRM 1247 1900 YRM 1136 1900 YRM 1620 2000 YRM 1137 2100 YRM 1328 2200 YRM 1097 2200 YRM 1128 2200 YRM 1130 2200 YRM 1131 2200 YRM 1142

08/13 05/14 03/13 03/13 04/14 03/13 03/14 12/13 07/13 03/13 04/14 12/14 04/14 02/14 05/14 12/14 12/14 12/14 04/14

524265342 524150797 524223780 550048616 550048609 550055283 524221866

4000 YRM 1250 8000 YRM 0231 8000 YRM 1134 8000 YRM 1571 8000 YRM 1572 8000 YRM 1585 9000 YRM 1112

02/14 10/13 12/14 11/13 04/13 04/14 12/14

Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center. 9000 YRM 1112 ON CD PART NO. 550048594 (12/14)

2100 YRM 1328

General

General This section contains repair procedures for tilt cylinders, main lift cylinder, and free-lift cylinders. The number and the design of the parts can be different, but the operation of the cylinders is the same.

Safety Procedures When Working Near Mast The following procedures MUST be used when inspecting or working near the mast. Additional precautions and procedures can be required when repairing or removing the mast.

WARNING Mast parts are heavy and can move. Distances between parts are small. Serious injury or death can result if part of the body is hit by parts of the mast or the carriage. •

Never put any part of the body into or under the mast or carriage unless all parts are completely lowered or a safety chain is installed. Also make sure that the power is OFF and the key is removed. Put a DO NOT OPERATE tag in the operator's compartment. Disconnect the battery and put a tag or lock on the battery connector.

•

Be careful of the forks. When the mast is raised, the forks can be at a height to cause an injury.

•

DO NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on the mast.

•

DO NOT use blocks to support the mast weldments nor to restrain their movement.

•

Mast repairs require disassembly and removal of parts and can require removal of the mast or carriage. Follow the repair procedures in this section.

WHEN WORKING NEAR THE MAST ALWAYS: •

Lower the mast and carriage completely. Push the lift/lower control lever forward and make sure there is no movement in the mast. Make sure that all parts of the mast that move are fully lowered. OR

•

If parts of the mast must be in a raised position, install a safety chain to restrain the moving parts of the mast. Connect moving parts to a part that does not move. Follow these procedures:

1. Put mast in vertical position. 2. Raise mast to align bottom crossmember of weldment that moves in outer weldment with crossmember on outer weldment. On the two-stage and free-lift mast, the moving part is the inner weldment. On the three-stage mast, it is the intermediate weldment. On the four-stage mast, it is the first intermediate weldment. See Figure 1. 3. Use a 3/8-inch minimum safety chain with a hook to fasten the crossmembers together so the movable member cannot lower. Put hook on back side of mast. Make sure hook is completely engaged with a link in the chain. Make sure safety chain does not touch lift chains or chain sheaves, tubes, hoses, fittings, or other parts on the mast. 4. Lower mast until there is tension in safety chain and free-lift cylinder (two-stage full free-lift, threestage, and four-stage) is completely retracted. If running, turn the power OFF. Apply the parking brake. Install a DO NOT REMOVE tag on the safety chain(s). 5. Install another safety chain (3/8-in. minimum) between the top or bottom crossmember of the carriage bar and a crossmember on the outer weldment. 6. After lowering or restraining the mast, shut off the power, and remove key. NOTE: Place a DO NOT OPERATE tag in the operator's compartment. 7. Disconnect battery and put a tag or lock on battery connector.

Safety Procedures When Working Near Mast

2100 YRM 1328

A. TWO-STAGE LFL MAST B. TWO-STAGE FFL MAST

C. THREE-STAGE FFL MAST D. FOUR-STAGE FFL MAST

1. 2. 3. 4.

5. 6. 7. 8.

OUTER WELDMENT INNER WELDMENT INTERMEDIATE WELDMENT HOOK

FREE-LIFT CYLINDER CARRIAGE BAR CROSSMEMBER FIRST INTERMEDIATE WELDMENT

Figure 1. Two-Stage LFL, Two-Stage FFL, Three-Stage FFL, and Four-Stage FFL Masts 2

2100 YRM 1328

Tilt Cylinder Repair

Tilt Cylinder Repair REMOVE

•

WARNING Before removing the tilt cylinder(s), tilt the mast forward. Use a chain to hold the mast to the frame and prevent the mast from moving forward or backwards.

WARNING DO NOT push the tilt pins out of the rod end with your fingers. DO NOT permit the tilt cylinders to drop and cause damage.

Frame 0100YRM1316 for lift truck models •

1. At the mast end mount, remove the capscrew and anchor pin from the tilt pin. Using a brass drift or similar tool, push the tilt pin out of the rod end. Remove lube fitting from tilt pin. See Figure 2 for lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (E878)

•

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (B909)

4. Disconnect the hydraulic lines at the cylinder hose ports. Install caps on the hydraulic lines and in the cylinder hose ports. See Figure 2 for lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

See Figure 3 for lift truck model •

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

2. Stroke cylinder to the full back tilt position. 3. Remove floor mats, floor plates and side covers to access the frame end mount of tilt cylinder. See Side Covers Remove procedures in

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878)

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

5. Use a lifting device to support tilt cylinders. At frame end mount, remove capscrew, washer, and anchor pin from the tilt pin. Using a brass drift or similar tool, push the tilt pin out to the bushing and frame end mount. Remove lube fitting from tilt pin. See Figure 2 for lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

Frame 0100YRM1321 for lift truck models •

GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

Frame 0100YRM1581 for lift truck models

NOTE: Insure that the parking brake is applied before starting the procedure below. NOTE: Perform Step 1 and Step 2 if mast is installed on the lift truck.

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909)

Tilt Cylinder Repair

2100 YRM 1328

Figure 2. Tilt Cylinder Installation for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 4

2100 YRM 1328

Tilt Cylinder Repair Legend for Figure 2

NOTE: HYDRAULIC HOSES ARE SHOWN DISCONNECTED FOR CLARITY. A. GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

B. GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

1. 2. 3. 4. 5.

6. 7. 8. 9. 10.

CAPSCREW LOCK NUT ANCHOR PIN TILT PIN FRAME END MOUNT See Figure 3 for lift truck model •

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

6. Using a lifting device, remove the tilt cylinder from the lift truck.

MAST END MOUNT CYLINDER HOSE PORTS ROD END LUBE FITTINGS WASHER

2. Place the tilt cylinder in a soft jaw vise. Remove hex nut, washer, capscrew and rod end from rod. See Figure 3. 3. Using a pin-type spanner wrench, remove the gland from the tilt cylinder shell. Remove the rod and piston assembly from the cylinder shell. See Figure 4 for lift truck models

7. Repeat Step 1 through Step 6 for the opposite tilt cylinder.

DISASSEMBLE

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

NOTE: Perform only those steps below required to repair the tilt cylinder. NOTE: Perform Step 1 for lift truck models: •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

NOTE: Note the position of the rod end and number of turns used to remove the rod end. 1. Place the tilt cylinder in a soft jaw vise. Remove capscrew, lock nut, and washer securing rod end to rod. See Figure 2. NOTE: Perform Step 2 for lift truck model GLP/ GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909).

See Figure 5 for lift truck model •

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

NOTE: To prevent damage to sealing surfaces, use brass tools when removing seals and O-rings. NOTE: Perform Step 4 for lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

4. Remove and discard the O-ring, backup ring, seal, and wiper ring from the gland. See Figure 4.

NOTE: Note the position of the rod end and number of turns used to remove the rod end.

Tilt Cylinder Repair

2100 YRM 1328

Figure 3. Tilt Cylinder Installation for Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 6

2100 YRM 1328

Tilt Cylinder Repair Legend for Figure 3

A. OUTER VIEW

B. INNER VIEW

1. 2. 3. 4. 5.

6. 7. 8. 9. 10.

TILT PIN CAPSCREW WASHER ANCHOR PIN CYLINDER HOSE PORT

NOTE: Perform Step 5 for lift truck model GLP/ GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909). 5. Remove and discard the rod wiper, O-rings, rod seal, and backup ring from the gland. See Figure 5.

FRAME END MOUNT MAST END MOUNT ROD END LUBE FITTING HEX NUT

8. Remove and discard the wear ring and piston seal from the piston. See Figure 4 for lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

NOTE: Perform Step 6 only if the piston or rod has been damaged. 6. Place the rod in a soft-jaw vise and remove lock nut and piston from the rod.

See Figure 5 for lift truck model •

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

See Figure 4 for lift truck models •

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

See Figure 5 for lift truck model •

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

7. Remove O-ring, and if equipped tilt spacer from rod. Discard O-ring.

CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer's recommended safety procedures. Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

See Figure 4 for lift truck models •

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

CAUTION DO NOT allow cleaning solvent to come in contact with rubber components, as it will damage those components. Clean all metal parts in solvent and dry with compressed air.

See Figure 5 for lift truck model •

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

Tilt Cylinder Repair

NOTE: * USED ON TILT CYLINDER 6° FORWARD/6° OR 10° BACK TILT FOR LIFT TRUCK MODELS GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

SHELL GLAND ROD WIPER RING SEAL BACKUP RING O-RING PISTON PISTON SEAL LOCK NUT WEAR RING BUSHING TILT SPACER* CYLINDER HOSE PORTS

Figure 4. Tilt Cylinder Assembly for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

2100 YRM 1328

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

SHELL GLAND ROD WIPER O-RING ROD SEAL BACKUP RING ROD PISTON SEAL WEAR RING PISTON LOCKNUT BUSHING CYLINDER HOSE PORT

Figure 5. Tilt Cylinder Assembly for Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)

2100 YRM 1328

INSPECT

Tilt Cylinder Repair See Figure 5 for lift truck model •

Inspect the gland for damage to the threads and the seal surfaces. Replace the gland if damaged. Inspect the piston for any damage to the seal surfaces and replace if damaged. Inspect the rod for damage to the rod surface and ensure that the rod is not bent. Replace the rod if found to be damaged. Inspect the inner surface of the cylinder shell for damage. If the shell is found to be damaged, replace the cylinder assembly.

ASSEMBLE NOTE: To prevent damage to sealing surfaces, use brass tools when installing seals and O-rings. 1. Install a new piston seal and wear ring on the piston. See Figure 4 for lift truck models

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

NOTE: Perform Step 3, if the piston was removed from the rod, for lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

3. Place the rod in a soft-jaw vise, and install the piston on the rod and tighten the lock nut to 400-440 N•m (295 to 325 lbf ft). See Figure 4. NOTE: Perform Step 4 and Step 5, if the piston was removed from the rod, for lift truck model GLP/ GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909).

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

4. Place the rod in a soft jaw vise and install the piston onto the rod. See Figure 5.

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

5. Install locknut onto rod. See Figure 5. Tighten locknut to 400 to 440 N•m (295 to 325 lbf ft).

See Figure 5 for lift truck model •

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

2. Install new O-ring, and if equipped, install tilt spacer onto rod. See Figure 4 for lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

NOTE: Perform Step 6 for lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

6. Install a new wiper ring, seal, backup ring, and Oring onto gland. See Figure 4. NOTE: Perform Step 7 for lift truck model GLP/ GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909).

Tilt Cylinder Repair 7. Install new O-rings, backup ring, rod seal, and rod wiper onto gland. See Figure 5 for specific part order. 8. Install the rod and piston assembly in the cylinder shell. See Figure 4 for lift truck models •

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

See Figure 5 for lift truck model •

2100 YRM 1328 11. Apply two drops of Loctite® 545 or equivalent on gland threads. 12. Using a pin-type spanner wrench, install the gland onto the rod inside the shell. Tighten gland to 400 to 500 N•m (295 to 370 lbf ft). See Figure 5. NOTE: Rod end to be turned and positioned as noted during disassembly. 13. Install rod end, capscrew, washer, and hex nut onto rod. Tighten hex nut to 120 to 130 N•m (89 to 96 lbf ft). See Figure 3. 14. Repeat Step 1 through Step 13 for the opposite tilt cylinder.

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

NOTE: Perform Step 9 and Step 10 for lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

9. Using a pin-type spanner wrench, install the gland in the cylinder shell. Tighten the gland to 400 to 500 N•m (295 to 370 lbf ft). See Figure 4. NOTE: Rod end to be turned and positioned as noted during disassembly. 10. Install rod end on rod. Lubricate threads on capscrew with lubricant (Yale P/N 504234269). Install capscrew in rod end so that capscrew head is on the inboard side of rod end. Install washer and nut on capscrew. Washer and nut must be on the outboard side of rod end. Tighten nut to 90 N•m (66 lbf ft). See Figure 6. NOTE: Perform Step 11 through Step 13 for lift truck model GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909).

NOTE: LEFT TILT CYLINDER SHOWN. TILT CYLINDER AND MAST FOR LIFT TRUCK MODELS GLC/ GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) SHOWN. PARTS OF MAST OMITTED FOR CLARITY. A. OUTBOARD SIDE B. INBOARD SIDE 1. NUT 2. WASHER

3. ROD END 4. CAPSCREW

Figure 6. Rod End Installation

2100 YRM 1328

Tilt Cylinder Repair

INSTALL

•

NOTE: Lock nut should be pointed toward outside of truck, on lift truck models: •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

1. Using a lifting device, place the tilt cylinder in mounting point on the lift truck frame end mount. See Figure 2 for lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

See Figure 3 for lift truck model •

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

2. Install the lube fitting in the tilt pin and coat the tilt pin with grease. See Figure 2 for lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

See Figure 3 for lift truck model •

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

See Figure 3 for lift truck model •

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

NOTE: Perform Step 4 for lift truck models: •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

NOTE: Lubricate the threads on the capscrew with packing lubricant (Yale Part No. 504234269) prior to installation. 4. Install the anchor pin and capscrew onto rod end at frame end mount. Tighten capscrew to 90 N•m (66 lbf ft). See Figure 2. NOTE: Perform Step 5 for lift truck model GLP/ GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909). NOTE: Lubricate threads on capscrew with multipurpose grease prior to installation. 5. Install anchor pin, washer, and capscrew onto rod end at frame end mount. Tighten capscrew to 66 N•m (49 lbf ft). See Figure 3. NOTE: Perform Step 6 and Step 7 if mast is installed on lift truck. 6. At the mast end mount, place the rod end on the mounting point. See Figure 2 for lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

3. Install tilt pin into rod end and frame end mount. See Figure 2 for lift truck models

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

Tilt Cylinder Repair See Figure 3 for lift truck model •

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

7. Install lube fitting in tilt pin and coat tilt pin with grease. Install tilt pin into rod end and mast end mount.

2100 YRM 1328 12. Install side covers, floor mats, and floor plates. See Side Covers Install procedures in Frame 0100YRM1321 for lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878)

•

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909)

See Figure 2 for lift truck models •

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

See Figure 3 for lift truck model •

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

NOTE: Perform Step 8 for lift truck models •

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

NOTE: Lubricate the threads on the capscrew with packing lubricant (Yale P/N 504234269). 8. Install anchor pin and capscrew. Tighten capscrew to 90 N•m (66 lbf ft). See Figure 2. NOTE: Perform Step 9 for lift truck model GLP/ GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909). 9. Install washer, anchor pin, and capscrew onto rod end at mast end mount. Tighten capscrew to 95 to 100 N•m (70 to 74 lbf ft). See Figure 3. 10. Uncap and connect the hydraulic lines to the tilt cylinder hose ports. Slowly stroke the cylinder until the rod holes line up with the mast tilt anchor holes. 11. Repeat Step 1 through Step 10 for opposite tilt cylinder.

