Professional Documents
Culture Documents
S6.0FT, S7.0FT
(S135FT,S155FT) [D024];
S30FT, S35FT, S40FTS [E010];
H1.6FT, H1.8FT, H2.0FTS
(H30FT, H35FT, H40FTS) [F001]; S2.0-3.5FT
(S40-70FT, S55FTS ) [F187]; S4.0, 4.5, 5.5FT,
S5.5FTS (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) [G004]; H6.0FT, H7.0FT
(H135FT, H155FT) [H006];
H2.0-3.5FT (H40-70FT) [L177]; H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, 120FT) [N005]
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.
• Keep the unit clean and the working area clean and orderly.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
Wire Harness Repair Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Deutsch Crimping Tool ...................................................................................................................................... 1
How to Strip a Wire for Use With Deutsch Crimping Tool.......................................................................... 1
How to Crimp With the Deutsch Crimping Tool .......................................................................................... 2
Calibration Test for the Deutsch Crimping Tool .......................................................................................... 3
Deutsch Connectors ........................................................................................................................................... 5
DT, DTM, and DTP Series Connectors ......................................................................................................... 5
Connector Receptacle Replacement.......................................................................................................... 13
Connector Plug Replacement.................................................................................................................... 21
Connector Receptacle Pin Replacement................................................................................................... 29
Connector Plug Socket Replacement........................................................................................................ 38
HD Series Connectors ................................................................................................................................... 47
Connector Receptacle Replacement.......................................................................................................... 49
Connector Plug Replacement.................................................................................................................... 53
Connector Receptacle Pin Replacement................................................................................................... 56
Connector Plug Socket Replacement........................................................................................................ 62
Sealing Plugs ................................................................................................................................................. 66
Metri-Pack Connectors ...................................................................................................................................... 68
Remove and Install........................................................................................................................................ 68
Micro-Pack Connectors ...................................................................................................................................... 70
Weather-Pack Connectors ................................................................................................................................. 71
Weather-Pack Terminal Repair .................................................................................................................... 71
Wire Repair ........................................................................................................................................................ 72
Wire Splicing Requirements ......................................................................................................................... 72
Deutsch Jiffy Splice ....................................................................................................................................... 72
Assemble .................................................................................................................................................... 73
Disassemble ............................................................................................................................................... 75
Del-City Crimp-Solder-Shrink Splice ........................................................................................................... 76
Twisted/Shielded Cable and Leads Repair ....................................................................................................... 78
Twisted/Shielded Cable Repair ..................................................................................................................... 78
Twisted Leads Repair .................................................................................................................................... 79
Special Tools ....................................................................................................................................................... 80
HYSTER
APPROVED
PARTS
2200 SRM 1128 Deutsch Crimping Tool
General
This section covers the repair of the wire harness connectors, pins, sockets, and splicing of wires.
1
Deutsch Crimping Tool 2200 SRM 1128
Contact Part Number Type Wire Gauge Range Recommended Strip Length
1463136 Pin 20 AWG (0.5 mm 2) 3.96 to 5.54 mm (0.156 to 0.218 in.)
2
1463137 Socket 20 AWG (0.5 mm ) 3.96 to 5.54 mm (0.156 to 0.218 in.)
1330433 Pin 16 to 20 AWG 6.35 to 7.92 mm (0.250 to 0.312 in.)
(1.0 to 0.5 mm 2)
1330434 Socket 16 to 20 AWG 6.35 to 7.92 mm (0.250 to 0.312 in.)
(1.0 to 0.5 mm 2)
1330435 Pin 14 AWG (2.0 mm 2) 6.35 to 7.92 mm (0.250 to 0.312 in.)
2
1330436 Socket 14 AWG (2.0 mm ) 6.35 to 7.92 mm (0.250 to 0.312 in.)
0866401 Pin 12 to 14 AWG 5.64 to 7.21 mm (0.222 to 0.284 in.)
(3.0 to 2.0 mm 2)
1554359 Socket 12 to 14 AWG 5.64 to 7.21 mm (0.222 to 0.284 in.)
(3.0 to 2.0 mm 2)
HOW TO CRIMP WITH THE DEUTSCH 3. Loosen lock nut and turn adjusting screw until it
CRIMPING TOOL stops. See Figure 5.
1. LOCK NUT
2. ADJUSTING SCREW
2
2200 SRM 1128 Deutsch Crimping Tool
3
Deutsch Crimping Tool 2200 SRM 1128
4
2200 SRM 1128 Deutsch Connectors
Deutsch Connectors
DT, DTM, AND DTP SERIES CONNECTORS For examples of the DT connectors, see Figure 14
for the different connector receptacles, Figure 15 for
All Deutsch DT, DTM, and DTP series pin- and the different connector receptacle secondary locks,
socket-type connectors are repaired in the same Figure 16 for the different connector plugs, and
manner. Figure 17 for the different connector plug secondary
locks.
NOTE: ALL CONNECTOR RECEPTACLES ARE SHOWN WITH THE SECONDARY LOCK INSTALLED.