Frame 0100YRM1316 for lift truck models •

GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

Frame 0100YRM1581 for lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (E878)

•

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (B909)

13. Remove chain holding the mast to the frame.

WARNING DO NOT put hands between the cylinder rod end and the mast. Serious injury can occur. 14. Operate the tilt cylinders. Check for correct operation and leakage. Adjust the tilt cylinders, see Tilt Cylinders, Adjust.

TILT CYLINDERS, ADJUST WARNING When the tilt cylinders have tilt limit spacers, make sure they are installed during installation procedures. Without the tilt limit spacers, the mast can tilt too much and cause an accident or serious injury. Check the tilt cylinder stroke by slowly tilting the mast fully forward and backward several times. Both tilt cylinders must stop their stroke at the same time. Adjust the rod ends as shown in Figure 7. There must be no twist in the mast weldments. NOTE: Tilt cylinders with 6° forward/6° or 10° back tilt for lift truck models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) have internal tilt spacers. See Figure 4.

2100 YRM 1328

Tilt Cylinder Repair

1. Adjust the stroke of the tilt cylinders with or without tilt spacers as follows (see Figure 7).

•

a. Adjust the rod ends to:

120 to 130 N•m (89 to 96 lbf ft) for lift truck model

15 mm (0.6 in.) for lift truck models •

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (C879, D879, E879, F879)

•

20 mm (0.8 in.) for lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878, E878)

•

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (C879, D879, E879, F879)

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

d. Tilt the mast fully backward and measure the tilt angle. See the Nameplate for tilt angles. If necessary, adjust both rod ends equally for the correct angle.

b. Slowly tilt the mast backward until one cylinder rod stops. On the opposite cylinder, loosen the capscrews on the rod end. Measure the distance from the end of the cylinder to the back end of the rod end. Use a wrench and turn the cylinder rod IN until the dimension starts to decrease, then stop. Repeat this procedure until both cylinder rods stop at the same position within 1 mm (0.04 in.) for lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878, E878)

•

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

0.5 mm (0.02 in.) for lift truck models •

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (C879, D879, E879, F879)

c. After the adjustments are complete, tighten lock nut on the rod end to 90 N•m (66 lbf ft) for lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878, E878)

1. 2. 3. 4. 5.

MAST ROD END TILT CYLINDER CAPSCREW LOCK NUT Figure 7. Tilt Cylinder Adjustments

Tilt Cylinder Repair

2100 YRM 1328

TILT CYLINDER LEAK CHECK WARNING Never allow anyone under a raised carriage. DO NOT put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the engine is STOPPED. DO NOT try to find hydraulic leaks by putting your hand on hydraulic components under pressure. Hydraulic oil can be injected into the body by the pressure. 1. Put a capacity load on the forks. Use a safety chain to hold the load to the carriage. Raise the load approximately 2.5 m (8 ft). Put the mast in a vertical position.

3. If the tilt rate is greater than the specifications, lower the mast and remove the load from the forks. Check for leaks in the hydraulic lines and fittings and install a gate valve between the port at the front of the tilt cylinder and the hydraulic line. Place a load on the forks and tilt the mast forward just past the vertical position and close the gate valve. The gate valve must be able to completely shut off the flow of hydraulic oil. If the mast continues to tilt SLOWLY forward, the seals on the piston are leaking. 4. If the mast does not move, open the gate valve and check the movement again. If the mast moves forward when the gate valve is open, the main control valve can be worn or damaged. Remove the load from the forks when the checks are complete.

2. Measure the distance that the rod for tilt cylinder extends from the shell. Check the distance the rod moves after ten minutes. Multiply the rate in Table 1 by the time of the test and compare the numbers. Table 1. Movement Rates (Maximum) for Tilt Cylinders Lift Truck Model

Hydraulic Oil Temperature/Mast Tilt Rate 20째C (68째F)

60째C (140째F)

mm/min

in./min

mm/min

in./min

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

1.236

0.54

8.20

0.323

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

1.303

0.51

8.65

0.323

1.3

0.51

8.9

0.35

GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)

2100 YRM 1328

Lift Cylinder Repair

Lift Cylinder Repair REMOVE

crossmember to a crossmember on the intermediate or outer mast section. See Figure 1. Lower the mast so the safety chains hold the weight of the mast sections.

WARNING Before working on or near the mast, see Safety Procedures When Working Near Mast and Figure 1. NOTE: The following procedures are for the removal of the lift cylinders with the mast installed on the lift truck. 1. Remove the carriage as described in the carriage removal procedures located in the section Mast Repairs (S/N A513, A514, A613, A702, A703, A704, A705, A706, A707, A752, B513, B514, B586, B587, B588, B590, B591, B749, B750, B751, B752, B754) 4000YRM1250 for lift truck models •

•

A614, A751, B589, B753,

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

Be careful when removing or installing snap rings. These snap rings can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers, and wear eye and face protection during removal or installation. 4. If working on a two-stage or three-stage mast, remove the snap rings at the top of the cylinder. See Figure 8 and Figure 9 for lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

Mast Repair (S/N A513, A514, A613, A614, A643, A644, A683, A684) 4000YRM1406 for lift truck model •

WARNING

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

2. On two-stage limited free-lift mast, raise the mast a few inches and attach safety chain prior to removing lift cylinder. a. Use safety chains to connect the bottom crossmember of the inner mast section to the top crossmember of the outer mast section. See Figure 1. Lower the mast so the safety chains hold the weight of the mast sections. 3. On full free-lift mast, raise the mast a few inches out of free-lift and attach safety chain prior to removing lift cylinder. a. Use safety chains to connect the bottom crossmember of the intermediate mast section to the top crossmember of the outer mast section. Use another safety chain to connect the bottom

WARNING Hydraulic oil is hot after system operation and can cause burns. DO NOT disconnect any hydraulic hoses until the oil in the system is cool. NOTE: Tag hydraulic lines during removal to aid in installation. 5. Put a drain pan under the area of the hydraulic fittings. Retract the rod into the lift cylinder. Disconnect and cap the hydraulic lines at the cylinder. See Figure 8 and Figure 9 for lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

See Figure 10 and Figure 11 for lift truck model •

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

Lift Cylinder Repair

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

BOLT WASHER SHIM SNAP RING LOCK NUT CAPSCREWS HOSE CLAMPS HYDRAULIC FITTINGS LOWERING CONTROL VALVE HOUSING

2100 YRM 1328

10. 11. 12. 13. 14. 15. 16. 17.

HYDRAULIC LINES HEADER HOSE (FIVE FUNCTION) HEADER HOSE (THREE FUNCTION) HEADER HOSE (FOUR FUNCTION) BRACKET CYLINDER MOUNT CHAIN ANCHOR OUTER MAST

Figure 8. Two-Stage Limited Free-Lift Mast, Cylinder Installation for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLC/GDC60VX, GLC/ GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

2100 YRM 1328

Lift Cylinder Repair

Figure 9. Three-Stage Full Free-Lift Mast, Cylinder Installation for Lift Truck Models GLP/GDP60VX, GLP/ GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLC/GDC60VX, GLC/ GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

Lift Cylinder Repair

2100 YRM 1328 Legend for Figure 9

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

MAIN CYLINDER (RH) FREE-LIFT CYLINDER MAIN CYLINDER (LH) LOCK NUT SPACER WASHER CAPSCREW HEADER HOSE (THREE FUNCTION) HYDRAULIC FITTINGS

10. 11. 12. 13. 14. 15. 16. 17. 18.

HEADER HOSE (FOUR FUNCTION) HEADER HOSE (FIVE FUNCTION) CHAIN ANCHOR LOWERING CONTROL VALVE HOUSING SNAP RING CYLINDER MOUNT HOSE CLAMPS HYDRAULIC LINES OUTER MAST

2100 YRM 1328

1. MAST 2. CARRIAGE 3. HYDRAULIC LINE

Lift Cylinder Repair

4. HYDRAULIC FITTING 5. LIFT CYLINDER 6. HOSE CLAMP

Figure 10. Two-Stage Mast, Hydraulic Lines and Fittings for Lift Truck Model GLP/GDP80VX, GLP/ GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)

Lift Cylinder Repair

1. 2. 3. 4.

MAST CARRIAGE HYDRAULIC LINE HYDRAULIC FITTING

2100 YRM 1328

5. LIFT CYLINDER 6. HOSE CLAMP 7. FREE-LIFT CYLINDER

Figure 11. Three-Stage Mast, Hydraulic Lines and Fittings for Lift Truck Model GLP/GDP80VX, GLP/ GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)

2100 YRM 1328 6. Remove hose clamps securing hoses to lift cylinder. See Figure 8 and Figure 9 for lift truck models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

9. For lift truck models equipped with a three-stage full free lift mast, see Figure 12.

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

a. Remove capscrews, washers, and bracket from anchor bracket.

•

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

NOTE: Perform Step 7 and Step 8 for lift truck models:

•

NOTE: Perform Step 9 and Step 10 for lift truck model GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909).

•

See Figure 10 and Figure 11 for lift truck model

•

Lift Cylinder Repair

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

b. Remove snap ring and washer at top of lift cylinder. c. Remove retention screw from mast and bottom of lift cylinder. 10. For lift truck model, GLP/GDP80VX, GLP/ GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909), equipped with a two-stage limited free-lift mast, see Figure 13 and Figure 14. a. Remove anchor screw, washer, and spacer from top of lift cylinder and crossmember. b. Remove retention screw from mast and bottom of lift cylinder.

7. For lift truck models equipped with a three-stage full free-lift mast, see Figure 9.

11. Using a lifting device, remove lift cylinder from mast.

a. Disconnect the main lift chain anchor and header hoses at the cylinder mount. b. Remove the lock nut, capscrew, and spacer securing the cylinder mount to the outer mast.

NOTE: Perform Step 12 for lift truck model GLP/ GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909).

8. For lift truck models equipped with a two-stage limited free-lift mast, see Figure 8.

12. Remove convex washer from top of lift cylinder. See Figure 15.

a. Remove the lock nuts and bracket and disconnect the main lift chain anchor at the cylinder mount.

13. Repeat Step 4 through Step 12 for opposite lift cylinder.

b. Remove the bolt, washer, and shims securing the cylinder mount to the outer mast.

Lift Cylinder Repair

1. 2. 3. 4. 5.

MAST LIFT CYLINDER SNAP RING WASHER CONVEX WASHER

2100 YRM 1328

6. 7. 8. 9. 10.

CAPSCREW WASHER BRACKET ANCHOR BRACKET RETENTION SCREW

Figure 12. Three-Stage Full Free-Lift Mast, Cylinder Installation for Lift Truck Model GLP/GDP80VX, GLP/ GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)

2100 YRM 1328

1. 2. 3. 4. 5.

LIFT CYLINDER ANCHOR SCREW WASHER SPACER CROSSMEMBER

Figure 13. Two-Stage Limited Free-Lift Mast, Cylinder Installation - Top for Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/ GDP190VX) (A909, B909)

Lift Cylinder Repair

1. MAST 2. LIFT CYLINDER 3. RETENTION SCREW Figure 14. Two-Stage Limited Free-Lift Mast, Cylinder Installation - Bottom for Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/ GDP190VX) (A909, B909)

Lift Cylinder Repair

2100 YRM 1328 See Figure 16 and Figure 17 for lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

See Figure 18 for lift truck model •

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

NOTE: Perform Step 2 for lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

NOTE: Note placement of components as removed from gland during disassembly to aid in assembly. 2. Remove gland from shell. Remove and discard rod wiper, backup ring, rod seal, O-ring, and wear ring from gland. See Figure 16 and Figure 17 for lift truck models NOTE: TWO-STAGE LIMITED FREE-LIFT MAST SHOWN. 1. MAST 2. LIFT CYLINDER 3. CONVEX WASHER Figure 15. Lift Cylinder with Convex Washer

DISASSEMBLE CAUTION

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

NOTE: Perform Step 3 and Step 4 for lift truck model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/ GDP190VX) (A909, B909). 3. Remove gland from shell. See Figure 18.

Carefully disassemble the main lift cylinders so the piston rods and sliding surfaces are not damaged.

4. Remove and discard rod wiper from gland. See Figure 18.

NOTE: To prevent damage to sealing surfaces, use brass tools when removing seals and O-rings.

5. Remove rod and piston assembly from shell. Drain hydraulic oil into container.

1. Loosen gland with a spanner wrench.

2100 YRM 1328 See Figure 16 and Figure 17 for lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

Lift Cylinder Repair 8. Remove backup ring, piston ring, piston seal, and O-ring from piston. Discard backup ring, piston seal, and O-ring. See Figure 18. 9. Repeat Step 1 through Step 8 for opposite lift cylinder.

See Figure 18 for lift truck model •

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

NOTE: Perform Step 6 and Step 7 for lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

6. On lift trucks equipped with a two-stage limited free-lift mast. Remove and discard backup ring, seal, and wear ring from piston. See Figure 16. 7. On lift trucks equipped with a three-stage full freelift mast. Remove and discard backup ring, seal, wear ring, and piston ring from piston. See Figure 17. NOTE: Perform Step 8 for lift truck model GLP/ GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909).

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

SHELL WEAR RING SEAL BACKUP RING ROD AND PISTON ASSEMBLY O-RING WEAR RING ROD SEAL ROD WIPER GLAND

Figure 16. Two-Stage Mast, Lift Cylinder Assembly for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878, E878) and GLC/ GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

Lift Cylinder Repair

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

2100 YRM 1328

SHELL PISTON RING WEAR RING SEAL BACKUP RING ROD AND PISTON ASSEMBLY ROD SEAL ROD WIPER O-RING GLAND

Figure 17. Three-Stage Mast, Lift Cylinder Assembly for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878, E878) and GLC/ GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

ROD WIPER GLAND BLEED-BACK PORT SHELL ROD PISTON O-RING PISTON SEAL PISTON RING BACKUP RING RETENTION SCREW

Figure 18. Lift Cylinder Assembly for Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)

2100 YRM 1328

CAUTION DO NOT allow cleaning solvent to come in contact with rubber components, as it will damage those components. Clean all metal parts in solvent and dry with compressed air.

Lift Cylinder Repair NOTE: Lubricate all internal parts of the lift cylinder with clean hydraulic oil during to assembly. 1. On lift trucks equipped with a two-stage limited free-lift mast. Install new backup ring, seal, and wear ring into onto piston. See Figure 16. 2. On lift trucks equipped with a three-stage full freelift mast. Install new backup ring, seal, wear ring, and piston ring onto piston. See Figure 17. 3. Install rod and piston assembly into shell. 4. Install new wear ring, O-ring, rod seal, backup ring, and rod wiper onto gland as noted during disassembly. See Figure 16 and Figure 17. 5. Using a spanner wrench, install gland onto piston rod inside shell. Tighten gland to 375 to 450 Nâ&#x20AC;˘m (277 to 332 lbf ft). See Figure 16 and Figure 17.

INSPECT

6. Repeat Step 1 through Step 5 for the opposite lift cylinder.

Inspect the gland for damage to the threads and the seal surfaces. If damaged, replace gland.

ASSEMBLE, LIFT TRUCK MODELS GLP/ GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

Inspect the piston for any damage to the seal surfaces. If damaged, replace piston. Inspect the rod for damage to the rod surface and ensure that the rod is not bent. If damaged replace rod. Inspect the inner surface of the cylinder shell for damage. If damaged, replace cylinder assembly.

CAUTION A difficult and important step in assembling lift cylinders is the correct installation of the seals. Most lift cylinder maintenance is caused by seal leaks. DO NOT damage any parts during assembly. NOTE: To prevent damage to sealing surfaces, use brass tools when installing seal and O-rings. NOTE: Lubricate all internal parts of the lift cylinder with clean hydraulic oil during to assembly. 1. Install new O-ring and piston seal onto piston. See Figure 18. 2. Install piston ring onto piston and tighten. See Figure 18. 3. Install new backup ring onto piston. See Figure 18.

Lift Cylinder Repair 4. Install rod and piston assembly into shell. 5. Install rod wiper onto gland. See Figure 18. 6. Apply two drops of Loctite® 545 or equivalent on gland threads. 7. Using a spanner wrench, install gland onto piston rod inside shell. Tighten gland to 350 to 400 N•m (258 to 295 lbf ft). See Figure 18. 8. Repeat Step 1 through Step 7 for the opposite lift cylinder.

INSTALL, LIFT TRUCK MODELS GLP/ GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) AND GLC/GDC60VX, GLC/ GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (C879, D879, E879, F879) 1. Using a lifting device, install the lift cylinder in the mount at the bottom of the outer mast. See Figure 8 and Figure 9. 2. For lift truck models equipped with a three-stage full free-lift mast, see Figure 9. a. Install spacer, capscrew, and lock nut to secure the cylinder mount to the outer mast. Tighten lock nut to 135 N•m (100 lbf ft). b. Connect the main lift chain anchor and hydraulic header hoses at the cylinder mount. Tighten chain anchor lock nut to 370 N•m (273 lbf ft). 3. For lift truck models equipped with a two-stage limited free-lift mast, see Figure 8. a. Install shims, washer, and bolt to secure cylinder mount to the outer mast. Tighten bolt to 555 N•m (410 lbf ft). b. Install the bracket and lock nuts and connect the main lift chain anchor at the cylinder mount. Tighten chain anchor lock nut to 370 N•m (273 lbf ft).

2100 YRM 1328 4. If working on a two-stage or three-stage mast, install the snap rings at the top of the cylinder. See Figure 8 and Figure 9. 5. Connect the hydraulic fittings and hydraulic lines to lift cylinders as tagged during removal. See Figure 8 and Figure 9. 6. Repeat Step 1 through Step 5 for opposite lift cylinder. 7. Remove safety chains. 8. Use a lifting device to lower the inner mast (twostage limited free-lift) or intermediate mast (threestage full free-lift) onto the lift cylinders. 9. Install the carriage as described in the carriage Install procedures. See Mast Repairs (S/N A513, A514, A613, A614, A702, A703, A704, A705, A706, A707, A751, A752, B513, B514, B586, B587, B588, B589, B590, B591, B749, B750, B751, B752, B753, B754) 4000YRM1250.

INSTALL, LIFT TRUCK MODELS GLP/ GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909) 1. Install convex washer on top of lift cylinder. See Figure 12 and Figure 15. 2. Using a lifting device, install the lift cylinder in the mount at the bottom of the outer mast. See Figure 12 and Figure 15. 3. For lift truck model equipped with a three-stage full free-lift mast, see Figure 12. a. Install retention screw into mast and bottom of lift cylinder. b. Install washer and snap ring onto top of lift cylinder. c. Install bracket, washers, and capscrews onto anchor bracket. 4. For lift truck model equipped with a two-stage full free-lift mast, see Figure 14. a. Install retention screw into mast and bottom of lift cylinder. b. Install spacer, washer, and anchor screw onto lift cylinder and crossmember.

2100 YRM 1328

Free-Lift Cylinder Repair

5. Connect the hydraulic fittings and hydraulic lines to lift cylinders as tagged during removal. See Figure 11.

8. Use a lifting device to lower the inner mast (twostage limited free-lift) or intermediate mast (threestage full free-lift) onto the lift cylinders.

6. Repeat Step 1 through Step 5 for opposite lift cylinder.

9. Install the carriage as described in the carriage Install procedures. See Mast Repair (S/N A513, A514, A613, A614, A643, A644, A683, A684) 4000YRM1406.

7. Remove safety chains.

Free-Lift Cylinder Repair REMOVE

See Figure 21 for lift truck model •

1. Remove the carriage and load backrest as described in the carriage removal procedures in the section Mast Repairs (S/N A513, A514, A613, A702, A703, A704, A705, A706, A707, A752, B513, B514, B586, B587, B588, B590, B591, B749, B750, B751, B752, B754) 4000YRM1250 for lift truck models

A614, A751, B589, B753,

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

Mast Repair (S/N A513, A514, A613, A614, A643, A644, A683, A684) 4000YRM1406 for lift truck model •

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

NOTE: Perform Step 3 and Step 4 for lift truck models: •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

3. Remove capscrews, washers, and lockwashers from hose sheave shaft and hose sheave bracket. Remove hose sheave bracket from chain guard. See Figure 20. 4. Remove hose sheaves and hose sheave shaft. 5. Disconnect and cap the hydraulic fittings at the hose mounting brackets. See Figure 19 for lift truck models

NOTE: Tag hydraulic lines during removal to aid in installation.

•

2. Place a drain pan under the free-lift cylinder. Disconnect and cap the hydraulic hose and fittings at the bottom of the cylinder.

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

See Figure 19 for lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

See Figure 21 for lift truck model •

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

Free-Lift Cylinder Repair 6. Remove hoses from hose sheaves. See Figure 20 for lift truck models •

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

2100 YRM 1328 13. Remove chain sheave from top of free-lift cylinder by unscrewing. See Figure 24. NOTE: Perform Step 14 and Step 15 for lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

See Figure 22 for lift truck model •

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

14. Remove two capscrews and washers securing crosshead to cylinder rod. Remove crosshead. See Figure 20.

NOTE: Perform Step 7 for lift truck model GLP/ GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909).

15. Remove two capscrews, lock nuts, lockwashers, washers, and spacer from inner mast mounting bracket. With a lifting device, remove free-lift cylinder assembly from inner mast.

7. Remove four screws and hose sheave assembly from chain guard. See Figure 22.

See Figure 19 and Figure 20 for lift truck models

NOTE: Perform Step 8 through Step 11 for lift truck models: •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

8. Remove chain guard from crosshead. See Figure 20. 9. Remove lock nuts from chain anchor and remove chain. See Figure 19. 10. Using a brass drift, remove pin from crosshead. See Figure 20.

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

NOTE: Perform Step 16 and Step 17 for lift truck model GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909). 16. Remove two screws, two washers, and bracket from crossmember and free-lift cylinder. See Figure 25. 17. Remove retention screw from bottom of free-lift cylinder and mast. See Figure 25.

11. Remove chain sheave assembly from crosshead.

18. Using a lifting device, remove free-lift cylinder from inner mast.

NOTE: Perform Step 12 and Step 13 for lift truck model GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909).

NOTE: Perform Step 19 for lift truck model GLP/ GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909).

12. Remove lock nut from chain anchor; remove chain anchor from crossmember; remove chain from chain sheave. See Figure 23.

19. Repeat above steps as required for opposite freelift cylinder.

2100 YRM 1328

Free-Lift Cylinder Repair

NOTE: BOTTOM CROSSMEMBER OF THE INNER MAST HAS BEEN REMOVED FOR CLARITY. A. REAR VIEW

B. FRONT VIEW

1. 2. 3. 4.

5. 6. 7. 8.

CAPSCREW LOCK NUT HYDRAULIC FITTINGS CHAIN

HOSE CHAIN ANCHOR INNER MAST HOSE MOUNTING BRACKET

Figure 19. Free-Lift Cylinder Removal for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

Free-Lift Cylinder Repair

2100 YRM 1328

Figure 20. Hose Sheave, Chain Sheave, and Crosshead Installation for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLC/GDC60VX, GLC/ GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

2100 YRM 1328

Free-Lift Cylinder Repair Legend for Figure 20

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

CAPSCREW WASHER LOCKWASHER HOSE SHEAVE BRACKET SNAP RING HOSE SHEAVE SHAFT HOSE SHEAVE HOSE HYDRAULIC FITTINGS CHAIN GUARD CHAIN COTTER PIN

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

PIN BEARING FREE-LIFT CYLINDER CHAIN SHEAVE ASSEMBLY SPACER PIN CROSSHEAD LOCK NUT CHAIN ANCHOR HOSE MOUNTING BRACKET INNER MAST MOUNTING BRACKET CYLINDER ROD

1. HOSE SHEAVE ASSEMBLY 2. CHAIN GUARD 3. SCREW NOTE: MAST CROSSMEMBERS REMOVED FOR CLARITY. 1. 2. 3. 4.

FREE-LIFT CYLINDER HYDRAULIC HOSE FITTING HOSE MOUNTING BRACKET

Figure 22. Hose Sheave for Lift Truck Model GLP/ GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)

Figure 21. Free Lift Cylinder Hydraulic Lines and Fittings for Lift Truck Model GLP/GDP80VX, GLP/ GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

Free-Lift Cylinder Repair

2100 YRM 1328

1. LOCKNUT 2. CHAIN ANCHOR 3. CHAIN Figure 23. Chain Anchor for Lift Truck Model GLP/ GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 1. CHAIN SHEAVE 2. FREE-LIFT CYLINDER Figure 24. Chain Sheave for Lift Truck Model GLP/ GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)

2100 YRM 1328

Free-Lift Cylinder Repair

A. FRONT VIEW

B. REAR VIEW

1. 2. 3. 4.

5. RETENTION SCREW 6. MAST 7. FREE-LIFT CYLINDER

CROSSMEMBER BRACKET SCREW WASHER

Figure 25. Free-Lift Cylinder Mount for Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)

Free-Lift Cylinder Repair

DISASSEMBLE

2100 YRM 1328 See Figure 27 for lift truck model •

CAUTION Carefully disassemble the free-lift cylinder so the piston rods and sliding surfaces are not damaged. NOTE: To prevent damage to sealing surfaces, use brass tools when removing or installing seal and Orings.

NOTE: Perform Step 5 through Step 7 for lift truck models: •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

1. Loosen gland with spanner wrench. 2. Remove gland from shell. See Figure 26 for lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

See Figure 27 for lift truck model •

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

NOTE: Perform Step 3 for lift truck model GLP/ GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909). 3. Remove and discard rod wiper, rod seal, and Oring from gland. See Figure 27. 4. Remove rod and piston assembly from shell. Drain hydraulic oil into container. See Figure 26 for lift truck models •

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

5. Remove and discard O-ring from outside of gland and remove, wear ring, backup ring, rod seal, and rod wiper from inside of gland. See Figure 26.

WARNING Be careful when removing or installing snap rings. These snap rings can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers, and wear eye and face protection during removal or installation. 6. Remove snap ring, washer, check valve from base of piston. Remove and discard seal from check valve. See Figure 26. 7. Remove wear ring and backup ring. Remove and discard piston seal from piston. See Figure 26. NOTE: Perform Step 8 and Step 9 for lift truck model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/ GDP190VX) (A909, B909). 8. Remove and discard wear ring from piston. See Figure 27. 9. Repeat above steps as required for opposite freelift cylinder.

2100 YRM 1328

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Free-Lift Cylinder Repair

GLAND O-RING ROD WIPER BACKUP RING ROD SEAL WEAR RING ROD AND PISTON ASSEMBLY PISTON SEAL CHECK VALVE SEAL WASHER SNAP RING SHELL

Figure 26. Free-Lift Cylinder Assembly for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

Figure 27. Free-Lift Cylinder Assembly for Lift Truck Model GLP/GDP80VX, GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)

Free-Lift Cylinder Repair Legend for Figure 27 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

ROD WIPER ROD SEAL GLAND O-RING BLEED SCREW SHELL ROD PISTON WEAR RING RETENTION SCREW

CAUTION Do not allow cleaning solvent to come in contact with rubber components, as it will damage those components. Clean all metal parts in solvent and dry with compressed air.

INSPECT Inspect the gland for damage to the threads and the seal surfaces. If damaged, replace gland.

2100 YRM 1328

ASSEMBLE, LIFT TRUCK MODELS GLP/ GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) AND GLC/GDC60VX, GLC/ GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (C879, D879, E879, F879) CAUTION A difficult and important step in assembling freelift cylinders is the correct installation of the seals. Most cylinders maintenance is caused by seal leaks. DO NOT damage any parts during assembly. NOTE: Lubricate all internal parts of the free-lift cylinder with clean hydraulic oil. NOTE: 1. Install check valve and new seal in base of piston of free-lift cylinder. Make sure arrow on check valve is toward base of piston. Install washer and snap ring for check valve. See Figure 26. 2. Install new wear ring, piston seal, and backup ring on rod an piston assembly. See Figure 26. 3. Carefully install rod and piston assembly into shell. See Figure 26. 4. Install new wear ring, new rod seal, new backup ring, and new rod wiper into gland. Install new Oring on outside of gland. See Figure 26. NOTE: Hydraulic oil is pored into the free-lift cylinder to act as a cushion during load lifting to prevent damage to the cylinder. 5. Before installing gland, pour 150 cc (5 oz) of hydraulic oil into the cylinder shell.

Inspect the piston for any damage to the seal surfaces. If damaged, replace piston.

6. Install gland on rod and piston assembly. See Figure 26. Tighten gland to 400 to 475 Nâ&#x20AC;˘m (295 to 350 lbf ft).

Inspect the rod for damage to the rod surface and ensure that the rod is not bent. If damaged replace rod.

7. Repeat above steps as required for opposite freelift cylinder.

Inspect the inner surface of the cylinder shell for damage. If damaged, replace cylinder assembly.

2100 YRM 1328

ASSEMBLE, LIFT TRUCK MODELS GLP/ GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909) CAUTION A difficult and important step in assembling freelift cylinders is the correct installation of the seals. Most cylinders maintenance is caused by seal leaks. DO NOT damage any parts during assembly. NOTE: Lubricate all internal parts of the free-lift cylinder with clean hydraulic oil. 1. Install new wear ring onto piston. See Figure 27. 2. Carefully install rod and piston assembly into shell. See Figure 27. 3. Install new O-ring, new rod sea, and new rod wiper onto gland. See Figure 27. 4. Install gland onto rod and piston assembly. See Figure 27. Tighten gland to 350 to 400 N•m (258 to 295 lbf ft). 5. Repeat above steps as required for opposite freelift cylinder.

INSTALL, LIFT TRUCK MODELS GLP/ GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) AND GLC/GDC60VX, GLC/ GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (C879, D879, E879, F879) 1. Install crosshead onto cylinder rod, then install two capscrews and lockwashers securing crosshead to cylinder rod. See Figure 20. 2. Install chain sheave assembly and spacers into crosshead. See Figure 20.

Free-Lift Cylinder Repair 4. Using a lifting device, install free-lift cylinder into the inner mast and align cylinder mount holes with inner mast mounting holes. 5. Install two capscrews through hose mounting bracket, spacers and inner mast mounting bracket. Secure capscrews with two washers, lockwashers, and lock nuts. See Figure 20. Tighten lock nut to 135 N•m (100 lbf ft). 6. Install chain and chain anchor over chain sheave assembly and install chain anchor into cylinder mount. Tighten lock nuts to 370 N•m (273 lbf ft). See Figure 19 and Figure 20. 7. Install chain guard over the chain sheave assembly. See Figure 20. 8. Install hose sheave brackets to crosshead with capscrews, washers, and lockwashers. Tighten capscrews to 33 N•m (25 lbf ft). See Figure 20. 9. Place hose sheaves and hose sheave shaft inside of hose sheave bracket and install two capscrews and washers. Tighten capscrews to 33 N•m (25 lbf ft). See Figure 20. 10. Install the hoses over the hose sheaves and through hose mounting bracket and uncap hoses. Connect hoses to hydraulic fittings. 11. Install hydraulic fittings at the bottom of the cylinder. See Figure 19. 12. Perform above steps as required for opposite free-lift cylinder. 13. Install the load backrest an carriage as described in the carriage install procedures. See Mast Repairs (S/N A513, A514, A613, A614, A702, A703, A704, A705, A706, A707, A751, A752, B513, B514, B586, B587, B588, B589, B590, B591, B749, B750, B751, B752, B753, B754) 4000YRM1250.

3. Using a brass drift, install pin through the chain sheave assembly. See Figure 20.

Sideshift Cylinder Repair

2100 YRM 1328

INSTALL, LIFT TRUCK MODELS GLP/ GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909) 1. Using a lifting device, install free-lift cylinder into the inner mast and align cylinder mount holes with inner mast mounting holes. 2. Install retention screw into bottom of mast and free-lift cylinder. See Figure 25. 3. Install bracket, two washers, and two screws on free-lift cylinder and crossmember. See Figure 25. 4. Install chain sheave into top of free-lift cylinder. See Figure 24.

6. Install the hoses over the hose sheaves and through hose mounting bracket and uncap hoses. Connect hoses to hydraulic fittings. 7. Install hose sheave assembly and four screws onto chain guard. See Figure 22. 8. Install hydraulic hoses onto hose sheave. 9. Uncap and connect hydraulic lines at bottom of free-lift cylinder. See Figure 25. 10. Perform above steps as required for opposite free-lift cylinder. 11. Install the load backrest an carriage as described in the carriage install procedures. See Mast Repair (S/N A513, A514, A613, A614, A643, A644, A683, A684) 4000YRM1406.

5. Install chain onto chain sheave; install chain anchor through crossmember; install locknut onto chain anchor. See Figure 23.

Sideshift Cylinder Repair REMOVE

GLP/GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

WARNING Before working on or near the mast, see Safety Procedures When Working Near Mast and Figure 1. 1. Remove carriage as described in carriage removal procedures. See Mast Repairs (S/N A513, A514, A613, A702, A703, A704, A705, A706, A707, A752, B513, B514, B586, B587, B588, B590, B591, B749, B750, B751, B752, B754) 4000YRM1250 for lift truck models

A614, A751, B589, B753,

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

See Mast Repair (S/N A513, A514, A613, A614, A643, A644, A683, A684) 4000YRM1406 for lift truck model •

GLP/GDP80VX, GLP/GDP80VX9,

NOTE: Perform Step 2 for lift truck models •

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

2. Remove sideshift cylinder from sideshift carriage as described in disassemble procedures. See Mast Repairs (S/N A513, A514, A613, A702, A703, A704, A705, A706, A707, A752, B513, B514, B586, B587, B588, B590, B591, B749, B750, B751, B752, B754) 4000YRM1250 for lift truck models

A614, A751, B589, B753,

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

2100 YRM 1328

1. SIDESHIFT CYLINDER 2. SNAP RING

Sideshift Cylinder Repair NOTE: Perform Step 3 for lift truck model GLP/ GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909). 3. Remove four snap rings, two clevis pins, and sideshift cylinder from carriage. See Figure 28.

3. CLEVIS PIN 4. ISS OUTER FRAME

Figure 28. Sideshift Cylinder Removal, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)

Sideshift Cylinder Repair

2100 YRM 1328

DISASSEMBLE

9. Remove the retainer. See Figure 30.

NOTE: For lift trucks manufactured before August, 2012, perform Step 1 through Step 8 for lift truck models

10. Remove rod wiper from retainer. See Figure 30.

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

1. Position cylinder rod in fully extended position and remove snap ring from retainer. See Figure 29.

11. Remove O-ring from retainer. See Figure 30. 12. Remove rod seal from retainer. See Figure 30. 13. Remove fittings and O-rings from cylinder assembly. See Figure 30. Discard O-rings.

CAUTION Carefully disassemble the sideshift cylinder so the piston rods and sliding surfaces are not damaged.

2. Push cylinder retainer into cylinder shell approximately 50 mm (2 in.) until retainer ring is exposed. 3. Remove retainer ring. See Figure 29. 4. Remove rod assembly and retainer from cylinder shell. See Figure 29. 5. Remove retainer from rod. See Figure 29.

CAUTION To prevent damage to sealing surfaces, use brass tools when removing seals and O-rings. 6. Remove and discard, wiper, rod seal, backup ring, and O-ring from retainer. See Figure 29. 7. Remove lock nut and piston from rod. See Figure 29. 8. Remove and discard backup ring and piston seal from piston. See Figure 29. NOTE: For lift trucks manufactured after August, 2012, perform Step 9 through Step 13 for lift truck models

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (E878)

CAUTION To prevent damage to sealing surfaces use brass tools when removing seals and O-rings. NOTE: Perform Step 14 through Step 18 for lift truck models •

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

14. Loosen gland with spanner wrench. See Figure 31. 15. Remove gland from shell. See Figure 31. 16. Remove and discard rod wiper from gland. See Figure 31. 17. Remove rod and piston assembly from shell. See Figure 31. Drain hydraulic oil into container. 18. Remove backup ring, piston ring, piston seal, and O-ring from piston. See Figure 31. Discard backup ring, piston seal, and O-ring.

2100 YRM 1328

1. 2. 3. 4. 5. 6. 7.

SNAP RING RETAINER RING ROD RETAINER CYLINDER SHELL WIPER ROD SEAL

Sideshift Cylinder Repair

8. 9. 10. 11. 12. 13.

BACKUP RING O-RING LOCK NUT PISTON PISTON SEAL BACKUP RING

Figure 29. Hang On Sideshift Cylinder for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) Manufactured Before August, 2012

Sideshift Cylinder Repair

1. 2. 3. 4.

ROD WIPER RETAINER O-RING ROD SEAL

2100 YRM 1328

5. ROD 6. FITTINGS 7. CYLINDER ASSEMBLY

Figure 30. Hang On Sideshift Cylinder for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (E879, F879) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878) Manufactured After August, 2012

2100 YRM 1328

1. 2. 3. 4. 5.

ROD ROD WIPER GLAND PISTON O-RING

Sideshift Cylinder Repair

6. 7. 8. 9.

PISTON SEAL PISTON RING BACKUP RING SHELL

Figure 31. Sideshift Cylinder for Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)

Sideshift Cylinder Repair

CAUTION DO NOT allow cleaning solvent to come in contact with rubber components, as it will damage those components.

2100 YRM 1328 NOTE: Lubricate all internal parts of the cylinder with clean hydraulic oil prior to assembly. 1. Install new piston seal and backup ring onto piston. See Figure 29.

CAUTION To prevent damage to the cylinder, DO NOT clamp on cylinder rod sealing surface. 2. Place cylinder shell in soft-jawed vise and install piston onto rod. See Figure 29. 3. Install lock nut onto rod. See Figure 29. Tighten lock nut to 135 to 163 N•m (100 to 120 lbf ft). 4. Install rod and piston into cylinder shell. 5. Install new O-ring and backup ring into groove of retainer. See Figure 29.

1. Clean all metal parts in solvent and dry with compressed air.

6. Push retainer into cylinder shell until retainer ring groove is exposed.

INSPECT

7. Install retainer rig into groove of cylinder shell. See Figure 29.

1. Inspect gland and fittings for damage to threads and seal surfaces. Replace if damaged. 2. Inspect piston for any damage to seal surfaces. Replace if damaged. 3. Inspect rod for damage to rod surface and ensure rod is not bent. Replace if damaged or bent. 4. Inspect inner surface of cylinder shell for damage. Replace cylinder assembly if damaged.

ASSEMBLE CAUTION To prevent damage to sealing surfaces, use brass tools when installing seals and O-rings. NOTE: For lift trucks manufactured before August, 2012, perform Step 1 through Step 9 for lift truck models •

•

8. Pull rod and piston out of cylinder shell until retainer stops on retainer ring and snap ring groove is exposed. See Figure 29. 9. Install snap ring onto retainer. See Figure 29. NOTE: For lift trucks manufactured after August, 2012, perform Step 10 through Step 14 for lift truck models •

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (E879, F879)

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (E878)

10. Install new O-ring on fittings and install fittings in cylinder. See Figure 30. 11. Install rod seal in retainer. See Figure 30.

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

12. Install O-ring on retainer. See Figure 30.

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

14. Install retainer onto cylinder assembly. See Figure 30.

13. Install rod wiper in retainer. See Figure 30.

2100 YRM 1328

Fork Positioner Cylinder Repair

CAUTION To prevent damage to sealing surfaces, use brass tools when installing seal and O-rings.

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

NOTE: Perform Step 15 through Step 21 for lift truck model •

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

NOTE: Lubricate all internal parts of the cylinder with clean hydraulic oil prior to assembly. 15. Install new O-ring and piston seal onto piston. See Figure 31. 16. Install piston ring onto piston and tighten. See Figure 31. 17. Install new backup ring onto piston. See Figure 31. 18. Install rod and piston assembly into shell. See Figure 31. 19. Install rod wiper onto gland. See Figure 31. 20. Apply two drops of Loctite® 545 or equivalent on gland threads. 21. Install gland onto shell. See Figure 31. Tighten gland to 350 to 400 N•m (258 to 295 lbf ft).

INSTALL

WARNING Be careful when removing or installing snap rings. These snap rings can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers, and wear eye and face protections during removal or installation. NOTE: Perform Step 2 for lift truck model GLP/ GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909). 2. Install sideshift cylinder, two clevis pins, and four snap rings onto carriage. See Figure 28. 3. Install carriage as described in the carriage install procedures located in the section Mast Repairs (S/N A513, A514, A613, A702, A703, A704, A705, A706, A707, A752, B513, B514, B586, B587, B588, B590, B591, B749, B750, B751, B752, B754) 4000YRM1250 for lift truck models •

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

NOTE: Perform Step 1 for lift truck models •

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

1. Install sideshift cylinder as described in install procedure in section Mast Repairs (S/N A513, A514, A613, A702, A703, A704, A705, A706, A707, A752, B513, B514, B586, B587, B588, B590, B591, B749, B750, B751, B752, B754) 4000YRM1250 for lift truck models

A614, A751, B589, B753,

Mast Repair (S/N A513, A514, A613, A614, A643, A644, A683, A684) 4000YRM1406 for lift truck model •

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

Fork Positioner Cylinder Repair

2100 YRM 1328

Fork Positioner Cylinder Repair REMOVE WARNING Before working on or near the mast, see Safety Procedures When Working Near Mast and Figure 1. NOTE: Perform Step 1 for lift truck models •

•

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

1. Remove fork positioner cylinder as described in Hang On Sideshift Carriage Repair removal procedures located in the section Mast Repairs (S/N A513, A514, A613, A614, A702, A703, A704, A705, A706, A707, A751, A752, B513, B514, B586, B587, B588, B589, B590, B591, B749, B750, B751, B752, B753, B754) 4000YRM1250. NOTE: Perform Step 2 through Step 7 for lift truck model •

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

7. Repeat Step 4 through Step 6 for upper fork positioner cylinder.

DISASSEMBLE CAUTION Carefully disassemble the fork positioner cylinders so the piston rods and sliding surfaces are not damaged. NOTE: For lift trucks manufactured before August, 2012, perform Step 1 through Step 7 for lift truck models •

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

1. Unscrew cylinder rod retainer. See Figure 34.

CAUTION To prevent damage to sealing surfaces, use brass tools when removing seals and O-rings. 2. Remove piston, rod, and cylinder rod retainer as an assembly from cylinder shell. See Figure 34.

2. Remove carriage as described in carriage removal procedures located in the section Mast Repair (S/N A513, A514, A613, A614, A643, A644, A683, A684) 4000YRM1406.

3. Remove cylinder rod retainer from cylinder rod. See Figure 34.

NOTE: The following step to be performed for both upper and lower fork positioner cylinders.

5. Remove and discard rod wiper, rod seal, backup rings, and O-rings from cylinder rod retainer. See Figure 34.

NOTE: Note placement of fork positioner cylinders prior to removal to aid in installation. 3. Disconnect all hydraulic fittings and lines from fork positioner cylinders on carriage. See Figure 32. 4. Remove screw, washer, and bushing from lower fork positioner cylinder rod end and carriage. See Figure 33. 5. Remove nut from lower fork positioner cylinder shell end. See Figure 33. 6. Retract rod into shell and remove lower fork positioner cylinder from carriage.

4. Remove spacer from cylinder rod. See Figure 34.

CAUTION To prevent damage to cylinder rod, DO NOT clamp on the cylinder rod sealing surface. 6. Place cylinder rod in soft-jawed vise and remove piston nut and piston. See Figure 34. 7. Remove and discard piston seal and O-ring from piston. See Figure 34.

2100 YRM 1328

Fork Positioner Cylinder Repair

1. CARRIAGE 2. FORK POSITIONER CYLINDER

3. HYDRAULIC FITTING 4. HYDRAULIC LINE

Figure 32. Hydraulic Connections Fork Positioner Cylinder

Fork Positioner Cylinder Repair

2100 YRM 1328

1. UPPER FORK POSITIONER CYLINDER ROD END 2. UPPER FORK POSITIONER CYLINDER SHELL END 3. LOWER FORK POSITIONER CYLINDER ROD END 4. LOWER FORK POSITIONER CYLINDER SHELL END 5. CARRIAGE

6. 7. 8. 9.

SCREW WASHER BUSHING NUT

Figure 33. Fork Positioner Cylinder Mount

2100 YRM 1328

1. 2. 3. 4. 5. 6.

CYLINDER ROD ROD SEAL ROD WIPER CYLINDER ROD RETAINER BACKUP RING O-RING

Fork Positioner Cylinder Repair

7. 8. 9. 10. 11.

SPACER CYLINDER SHELL PISTON PISTON SEAL PISTON NUT

Figure 34. Fork Positioner Cylinder for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) Manufactured Before August, 2012

CAUTION Carefully disassemble the fork positioner cylinders so the piston rods and sliding surfaces are not damaged.

CAUTION To prevent damage to sealing surfaces use brass tools when removing seals and O-rings. NOTE: For lift trucks manufactured after August, 2012, perform Step 8 through Step 15 for lift truck models •

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (D879, E879, F879)

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (D878, E878)

8. Place fork positioner on flat surface. Use clamps to hold fork positioner in position and blocks for clearance and to keep parts in alignment. See Figure 35.

9. Remove cylinder rod anchor plug. Move fork carrier lug towards manifold and remove half-ring keepers. Move cylinder rod to fully retracted position shown in Figure 35. 10. Using retainer socket tool (see Special Tools), unscrew cylinder retainer to remove cylinder assembly from manifold.

CAUTION DO NOT bend hydraulic tubes when removing them. Damage to hydraulic tubes can result if they are bent. NOTE: Make note of which end hydraulic tubes are removed from. If hydraulic tubes are removed from cylinder head end, install hydraulic tubes first, before installing cylinder and fork carrier lug assembly to manifold. 11. Disconnect hydraulic tubes at manifold. Remove clamps and remove cylinder and fork carrier lug assembly. See Figure 35. 12. Slide fork carrier lug from cylinder shell. Remove piston/rod assembly from cylinder shell.

Fork Positioner Cylinder Repair

1. 2. 3. 4.

ANCHOR PLUG HALF-RING KEEPERS FORK CARRIER LUG RETAINER SOCKET TOOL

2100 YRM 1328

5. 6. 7. 8.

CYLINDER RETAINER CYLINDER ROD HEAD TIGHTENING TOOL CYLINDER SHELL

Figure 35. Fork Positioner Assembly for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (E879, F879) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878) Manufactured After August, 2012 NOTE: DO NOT scratch seal grooves. Use brass seal removal tools to pry items from grooves.

16. Loosen gland with spanner wrench. See Figure 37.

13. Remove all seals, O-ring, wear rings and bearings from components as shown in Figure 36.

17. Remove gland from shell. See Figure 37.

14. If required, unscrew cylinder shell from head end using head tightening tool. See Special Tools. 15. Repeat Step 9 through Step 14 for other cylinder. NOTE: Perform Step 16 through Step 20 for lift truck model: â&#x20AC;¢

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

18. Remove and discard rod wiper from gland. See Figure 37. 19. Remove rod and piston assembly from shell. Drain hydraulic oil into container. See Figure 37. 20. Remove backup ring, piston ring, piston seal, and O-ring from piston. Discard backup ring, piston seal, and O-ring. See Figure 37. 21. Repeat Step 16 through Step 20 for other fork positioner cylinder.

2100 YRM 1328

Fork Positioner Cylinder Repair

A. RETAINER

B. PISTON

C. FORK CARRIER LUG

1. 2. 3. 4. 5. 6.

7. HEAD END/MOUNTING FOOT 8. O-RING 9. U-CUP PRESSURE SEAL 10. WIPER SEAL

11. 12. 13. 14.

RETAINER MANIFOLD CYLINDER SHELL CYLINDER ROD FORK CARRIER LUG INTERNAL SPACER (IF REQUIRED)

WEAR RING TWO-PIECE PRESSURE SEAL WIPERS BEARINGS

Figure 36. Fork Positioner Cylinder for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (E879, F879) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878) Manufactured After August, 2012

Fork Positioner Cylinder Repair

2100 YRM 1328 Legend for Figure 37 1. 2. 3. 4. 5. 6. 7. 8. 9.

ROD WIPER GLAND SHELL ROD PISTON O-RING PISTON SEAL PISTON RING BACKUP RING

CAUTION DO NOT allow cleaning solvent to come in contact with rubber components, as it will damage those components. 1. Clean all metal parts in solvent and dry with compressed air.

INSPECT 1. Inspect gland for damage to threads and seal surfaces. Replace if damaged. 2. Inspect piston for any damage to seal surfaces. Replace if damaged. 3. Inspect rod for damage to rod surface and ensure rod is not bent. Replace if damaged or bent. 4. Inspect inner surface of cylinder shell for damage. Replace cylinder assembly if damaged.

Figure 37. Fork Positioner Cylinder

2100 YRM 1328

ASSEMBLE CAUTION To prevent damage to sealing surfaces, use brass tools when installing seal and O-ring. NOTE: Lubricate all internal parts of the cylinder with clean hydraulic oil during assembly. NOTE: For lift trucks manufactured before August, 2012, perform Step 1 through Step 7 for lift truck models •

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

Fork Positioner Cylinder Repair 6. If the cylinder head end was removed during disassembly, replace cylinder head end O-ring and apply Loctite® 242 (Blue) to threads. Clamp head end in vice and tighten cylinder shell to 270 N•m (200 lbf ft). 7. Lubricate new seals, O-rings and wear rings with O-ring lube or hydraulic fluid. NOTE: Fork carrier lug bearings snap into their respective grooves. Bronze bearings consist of three separate segments. 8. Install new seals, O-rings, wear rings and fork carrier lug bearings as shown in Figure 36. 9. Twist seal into "figure 8" or half circle shape see Figure 38.

1. Install new O-rings, backup rings, rod seal, and rod wiper onto cylinder rod retainer. See Figure 34.

CAUTION To prevent damage to cylinder rod, DO NOT clamp on cylinder rod sealing surface. 2. Place cylinder rod in soft-jawed vise and install piston onto rod. See Figure 34. 3. Apply Loctite®242 (Blue) to threads of piston nut. Install piston nut onto cylinder rod. Tighten piston nut to 75 N•m (55 lbf ft). See Figure 34. 4. Install new piston seal onto piston. See Figure 34. 5. Install cylinder rod retainer onto cylinder rod. See Figure 34. NOTE: For lift trucks manufactured after August, 2012, perform Step 6 through Step 15 for lift truck models •

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (D878, E878)

NOTE: If necessary, use 400-grit emery cloth to break any sharp edge on the piston, retainer and cylinder shell chamfer angles and threads to prevent seal damage.

1. 2. 3. 4. 5.

SEAL ROD RETAINER PIN PUNCH FLAT BRASS O-RING TOOL

Figure 38. Installing Retainer Internal Seals for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879, F879) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878) Manufactured After August, 2012

Fork Positioner Cylinder Repair

2100 YRM 1328

NOTE: DO NOT use a pin punch with sharp edges.

21. Install rod wiper onto gland. See Figure 37.

10. Lubricate seal and force partially into grove using 15 mm (0.6 in.) pin punch. See Figure 38.

22. Apply two drops of Loctite® 545 or equivalent on gland threads.

NOTE: Make sure piston seal is not damaged by cylinder shell threads during installation.

23. Install gland onto shell. Tighten gland to 350 to 400 N•m (258 to 295 lbf ft). See Figure 37.

11. Use flat brass O-ring tool to seat seals fully into groove. See Figure 38.

24. Repeat Step 17 through Step 23 for other fork positioner cylinder.

12. Slide fork carrier lug onto cylinder shell with the plug heads facing outwards. See Figure 35.

INSTALL

13. Align cylinder assembly to manifold and engage opposite cylinder rod into fork carrier. Install external spacer on cylinder rod, if required. Install cylinder retainer through opposite side of manifold and screw partially into cylinder shell. See Figure 35. 14. Make sure cylinder is properly oriented with restrictor fittings on backside. Engage tube and screw retainer fully into shell. Reclamp assembly to bench. 15. Tighten retainer to 165 N•m (120 lbf ft). Tighten hydraulic tubes at manifold and cylinder head end. 16. Repeat Step 6 through Step 15 for other cylinder.

CAUTION To prevent damage to sealing surfaces, use brass tools when installing seal and O-ring. NOTE: Perform Step 17 through Step 23 for lift truck models •

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

NOTE: Lubricate all internal parts of the cylinder with clean hydraulic oil during assembly. 17. Install new O-ring and piston seal onto piston. See Figure 37. 18. Install piston ring onto piston and tighten. See Figure 37.

NOTE: Perform Step 1 for lift truck models •

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

•

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

1. Install fork positioner cylinder and carriage as described in Hang On Sideshift Carriage Repair installation procedures located in the section Mast Repairs (S/N A513, A514, A613, A614, A702, A703, A704, A705, A706, A707, A751, A752, B513, B514, B586, B587, B588, B589, B590, B591, B749, B750, B751, B752, B753, B754) 4000YRM1250. NOTE: Perform Step 2 through Step 10 for lift truck model •

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

2. Install upper fork positioner cylinder onto carriage as noted during removal. See Figure 33. 3. Install nut onto upper fork positioner cylinder shell end. See Figure 33. 4. Install bushing, washer, and screw onto upper fork positioner rod end and carriage. See Figure 33. 5. Connect hydraulic fittings and lines onto upper fork positioner cylinder. See Figure 32.

19. Install new backup ring onto piston. See Figure 37.

6. Install lower fork positioner cylinder onto carriage as noted during removal. Install bushing, washer, and screw onto lower fork positioner rod end and carriage. See Figure 33.

20. Install rod and piston assembly into shell. See Figure 37.

7. Install nut onto lower fork positioner cylinder shell end. See Figure 33.

2100 YRM 1328

Lift Cylinder Leak Check

8. Install bushing, washer, and screw onto lower fork positioner rod end and carriage. See Figure 33. 9. Connect hydraulic fittings and lines onto lower fork positioner cylinder. See Figure 32.

10. Install carriage as described in carriage install procedures in the section Mast Repair (S/N A513, A514, A613, A614, A643, A644, A683, A684) 4000YRM1406.

Lift Cylinder Leak Check WARNING During the test procedures for the hydraulic system, use chains to fasten the load to the carriage to prevent it from falling. Keep all people away from the lift truck during the tests. DO NOT try to find hydraulic leaks by putting your hand on hydraulic components under pressure. Hydraulic oil can be injected into the body by the pressure. NOTE: The following checks are to be performed with a capacity load on forks and with hydraulic oil at normal operating temperature. 1. Operate hydraulic system. Put capacity load on forks. Use safety chain to hold load to carriage. Raise and lower load several times. Lower load and tilt mast forward and backward several times. Check for leaks.

If carriage slowly lowers when control valve is in NEUTRAL position, there are leaks in hydraulic system. The maximum speed the carriage is allowed to lower is 100 mm (4 in.) per 10 minutes when hydraulic oil is at normal operating temperature. 3. Check lift cylinders for internal leaks. Remove load from forks. Install valve in supply line between main control valve and mast. Put capacity load on forks again. Raise carriage 2.5 m (8 ft). Close valve. If carriage or mast lower slowly, seals in lift cylinders have leaks. 4. If carriage does not move, open valve and check movement again. If carriage lowers when valve is open, check for leaks in hydraulic lines and fittings. If no leaks are found, main control valve can be worn or damaged. Remove load from forks.

2. Put mast in vertical position and raise carriage and load 2.5 m (8 ft).

Seal Kit Installation EXTERNAL INSTALLATION (SEAL AND BACK-UP RING)

5. Slide seal over external installation sleeve and into piston rod groove. See Figure 39.

NOTE: It is recommended that seal is heated in hydraulic oil prior to installation to make it more flexible and pliable.

6. Remove external installation sleeve.

1. Lubricate seal, back-up ring, external installation sleeve and piston rod groove with hydraulic fluid. 2. Install wear ring onto piston rod assembly. See Figure 39. 3. Slide external installation sleeve over piston rod assembly and wear ring. See Figure 39.

INTERNAL INSTALLATION (PISTON ROD ASSEMBLY) 1. Insert internal installation sleeve into end of cylinder tube. See Figure 40. 2. Install piston rod assembly into cylinder tube. See Figure 40. 3. Remove internal installation sleeve from cylinder tube and piston rod assembly. See Figure 40.

4. Install back-up ring into piston rod groove. See Figure 39.

Cylinder Repair (Mast S/N A513, A514, A613, A614, B513, B514)

1. 2. 3. 4. 5.

PISTON ROD ASSEMBLY WEAR RING EXTERNAL INSTALLATION SLEEVE BACK-UP RING SEAL Figure 39. Cylinder External Seal Installation

1. 2. 3. 4. 5. 6.

2100 YRM 1328

PISTON ROD ASSEMBLY BACK-UP RING SEAL INTERNAL INSTALLATION SLEEVE CYLINDER TUBE WEAR RING Figure 40. Cylinder Internal Installation

SPECIAL TOOLS Special Tool

Cascade Part Number 6075028

6075087

2100 YRM 1328

Torque Specifications

Torque Specifications FOR LIFT TRUCK MODELS GLC/ GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) AND GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) Tilt Cylinder Piston Rod Nut 400 to 440 N•m (295 to 325 lbf ft)

Free- Lift Cylinder Hose Sheave Bracket to Chain Sheave Bracket Capscrews 33 N•m (25 lbf ft) Free- Lift Cylinder Hose Sheave Bracket to Hose Sheave Shaft Capscrews 33 N•m (25 lbf ft)

Tilt Cylinder Gland 400 to 440 N•m (295 to 325 lbf ft)

FOR LIFT TRUCK MODEL GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/ GDP190VX) (A909, B909)

Tilt Cylinder Rod End to Rod Locknut- Mast End 90 N•m (66 lbf ft)

Tilt Cylinder Piston Rod Nut 400 to 440 N•m (295 to 325 lbf ft)

Tilt Cylinder Rod End to Rod Capscrew - Frame End 90 N•m (66 lbf ft)

Tilt Cylinder Gland 400 to 500 N•m (295 to 325 lbf ft)

Tilt Cylinder Anchor Pin Capscrew 90 N•m (66 lbf ft) Lift Cylinder Gland 375 to 450 N•m (277 to 332 lbf ft)

Rod End Hex Nut 120 to 130 N•m (89 to 96 lbf ft) Tilt Cylinder Rod End to Rod Capscrew- Mast End 95 to 100 N•m (70 to 74 lbf ft)

Lift Cylinder Mount to Outer Mast Lock Nut 135 N•m (100 lbf ft)

Tilt Cylinder Rod End to Rod Capscrew - Frame End 66 N•m (49 lbf ft)

Lift Cylinder Chain Anchor Lock Nuts 370 N•m (273 lbf ft)

Tilt Cylinder Anchor Pin Capscrew 90 N•m (66 lbf ft)

Lift Cylinder Mounting Bolts to Outer Mast 555 N•m (410 lbf ft)

Lift Cylinder Gland 350 to 400 N•m (258 to 295 lbf ft)

Free- Lift Cylinder Gland 400 to 475 N•m (295 to 350 lbf ft)

Fork Positioner Cylinder Gland 350 to 400 N•m (258 to 295 lbf ft)

Free- Lift Cylinder Mount Lock Nut to Inner Mast 370 N•m (273 lbf ft)

Sideshift Cylinder Gland 350 to 400 N•m (258 to 295 lbf ft)

Free- Lift Cylinder Chain Anchor to Cylinder Mount Lock Nuts 135 N•m (100 lbf ft)

2200 YRM 1128

General

General This section covers the repair of the wire harness connectors, pins, sockets, and splicing of wires.

Deutsch Crimping Tool HOW TO STRIP A WIRE FOR USE WITH DEUTSCH CRIMPING TOOL 1. Choose the correct AWG for the contact being used. See Table 1. 2. See Table 1 for recommended strip length for contact size. Measure strip length from end of wire as shown in Figure 1.

Figure 2. Stripped Wire 4. Check for any broken strands or for a nick in the wire. If either exists, the wires are damaged and should be cut and stripped again. 5. Measure the exposed strands to verify strip length is correct. See Figure 3. Figure 1. Strip Length Measurement 3. Strip the wire to the recommended strip length. A small piece of insulation should come off the wire after stripping. See Figure 2.

Figure 3. Strip Length Measurement Verification

Deutsch Crimping Tool

2200 YRM 1128

Table 1. Wire Strip Length Specifications Contact Part Number

Type

Wire Gauge Range

580039516

20 AWG (0.5 mm )

3.96 to 5.54 mm (0.156 to 0.218 in.)

580039517

Socket

20 AWG (0.5 mm2)

3.96 to 5.54 mm (0.156 to 0.218 in.)

580094445

20 AWG (0.5 mm2)

4.0 to 5.5 mm (0.157 to 0.217 in.)

505972554

16 to 20 AWG (1.0 to 0.5 mm2)

6.35 to 7.92 mm (0.250 to 0.312 in.)

505064713

Socket

16 to 20 AWG (1.0 to 0.5 mm2)

6.35 to 7.92 mm (0.250 to 0.312 in.)

580082335

16 to 20 AWG (1.0 to 0.5 mm2)

6.4 to 7.9 mm (0.252 to 0.311 in.)

580082337

Socket

16 to 20 AWG (1.0 to 0.5 mm2)

6.4 to 7.9 mm (0.252 to 0.311 in.)

520038865

14 AWG (2.0 mm2)

6.35 to 7.92 mm (0.250 to 0.312 in.)

505064747

Socket

14 AWG (2.0 mm2)

6.35 to 7.92 mm (0.250 to 0.312 in.)

580079525

Socket

14 AWG (2.0 mm2)

6.4 to 7.9 mm (0.252 to 0.311 in.)

150121835

12 to 14 AWG (3.0 to 2.0 mm2)

5.64 to 7.21 mm (0.222 to 0.284 in.)

580050627

Socket

12 to 14 AWG (3.0 to 2.0 mm2)

5.64 to 7.21 mm (0.222 to 0.284 in.)

Recommended Strip Length

HOW TO CRIMP WITH THE DEUTSCH CRIMPING TOOL 1. Strip the insulation from the wire. See How to Strip a Wire for Use With Deutsch Crimping Tool. 2. Raise the selector knob and rotate until arrow is aligned with wire gauge to be crimped. See Figure 4. 3. Loosen lock nut and turn adjusting screw until it stops. See Figure 5.

Figure 4. Selector Knob

2200 YRM 1128

1. LOCK NUT 2. ADJUSTING SCREW Figure 5. Adjusting Screw and Lock Nut 4. Insert the contact into the crimping tool; for pin contacts, insert short end into crimping tool; for socket contacts, insert long end into crimping tool. See Figure 6.

Deutsch Crimping Tool

Figure 7. Wire Insertion 7. Close handles until handles stop. 8. Release handles and remove crimped contact. 9. Visually check the crimped contact for the following: a. The conductor is inserted to the proper depth and is visible through the inspection hole. See Figure 8. b. There is about 0.635 to 2.54 mm (0.025 to 0.100 in.) of conductor between the contact and the insulator. c. There are no damaged wire strands. d. There are no frayed wires or wires not entering the contact barrel.

1. INSERTION POINT 2. INDENTOR COVER Figure 6. Insertion Point 5. Turn the adjusting screw clockwise until the contact is flush or slightly above flush with the indentor cover (cover around insertion point). See Figure 6. Tighten the lock nut. 6. Insert the wire into the contact. There should be no loose strands. All strands should be contained in the contact barrel. The contact must be centered between indicators. See Figure 7.

1. INSPECTION HOLE 2. CRIMP 3. INSULATION GAP, 0.635 TO 2.54 mm (0.025 TO 0.100 in.) Figure 8. Proper Crimp

Deutsch Crimping Tool

2200 YRM 1128

10. If any of the conditions in Step 9 are not met, discard the contact, re-cut and strip the wire, and start the crimping process over.

CALIBRATION TEST FOR THE DEUTSCH CRIMPING TOOL The G454 testing tool is needed for the following procedures. The G454 testing tool is for use with the Deutsch hand crimping tool only. See Figure 9.

1. SELECTOR SET AT #20 WIRE SIZE, SELECTOR NUMBER 4 Figure 10. Selector Test Setting 1. GO END (GREEN) 2. NO-GO END (RED) Figure 9. G454 Testing Tool

2. Squeeze the handles of the crimp tool completely together. See Figure 11.

NOTE: Testing for all wire sizes should be #20 wire size, selector number 4. This ensures proper calibration for all settings and further testing is not needed for the other selections. 1. Set the Deutsch hand crimp tool to #20 wire size, selector number 4. See Figure 10.

Figure 11. Insertion Point 3. Insert the Go end (green) of the G454 testing tool into the insertion point of the crimp tool while the handles are completely closed. The Go end (green) should insert easily. If it does not insert, the calibration is incorrect and the crimp tool must be replaced. See Figure 12.

2200 YRM 1128

Deutsch Crimping Tool

1. GO END (GREEN) 2. GO END COMPLETELY INSERTED Figure 12. Go End Test 4. Insert the No-Go end (red) of the G454 testing tool into the insertion point of the crimp tool while the handles are still completely closed. The NoGo end (red) should not insert. If it does insert, the calibration is incorrect and the crimp tool must be replaced. See Figure 13.

1. NO-GO END (RED) 2. NO-GO END SHOULD NOT INSERT ANY FURTHER Figure 13. No-Go End Test

Deutsch Connectors DT, DTM, AND DTP SERIES CONNECTORS All Deutsch DT, DTM, and DTP series pin- and socket-type connectors are repaired in the same manner.

For examples of the DTM and DTP connectors, see Figure 18 for the different connector receptacles, Figure 19 for the different connector receptacle secondary locks, Figure 20 for the different connector plugs, and Figure 21 for the different connector plug secondary locks.

For examples of the DT connectors, see Figure 14 for the different connector receptacles, Figure 15 for the different connector receptacle secondary locks, Figure 16 for the different connector plugs, and Figure 17 for the different connector plug secondary locks.

Deutsch Connectors

2200 YRM 1128

NOTE: ALL CONNECTOR RECEPTACLES ARE SHOWN WITH THE SECONDARY LOCK INSTALLED. A. B. C. D. E.

CONNECTOR TYPE AA CONNECTOR TYPE AB CONNECTOR TYPE AC CONNECTOR TYPE AD CONNECTOR TYPE AE

F. CONNECTOR TYPE AF G. CONNECTOR TYPE AB-A (SIMILAR TO TYPE AB) H. CONNECTOR TYPE AB-B (SIMILAR TO TYPE AB) I. CONNECTOR TYPE AB-C (SIMILAR TO TYPE AB) Figure 14. DT Connector Receptacles

2200 YRM 1128

A. B. C. D.

Deutsch Connectors

SECONDARY LOCK TYPE BA SECONDARY LOCK TYPE BB SECONDARY LOCK TYPE BC SECONDARY LOCK TYPE BD

E. F. G. H.

SECONDARY LOCK TYPE BE SECONDARY LOCK TYPE BF SECONDARY LOCK TYPE BG SECONDARY LOCK TYPE BH

Figure 15. DT Connector Receptacle Secondary Locks

Deutsch Connectors

2200 YRM 1128

NOTE: ALL CONNECTOR PLUGS ARE SHOWN WITH THE SECONDARY LOCK INSTALLED. A. B. C. D.

CONNECTOR TYPE CA CONNECTOR TYPE CB CONNECTOR TYPE CC CONNECTOR TYPE CD

E. CONNECTOR TYPE CE F. CONNECTOR TYPE CF G. CONNECTOR TYPE CH (SIMILAR TO TYPE CB) H. CONNECTOR TYPE CG Figure 16. DT Connector Plugs

2200 YRM 1128

A. B. C. D.

Deutsch Connectors

SECONDARY LOCK TYPE DA SECONDARY LOCK TYPE DB SECONDARY LOCK TYPE DC SECONDARY LOCK TYPE DD

E. F. G. H.

SECONDARY LOCK TYPE DE SECONDARY LOCK TYPE DF SECONDARY LOCK TYPE DG SECONDARY LOCK TYPE DH

Figure 17. DT Connector Plug Secondary Locks

Deutsch Connectors

2200 YRM 1128

Figure 18. DTM and DTP Connector Receptacles

2200 YRM 1128

Deutsch Connectors Legend for Figure 18

A. DTP CONNECTOR TYPE EA B. DTM CONNECTOR TYPE EB C. DTM CONNECTOR TYPE EC

D. DTP CONNECTOR TYPE ED E. DTM CONNECTOR TYPE EE F. DTM CONNECTOR TYPE EF

A. DTP SECONDARY LOCK TYPE FA B. DTM SECONDARY LOCK TYPE FB C. DTM SECONDARY LOCK TYPE FC

D. DTP SECONDARY LOCK TYPE FD E. DTM SECONDARY LOCK TYPE FE F. DTM SECONDARY LOCK TYPE FF

Figure 19. DTM and DTP Connector Receptacle Secondary Locks

Deutsch Connectors

A. B. C. D.

2200 YRM 1128

DTM CONNECTOR TYPE GA DTM CONNECTOR TYPE GB DTM CONNECTOR TYPE GC DTP CONNECTOR TYPE GD

E. F. G. H.

DTM CONNECTOR TYPE GF DTM CONNECTOR TYPE GE DTP CONNECTOR TYPE GG DTM CONNECTOR TYPE GH

Figure 20. DTM and DTP Connector Plugs

2200 YRM 1128

A. B. C. D. E.

Deutsch Connectors

DTM SECONDARY LOCK TYPE HA DTM SECONDARY LOCK TYPE HB DTM SECONDARY LOCK TYPE HC DTP SECONDARY LOCK TYPE HD DTM SECONDARY LOCK TYPE HE

F. G. H. I.

DTM SECONDARY LOCK TYPE HF DTM SECONDARY LOCK TYPE HG DTP SECONDARY LOCK TYPE HH DTM SECONDARY LOCK TYPE HJ

Figure 21. DTM and DTP Connector Plug Secondary Locks

Connector Receptacle Replacement STEP 1. Release the external locking clip(s) and separate the connector plug from the connector receptacle.

Deutsch Connectors

STEP 2. Using a small hook end tool (Yale Part No. 150121838), or needle nose pliers, remove the secondary lock from the connector receptacle.

2200 YRM 1128

Deutsch Connectors

STEP 3. Using a small, flat-blade screwdriver (Yale P/N 150121838), release the locking finger by moving it away from the pin.

STEP 4. Gently pull the wire backward while, at the same time, releasing the locking finger with the small, flatblade screwdriver (Yale P/N 150121838).

Deutsch Connectors

STEP 5. Tag the wire and mark it with the corresponding number or letter on the back of the connector from which the wire was removed.

STEP 6. Repeat STEP 3 through STEP 5 for the removal of the remaining wires.

2200 YRM 1128

Deutsch Connectors

STEP 7. Insert the wires into the new connector receptacle according to the number or letter on the tag and connector receptacle. Push the wires straight into the back of the receptacle until a click is felt. Slightly tug each wire to verify the wire is properly locked in place. Remove tags.

NOTE: Verify that the seal is in place on the connector plug before installing the secondary lock. STEP 8. Install the secondary lock. Push the lock straight in until the lock snaps into place.

Deutsch Connectors

STEP 9. Push the connector plug into the connector receptacle until the external locking mechanism(s) snap(s) into place.

2200 YRM 1128

Deutsch Connectors

Connector Plug Replacement STEP 1. Release the external locking clip(s) and separate the connector plug from the connector receptacle.

STEP 2. Using a small, flat-blade screwdriver (Yale P/N 150121838), remove the secondary lock from the connector plug.

Deutsch Connectors

STEP 3. Using a small, flat-blade screwdriver (Yale P/N 150121838), release the locking finger by moving it away from the socket.

2200 YRM 1128

Deutsch Connectors

STEP 4. Gently pull the wire backward while, at the same time, releasing the locking finger with the small, flatblade screwdriver (Yale P/N 150121838).

STEP 5. Tag the wire and mark it with the corresponding number or letter on the back of the connector from which the wire was removed.

Deutsch Connectors

STEP 6. Repeat STEP 3 through STEP 5 for the removal of the remaining wires. STEP 7. Insert the wires into the back of the new connector plug according to the number or letter on the tag and connector plug. Push the wires straight into the back of the plug until a click is felt. Slightly tug each wire to verify the wire is properly locked in place. Remove tags.

NOTE: Verify that the seal is in place on the connector plug before installing the secondary lock.

2200 YRM 1128

Deutsch Connectors

STEP 8. Install the secondary lock. Push the lock straight in until the lock snaps into place. On 3-way secondary locks, the arrow on the lock must be oriented toward the exterior locking mechanism.

1. SEAL

1. SEAL STEP 9. Push the connector plug into the connector receptacle until the external locking mechanism(s) snap(s) into place.

Deutsch Connectors

Connector Receptacle Pin Replacement STEP 1. Release the external locking clip(s) and separate the connector plug from the connector receptacle.

2200 YRM 1128

Deutsch Connectors

STEP 2. Using a small hook end tool (Yale P/N 150121838), or needle nose pliers, remove the secondary lock from the connector receptacle.

STEP 3. Using a small, flat-blade screwdriver (Yale P/N 150121838), release the locking finger by moving it away from the pin.

Deutsch Connectors

STEP 4. Gently pull the wire backward while, at the same time, releasing the locking finger with the small, flatblade screwdriver (Yale P/N 150121838).

2200 YRM 1128

Deutsch Connectors

STEP 5. If more than one pin is being replaced, tag the wire and mark it with the corresponding number or letter on the back of the connector from which the wire was removed.

STEP 6. Using wire cutters, cut the wire behind the old pin and discard old pin.

Deutsch Connectors STEP 7. Using wire strippers (Yale P/N 150121841), strip the wire to the recommended length shown in Table 1.

STEP 8. Using the Deutsch Crimping Tool (Yale P/N 150121900), crimp the new pin on the wire as shown in How to Crimp With the Deutsch Crimping Tool.

STEP 9. Insert the wire into the connector receptacle according to the number or letter on the tag and connector receptacle. Push the wire straight into the back of the receptacle until a click is felt. Slightly tug the wire to verify the wire is properly locked in place. Remove tag.

2200 YRM 1128

Deutsch Connectors

NOTE: Verify that the seal is in place on the connector plug before installing the secondary lock. STEP 10. Install the secondary lock. Push the lock straight in until the lock snaps into place.

Deutsch Connectors STEP 11. Push the connector plug into the connector receptacle until the external locking mechanism(s) snap(s) into place.

Connector Plug Socket Replacement STEP 1. Release the external locking clip(s) and separate the connector plug from the connector receptacle.

2200 YRM 1128

Deutsch Connectors

STEP 2. Using a small, flat-blade screwdriver (Yale P/N 150121838), remove the secondary lock from the connector plug.

Deutsch Connectors STEP 3. Using a small, flat-blade screwdriver (Yale P/N 150121838), release the locking finger by moving it away from the socket.

STEP 4. Gently pull the wire backward while, at the same time, releasing the locking finger with the small, flatblade screwdriver (Yale P/N 150121838).

2200 YRM 1128

Deutsch Connectors

STEP 5. If more than one socket is being removed, tag the wire and mark it with the corresponding number or letter on the back of the connector from which the wire was removed.

Deutsch Connectors STEP 6. Using wire cutters, cut the wire behind the old socket and discard old socket.

STEP 7. Using wire strippers Yale P/N 150121841, strip the wire to the recommended length shown in Table 1.

STEP 8. Using the Deutsch Crimping Tool (Yale P/N 150121900), crimp the new socket on the wire as shown in How to Crimp With the Deutsch Crimping Tool.

2200 YRM 1128

Deutsch Connectors

STEP 9. Insert the wire into the back of the new connector plug according to the number or letter on the tag and connector plug. Push the wire straight into the back of the plug until a click is felt. Slightly tug the wire to verify the wire is properly locked in place. Remove tag.

NOTE: Verify that the seal is in place on the connector plug before installing the secondary lock. STEP 10. Install the secondary lock. Push the lock straight in until the lock snaps into place. On 3-way secondary locks, the arrow on the lock must be oriented toward the exterior locking mechanism.

1. SEAL

Deutsch Connectors

2200 YRM 1128

1. SEAL STEP 11. Push the connector plug into the connector receptacle until the external locking mechanism(s) snap(s) into place.

HD SERIES CONNECTORS All Deutsch HD series pin-type connectors are repaired in the same manner.

For examples of the HD connectors, see Figure 22 for the different connector receptacles and Figure 23 for the different connector plugs.

2200 YRM 1128

A. TYPE A

Deutsch Connectors

B. TYPE B Figure 22. HD Connector Receptacles

Deutsch Connectors

A. TYPE 1

2200 YRM 1128

B. TYPE 2 Figure 23. HD Connector Plugs

2200 YRM 1128

Deutsch Connectors

Connector Receptacle Replacement STEP 1. Separate the connector plug from the connector receptacle.

STEP 2. Remove the lock nut and washer retaining the receptacle to the mounting structure. Remove receptacle from mounting structure.

NOTE: Be sure to use correct extraction tool; see Special Tools section of this manual. STEP 3. Insert a Deutsch extraction tool over the wire being removed.

Deutsch Connectors

2200 YRM 1128

NOTE: Do not twist the tool or insert the tool at an angle. STEP 4. Push the tool into the connector about 25 mm (1 in.) until it bottoms on the contact flange.

NOTE: If pin is difficult to remove, remove the extraction tool, turn the extraction tool 90 degrees, and reinsert the tool into the connector. STEP 5. Hold the tool on the contact flange and pull the wire and the connection pin out of the connector.

2200 YRM 1128

Deutsch Connectors

STEP 6. Tag the wire and mark it with the corresponding number or letter on the back of the connector from which the wire was removed.

STEP 7. Repeat STEP 3 through STEP 6 for the removal of the remaining wires. STEP 8. Insert the wires into the back of the new connector receptacle according to the number or letter on the tag and connector receptacle. Push the wire straight into the back of the receptacle until a click is felt. Slightly tug each wire to verify the wire is properly locked in place. Remove tags.

Deutsch Connectors STEP 9. Install receptacle into mounting structure. Install the lock nut and washer to retain the receptacle to the mounting structure.

STEP 10. Connect the connector plug to the connector receptacle.

Connector Plug Replacement STEP 1. Separate the connector plug from the connector receptacle.

NOTE: Be sure to use correct extraction tool; see Special Tools section of this manual.

2200 YRM 1128

Deutsch Connectors

STEP 2. Insert a Deutsch extraction tool over the wire being removed.

NOTE: Do not twist the tool or insert the tool at an angle. STEP 3. Push the tool into the connector about 25 mm (1 in.) until it bottoms on the contact flange.

NOTE: If pin is difficult to remove, remove the extraction tool, turn the extraction tool 90 degrees, and reinsert the tool into the connector.

Deutsch Connectors STEP 4. Hold the tool on the contact flange and pull the wire and the connection socket out of the connector.

STEP 5. Tag the wire and mark it with the corresponding number or letter on the back of the connector from which the wire was removed.

STEP 6. Repeat STEP 2 through STEP 5 for the removal of the remaining wires.

2200 YRM 1128

Deutsch Connectors

STEP 7. Insert the wires into the back of the new connector plug according to the number or letter on the tag and connector plug. Push the wire straight into the back of the plug until a click is felt. Slightly tug each wire to verify the wire is properly locked in place. Remove tags.

STEP 8. Connect the connector plug to the connector receptacle.

Connector Receptacle Pin Replacement STEP 1. Separate the connector plug from the connector receptacle.

Deutsch Connectors STEP 2. Remove the lock nut and washer retaining the receptacle to the mounting structure. Remove receptacle from mounting structure.

NOTE: Be sure to use correct extraction tool; see Special Tools section of this manual. STEP 3. Insert a Deutsch extraction tool over the wire being removed.

NOTE: Do not twist the tool or insert the tool at an angle.

2200 YRM 1128

Deutsch Connectors

STEP 4. Push the tool into the connector about 25 mm (1 in.) until it bottoms on the contact flange.

STEP 5. Hold the tool on the contact flange and pull the wire and the connection pin out of the connector.

STEP 6. If more than one wire is being removed, tag the wire and mark it with the corresponding number or letter on the back of the connector from which the wire was removed.

Deutsch Connectors

STEP 7. Using wire cutters, cut the wire behind the old pin and discard old pin.

STEP 8. Using wire strippers, Yale P/N 150121841, strip the wire to the recommended length shown in Table 1.

2200 YRM 1128

Deutsch Connectors

STEP 9. Using the Deutsch Crimping Tool (Yale P/N 150121900), crimp the new pin on the wire as shown in How to Crimp With the Deutsch Crimping Tool.

NOTE: The rear seal/grommet must be seated properly before inserting wires. STEP 10. Insert the wires into the back of the new connector receptacle according to the number or letter on the tag and connector receptacle. Push the wire straight into the back of the receptacle until a click is felt. Slightly tug each wire to verify the wire is properly locked in place. Remove tags.

STEP 11. Install receptacle into mounting structure. Install the lock nut and washer to retain the receptacle to the mounting structure.

Deutsch Connectors STEP 12. Connect the connector plug to the connector receptacle.

Connector Plug Socket Replacement STEP 1. Separate the connector plug from the connector receptacle.

NOTE: Be sure to use correct extraction tool; see Special Tools section of this manual. STEP 2. Insert a Deutsch extraction tool over the wire being removed.

2200 YRM 1128

Deutsch Connectors

NOTE: Do not twist the tool or insert the tool at an angle. STEP 3. Push the tool into the connector about 25 mm (1 in.) until it bottoms on the contact flange.

STEP 4. Hold the tool on the contact flange and pull the wire and the connection socket out of the connector.

Deutsch Connectors STEP 5. If more than one wire is being removed, tag the wire and mark it with the corresponding number or letter on the back of the connector from which the wire was removed.

2200 YRM 1128

Deutsch Connectors

STEP 6. Using wire cutters, cut the wire behind the old socket and discard old socket.

STEP 7. Using wire strippers, Yale P/N 150121841, strip the wire to the recommended length shown in Table 1.

STEP 8. Using the Deutsch Crimping Tool (Yale P/N 150121900), crimp the new socket on the wire as shown in How to Crimp With the Deutsch Crimping Tool.

NOTE: The rear seal/grommet must be seated properly before inserting wires.

Deutsch Connectors STEP 9. Insert the wires into the back of the new connector plug according to the number or letter on the tag and connector plug. Push the wire straight into the back of the plug until a click is felt. Slightly tug wire to verify the wire is properly locked in place. Remove tags.

STEP 10. Connect the connector plug to the connector receptacle.

2200 YRM 1128

Deutsch Connectors

SEALING PLUGS All empty contact cavities must be filled with a sealing plug. See Figure 24.

A. 6 AWG (DARK RED) B. 8 AWG (CLEAR WHITE)

C. 12 TO 18 AWG (WHITE) D. 20 AWG (RED) Figure 24. Sealing Plugs

STEP 1. Hold the sealing plug with the large diameter end away from the connector.

Deutsch Connectors

2200 YRM 1128

STEP 2. Insert the sealing plug into the connector contact cavity. Gently apply downward pressure to force the sealing plug into the cavity.

STEP 3. Apply pressure until sealing plug is forced to stop by the connector rear grommet. Visually inspect the sealing plug to ensure it is flush with the cavity opening.

Metri-Pack Connectors Some connectors use terminals called Metri-Pack Series 150. These may be used at the coolant sensor and TBI units on ICE lift trucks. They are also called push-to-seat terminals because to install a terminal on a wire, the wire is first inserted through the seal and connector. The terminal is then crimped on the wire and the terminal pulled back into the connector to seat it in place.

NOTE: DO NOT cut contacts from reel, use loose contacts only.

REMOVE AND INSTALL 1. Slide the seal back on the wire. 2. Hold the wire and use it to push the terminal to its forward position in the connector body. Hold the terminal in this position. See Figure 25.

2200 YRM 1128

Metri-Pack Connectors

1. FEMALE TERMINAL 2. LOCKING TAB 3. TOOL KIT

4. CONNECTOR BODY 5. SEAL Figure 25. Metri-Pack Terminal Removal

3. Find the lock tab for the terminal in the connector channel. Push a removal tool (pick) (YALE P/N 150121850) of the correct size into the connector channel. See Figure 26 and Figure 27.

1. 2. 3. 4.

TOOL (PICK) LOCK TAB TERMINAL CONNECTOR BODY Figure 27. Metri-Pack Pull-to-Seat Connector

1. 2. 3. 4.

TOOL (PICK) LOCK TAB TERMINAL CONNECTOR BODY Figure 26. Metri-Pack Push-to-Seat Connector

4. Use the removal tool (YALE P/N 150121850) to move the lock tab to release the terminal from its seat. Push-to-Seat - Gently pull the wire to remove the terminal from the back of the connector. Pull-to-Seat - Gently push the wire to remove the terminal through the front of the connector. See Figure 28.

Metri-Pack Connectors

2200 YRM 1128

NOTE: THE GREATER DISTANCE D, A FAULT CAN OCCUR IN THE CONNECTION. 1. 2. 3. 4. 5.

TERMINAL LOCK TAB TOOL KIT CONNECTOR BODY SEAL Figure 28. Metri-Pack Pull-to-Seat Terminal Removal

CAUTION

1. CONTACT TAB Figure 29. Metri-Pack Terminal Inspection NOTE: If reusing the terminal, reshape the locking tab. 6. If the terminal will be used again, make sure the lock tab is correctly bent so that the terminal will be locked in the connector again.

Work carefully and do not use enough force to damage the terminal or the connector.

7. Push the terminal into the connector channel. Make sure that the lock tab correctly locks the terminal in position.

5. Inspect the terminal and connector for damage. See Figure 29.

8. Push the seals into their position and install any secondary locks.

2200 YRM 1128

Micro-Pack Connectors

Micro-Pack Connectors The Micro-Pack connector is shown in Figure 30. This connector is normally used to connect the wire harness to the ECM. The repair procedures for the MicroPack connectors are the same as the Metri-Pack connectors. Refer to the section Metri-Pack Connectors for the repair procedures.

1. 2. 3. 4.

CABLE TERMINAL LOCKING TAB TOOL KIT (YALE P/N 150121852 Figure 30. Micro-Pack Connector

Weather-Pack Connectors A Weather-Pack connector can be identified by a rubber seal at the rear of the connector. This connector, which is used in the engine compartment, protects against moisture and dirt which could create oxidation and deposits on the terminals. This protection is important because of the very low voltage and current levels found in the electronic system.

Make certain that the connectors are properly seated and all of the sealing rings are in place when connecting leads. The hinge-type flap provides a backup or secondary locking feature for the connector. They are used to improve the connector reliability by retaining the terminals if the small terminal lock tabs are not positioned properly.

Repair of a Weather-Pack terminal is shown in Weather-Pack Terminal Repair. Use the tool kit to remove the pin and sleeve terminals. See Special Tools.

Weather-Pack connections cannot be replaced with standard connections. Instructions are provided with Weather-Pack connector and terminal packages.

If removal is attempted with an ordinary pick, there is a good chance that the terminal will be bent or deformed. Unlike standard blade-type terminals, these terminals cannot be straightened once they are bent.

Weather-Pack Connectors

2200 YRM 1128

WEATHER-PACK TERMINAL REPAIR STEP 1. Open secondary lock hinge on connector.

1. FEMALE CONNECTOR 2. MALE CONNECTOR 3. SECONDARY LOCK HINGE STEP 2. Remove terminal, using tool YALE P/N 150121851.

1. TERMINAL 2. TOOL STEP 3. Cut wire immediately behind cable seal.

1. WIRE 2. SEAL STEP 4. Replace terminal. a. Slip new seal onto wire. b. Strip 5 mm (0.2 in.) of insulation from wire. c. Crimp terminal over wire and seal. STEP 5. Push terminal and connector onto wire and engage locking tabs.

2200 YRM 1128

Weather-Pack Connectors

STEP 6. Close secondary lock hinge.

1. SEAL

AMPSEAL Crimping Tools AMP HAND CRIMPING TOOL WITH CERTI-CRIMP Description The tool, Yale P/N 580093883, features two upper inserts, two anvils, an insulation crimp adjustment lever, a contact support, a locator, an ejector, and a CERTICRIMP ratchet. The contact is inserted into the FRONT of the tool. The wire is inserted into the BACK of the tool. See Figure 31.

AMPSEAL Crimping Tools

2200 YRM 1128 Legend for Figure 31 A. FRONT OF TOOL B. BACK OF TOOL 1. 2. 3. 4. 5. 6. 7.

UPPER INSERT ANVIL INSULATION CRIMP ADJUSTMENT LEVER CONTACT SUPPORT LOCATOR CERTI-CRIMP RATCHET STRIPPED WIRE

The insulation adjust lever regulates the crimp height. See Insulation Crimp Adjustment. The contact support prevents the contact from bending during crimping. The locator functions two ways: •

position the contact between the upper insert and the anvil before crimping

•

limits the insertion distance of the stripped wire into the contact.

The ejector pulls the locator down, and ejects the crimped contact when the tool handles are fully opened.

CAUTION The crimping jaws bottom before the CERTICRIMP ratchet releases. This is a design feature that ensures maximum electrical and tensile performance of the crimp DO NOT readjust the ratchet. The CERTI-CRIMP ratchet assures full crimping of the contact. Once engaged, the ratchet will not release until the handles have been fully closed.

Figure 31. AMP Hand Crimping Tool

Stripping Wire for Use with AMP Hand Crimping Tool 1. Choose the correct AWG for the contact being used. 2. See Table 2 for recommended strip length.

2200 YRM 1128

AMPSEAL Crimping Tools Table 2. Wire Size (AWG)

Wire Size (AWG)

Insulation Diameter Range

Tool Wire Size Marking

Contact

Wire Strip Length

1.7 to 2.7 mm (0.067 to 0.106 in.)

Yale P/N 520202601

5.5 mm (0.215 in.)

20 - 18

CAUTION DO NOT cut or nick the wire strands. 3. Strip wire to recommended strip length. A small piece of insulation should come off the wire after stripping. See Figure 32.

4.7 mm (0.185 in.)

Maintenance and Inspection for AMP Hand Crimping Tool AMP Hand Crimping Tool 1. Perform maintenance and inspections as specified by AMP.

Crimp Height Inspection 1. This inspection requires the use of a micrometer with a modified anvil as shown in Figure 33. 2. Refer to Table 3 and select contact and wire (maximum size) for each crimp section listed. 3. Crimp a contact on to the wire according to How to use AMP Hand Crimping Tool procedure. NOTE: SEE TABLE 2 FOR WIRE STRIP LENGTH. 1. STRIPPED WIRE 2. LOCATOR SLOT

4. Using a modified micrometer, measure wire barrel crimp height as shown in Figure 33. If the crimp height conforms to measurement in Table 3 the tool is correct. If not, replace tool.

Figure 32. Strip Length

Insulation Crimp Adjustment The insulation barrel crimp height is regulated by the insulation adjustment lever. To determine the proper setting, test crimp a contact using the setting which approximates the insulation size: 1) small, 2) medium, or 3) large. If the crimped insulation barrel is too tight or too loose, change the setting accordingly. The crimp should hold the insulation firmly without cutting into it.

AMPSEAL Crimping Tools

2200 YRM 1128 Legend for Figure 33 A. CRIMP HEIGHT - SEE TABLE 3 1. 2. 3. 4. 5.

TOOL CRIMP SECTION MARKING WIRE SLOT IN LOCATOR WIRE BARREL LOCATOR SLOT IN CONTACT MODIFIED ANVIL ON MICROMETER

Figure 33. AMP Crimp Tool Inspection Table 3. Crimp Height Contact Part No

Yale P/N 520202601

Wire Size (AWG)

Tool Crimp Section Marking

Crimp Height

20-18

1.22 ±0.05 mm (0.048 ±0.002 in.)

20-18

1.22 ±0.05 mm (0.048 ±0.002 in.)

1.40 ±0.05 mm (0.055 ±0.002 in.)

HOW TO USE AMP HAND CRIMPING TOOL 1. Strip insulation from wire. See Stripping Wire for Use with AMP Hand Crimping Tool. 2. Hold tool so BACK side (wire side) faces you. 3. Release tool ratchet by squeezing tool handles then allowing them to open.

4. Holding contact by its mating portion and looking straight into crimp section, insert contact from the FRONT of tool into BACK of crimp section. Position contact as shown in Figure 34.

2200 YRM 1128

AMPSEAL Crimping Tools The locator assembly, on the outside of the frame, contains a locator, a spring retainer, and a contact support. The dies are secured to the frame with retaining pins and retaining screws. A nut on the upper retaining screw holds the locator assembly in place.

1. 2. 3. 4. 5.

BACK OF TOOL STRIPPED WIRE WIRE BARREL CONTACT LOCATOR Figure 34. Crimp Contact to Wire

NOTE: Make sure wire barrel is not deformed during crimping procedure. 5. Holding contact in this position, squeeze tool handles together. 6. Insert properly stripped wire through locator and into wire barrel of contact. 7. Crimp contact onto wire while holding wire in place by squeezing tool handles together until ratchet releases. 8. Allow tool handles to open fully and remove crimped contact from tool.

AMP PRO-CRIMPER II TOOL Description This tool has a tool frame with stationary jaw and handle, a moving jaw and handle, and an adjustable ratchet to ensure full contact crimping. The tool frame contains a die assembly with two crimping sections. The die assembly contains a wire anvil, an insulation anvil, a wire crimper and an insulation crimper. See Figure 35.

A. TOOL FRONT B. TOOL BACK 1. 2. 3. 4. 5. 6.

STATIONARY JAW STATIONARY HANDLE MOVING JAW MOVING HANDLE DIE ASSEMBLY LOCATOR ASSEMBLY Figure 35. AMP PRO-CRIMPER II Tool

Remove and Install Die Set and Locator Assembly NOTE: Perform Step 1 through Step 3 for removal of die set and locator assembly. Follow Step 4 through Step 12 for installation of die set and locator assembly. 1. Close tool handles until ratchet releases. 2. Remove nut, locator assembly, upper and lower die retaining screws, and upper and lower die retaining pins. See Figure 36. 3. Slide wire anvil, insulation anvil, wire crimper, and insulation crimper out of tool frame. See Figure 36.

AMPSEAL Crimping Tools

2200 YRM 1128

4. Install wire anvil and insulation anvil into moving jaw of tool frame, with chamfered sides and marked surfaces facing outward. See Figure 36. 5. Insert lower die retaining pins. See Figure 36. 6. Insert lower die retaining screw through moving jaw and both anvils. Tighten screw enough to hold the anvils in place, but DO NOT tighten completely. See Figure 36. 7. Insert wire crimper and insulation crimper into stationary jaw, with chamfered sides and marked surfaces facing outward. See Figure 36. 8. Insert upper die retaining pins. See Figure 36. 9. Insert upper die retaining screw through stationary jaw and both crimpers. See Figure 36. Tighten screw enough to hold crimpers in place, but DO NOT tighten completely. 10. Carefully close tool handles. Make sure anvils and crimpers align properly. Completely close tool handles until ratchet is engaged enough to hold anvils and crimpers in position. Tighten upper and lower die retaining screws. 11. Install locator assembly over the end of upper die retaining screw and position against the side of the tool jaw. See Figure 36. 12. Install nut onto the end of upper die retaining screw and tighten enough to hold locator assembly in place while allowing the locator to slide up and down. See Figure 36.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

UPPER DIE RETAINING SCREW LOWER DIE RETAINING SCREW WIRE ANVIL INSULATION ANVIL LOWER DIE RETAINING PIN WIRE CRIMPER INSULATION CRIMPER UPPER DIE RETAINING PIN LOCATOR ASSEMBLY NUT LOCATOR TOOL FRAME Figure 36. Die Set and Locator Assembly

Stripping Wire for Use With AMP PROCRIMPER II Tool 1. Choose the correct AWG for the contact being used. 2. See Table 4 for recommended strip length. Table 4. Strip Length for PRO-CRIMPER II Tool Wire Size Wire Insulation Di(AWG) ameter 16 18-20

Strip Length

1.7 to 2.7 mm (0.07 5.1 ±0.4 mm (0.20 to 0.11 in.) ±0.02 in.)

CAUTION DO NOT cut or nick the wire strands. 3. Strip wire to recommended strip length. See Figure 37.

2200 YRM 1128

1. 2. 3. 4.

CONTACT LOCATOR (IN WIRE STOP SLOT) WIRE (INSERTED TO STOP) STRIP LENGTH Figure 37. Contact and Wire Strip

AMPSEAL Crimping Tools

1. 2. 3. 4. 5.

ADJUSTMENT SCREW CONTACT SUPPORT LOCATOR WIRE BACK OF TOOL Figure 38. Contact Support Adjustment

Contact Support Adjustment 1. Make a sample crimp. Determine if contact is straight, bent upward or downward. 2. If adjustment is required, loosen adjustment screw, DO NOT remove screw. See Figure 38.

Crimp Height Adjustment 1. Remove lockscrew from wheel. See Figure 39.

ratchet

adjustment

2. Using screwdriver, adjust ratchet wheel as indicated in Step 3 or Step 4.

3. Insert contact and wire into tool as shown in Figure 37. Close tool handles until the ratchet reaches the sixth clip or the contact support touches the contact.

3. To tighten crimp, rotate ratchet adjustment wheel COUNTERCLOCKWISE. See Figure 39.

4. Loosen the nut, slightly, that holds the locator assembly onto the tool frame. See Figure 38.

4. To loosen crimp, rotate ratchet adjustment wheel CLOCKWISE. See Figure 39.

5. Move the contact support to eliminate bending the contact.

5. Replace lockscrew onto wheel. See Figure 39.

6. Tighten the nut and squeeze handles until ratchet releases.

6. Make a sample crimp and measure the crimp height.

ratchet

adjustment

7. Remove and inspect the contact. 8. Make another sample crimp. If the contact is straight, tighten the adjustment screw. If the contact is bent, repeat Step 2 through Step 8.

AMPSEAL Crimping Tools

2200 YRM 1128

A. POSITION POINT ON CENTER OF WIRE BARREL OPPOSITE SEAM. 1. MODIFIED ANVIL ON MICROMETER 2. CRIMP HEIGHT, SEE TABLE 5 1. LOCKSCREW 2. RATCHET ADJUSTMENT WHEEL 3. SCREWDRIVER Figure 39. Ratchet Adjustment Wheel

Maintenance and Inspection Procedures PRO-CRIMPER II Tool 1. Make sure the tool and dies are clean by wiping them with a clean, soft cloth. If debris is present, clear away with a soft brush. Keep handles closed when not in use to prevent objects from becoming stuck in crimping dies. Store in clean, dry area. 2. Inspect the crimping dies on a regular basis to ensure they are not worn or damaged. If crimp sections are flattened, chipped, worn or broken replace tool.

Crimp Height Inspection 1. This inspection requires the use of a micrometer with a modified anvil as shown in Figure 40.

Figure 40. Crimp Height 2. Refer to Table 5 to select wire for each crimp section listed. Table 5. Crimp Measurement Wire Size (AWG)

Crimp Height

1.22 ±0.05 mm (0.048 ±0.002 in.)

1.41 ±0.05 mm (0.056 ±0.002 in.)

3. Crimp a contact onto the selected wire according to How to Use AMP PRO-CRIMPER II Tool procedure. 4. Using a modified micrometer, measure wire barrel height as shown in Figure 40. If the crimp height matches measurement shown in Table 5 the tool is correct. If not, follow Crimp Height Adjustment procedure.

2200 YRM 1128

AMPSEAL Crimping Tools

HOW TO USE AMP PRO-CRIMPER II TOOL

NOTE: Make sure neither wire barrel nor insulation barrel are damaged.

1. Strip insulation from wire. See Stripping Wire for Use With AMP PRO-CRIMPER II Tool procedure.

6. Hold contact in position and squeeze tool handles until ratchet engages enough to hold contact.

2. Hold PRO-CRIMPER II tool so BACK side (wire side) is facing you.

7. Insert stripped wire into contact insulation and wire barrels until butted against wire stop.

3. Squeeze tool handles together, then allow to fully open.

8. Squeeze tool handles, while holding wire in position, until ratchet releases.

4. Holding contact by mating end, insulation barrel first, insert contact through front of tool and into appropriate crimp section.

9. Allow tool handles to open and remove crimped contact from tool.

5. Mating end of contact should be on locator side of tool; the open "U" of wire barrel and insulation barrel should face the top of the tool. The contact to be placed to that movable locator drips into slot in the contact. Butt the front end of the wire barrel against locator.

10. Check crimp height as described in Crimp Height Inspection.

AMPSEAL Connector Assemblies DESCRIPTION FOR PLUG CONNECTOR ASSEMBLY The plug assembly consists of a housing, a wedge lock, a wire seal, and a mating seal. See Figure 41.

AMPSEAL Connector Assemblies

2200 YRM 1128 Table 6. Current Rating Single Circuit Plating

Wire Size (AWG)

Current Rating (Max.)

Tin

16, 18, and 20

Gold

14.5A

13A

11.5A

Seal Plug All circuits are sealed by a diaphragm in the rubber wire seal. When assembling the connector, the diaphragm is pierced as the contact passes through it. Unused circuit cavities will remain sealed unless perforated by accidental insertion and removal of contact in the wrong cavity. The seal plug is designed to keep out contaminants if the diaphragm is pierced. 1. Insert the seal plug, large end first, into the circuit cavity as far as it will go. No insertion tool is usually required for this procedure. See Figure 42.

1. 2. 3. 4. 5. 6. 7.

HOUSING WEDGE LOCK WIRE SEAL MATING SEAL DIAPHRAGM CONTACT RETENTION FINGERS Figure 41. AMPSEAL Plug Connector

For current ratings of special use connectors, AMPSEAL, refer to Table 6.

1. PLUG CONNECTOR 2. SEAL PLUG 3. CIRCUIT CAVITY Figure 42. Seal Plug

Contact Crimping Information on contact crimping can be found in AMPSEAL Crimping Tools.

2200 YRM 1128

AMPSEAL Connector Assemblies

Contact Removal NOTE: The wedge lock should never be removed from the housing for insertion or removal of the contacts. STEP 1. Insert a screwdriver blade between the mating seal and one of the red wedge lock tabs. Pry open the wedge lock to the OPEN position.

NOTE: SCREWDRIVER TO BE MOVED IN DIRECTION OF ARROW. A. CLOSED POSITION B. OPEN POSITION 1. WEDGE LOCK TAB

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