A. CONNECTOR TYPE AA G. CONNECTOR TYPE AB-A (SIMILAR TO TYPE
B. CONNECTOR TYPE AB AB)
C. CONNECTOR TYPE AC H. CONNECTOR TYPE AB-B (SIMILAR TO TYPE
D. CONNECTOR TYPE AD AB)
E. CONNECTOR TYPE AE I. CONNECTOR TYPE AB-C (SIMILAR TO TYPE
F. CONNECTOR TYPE AF AB)
5
Deutsch Connectors 2200 SRM 1128
6
2200 SRM 1128 Deutsch Connectors
NOTE: ALL CONNECTOR PLUGS ARE SHOWN WITH THE SECONDARY LOCK INSTALLED.
A. CONNECTOR TYPE CA E. CONNECTOR TYPE CE
B. CONNECTOR TYPE CB F. CONNECTOR TYPE CF
C. CONNECTOR TYPE CC G. CONNECTOR TYPE CH (SIMILAR TO TYPE CB)
D. CONNECTOR TYPE CD H. CONNECTOR TYPE CG
7
Deutsch Connectors 2200 SRM 1128
For examples of the DTM and DTP connectors, see secondary locks, Figure 20 for the different connec-
Figure 18 for the different connector receptacles, tor plugs, and Figure 21 for the different connector
Figure 19 for the different connector receptacle plug secondary locks.
8
2200 SRM 1128 Deutsch Connectors
9
Deutsch Connectors 2200 SRM 1128
10
2200 SRM 1128 Deutsch Connectors
11
Deutsch Connectors 2200 SRM 1128
12
2200 SRM 1128 Deutsch Connectors
13
Deutsch Connectors 2200 SRM 1128
STEP 2.
Using a small hook end tool or needle nose pliers, re-
move the secondary lock from the connector recepta-
cle.
14
2200 SRM 1128 Deutsch Connectors
STEP 3.
Using a small, flat-blade screwdriver, release the
locking finger by moving it away from the pin.
15
Deutsch Connectors 2200 SRM 1128
STEP 4.
Gently pull the wire backward while, at the same
time, releasing the locking finger with the small,
flat-blade screwdriver.
16
2200 SRM 1128 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.
17
Deutsch Connectors 2200 SRM 1128
STEP 7.
Insert the wires into the new connector receptacle ac-
cording to the number or letter on the tag and connec-
tor 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. Re-
move tags.
18
2200 SRM 1128 Deutsch Connectors
STEP 8.
Install the secondary lock. Push the lock straight in
until the lock snaps into place.
19
Deutsch Connectors 2200 SRM 1128
STEP 9.
Push the connector plug into the connector receptacle
until the external locking mechanism(s) snap(s) into
place.
20
2200 SRM 1128 Deutsch Connectors
21
Deutsch Connectors 2200 SRM 1128
STEP 2.
Using a small, flat-blade screwdriver, remove the sec-
ondary lock from the connector plug.
22
2200 SRM 1128 Deutsch Connectors
STEP 3.
Using a small, flat-blade screwdriver, release the
locking finger by moving it away from the socket.
23
Deutsch Connectors 2200 SRM 1128
STEP 4.
Gently pull the wire backward while, at the same
time, releasing the locking finger with the small,
flat-blade screwdriver.
24
2200 SRM 1128 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.
25
Deutsch Connectors 2200 SRM 1128
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.
26
2200 SRM 1128 Deutsch Connectors
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. On 3-way secondary
locks, the arrow on the lock must be oriented toward
the exterior locking mechanism.
1. SEAL
1. SEAL
27
Deutsch Connectors 2200 SRM 1128
STEP 9.
Push the connector plug into the connector receptacle
until the external locking mechanism(s) snap(s) into
place.
28
2200 SRM 1128 Deutsch Connectors
29
Deutsch Connectors 2200 SRM 1128
STEP 2.
Using a small hook end tool or needle nose pliers, re-
move the secondary lock from the connector recepta-
cle.
30
2200 SRM 1128 Deutsch Connectors
STEP 3.
Using a small, flat-blade screwdriver, release the
locking finger by moving it away from the pin.
31
Deutsch Connectors 2200 SRM 1128
STEP 4.
Gently pull the wire backward while, at the same
time, releasing the locking finger with the small,
flat-blade screwdriver.
32
2200 SRM 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.
33
Deutsch Connectors 2200 SRM 1128
STEP 6.
Using wire cutters, cut the wire behind the old pin
and discard old pin.
STEP 7.
Strip the wire to the recommended length shown in
Table 1.
34
2200 SRM 1128 Deutsch Connectors
STEP 8.
Using the Deutsch Crimping Tool (HDT 48-00), 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 accord-
ing 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.
35
Deutsch Connectors 2200 SRM 1128
STEP 10.
Install the secondary lock. Push the lock straight in
until the lock snaps into place.
36
2200 SRM 1128 Deutsch Connectors
STEP 11.
Push the connector plug into the connector receptacle
until the external locking mechanism(s) snap(s) into
place.
37
Deutsch Connectors 2200 SRM 1128
38
2200 SRM 1128 Deutsch Connectors
STEP 2.
Using a small, flat-blade screwdriver, remove the sec-
ondary lock from the connector plug.
39
Deutsch Connectors 2200 SRM 1128
STEP 3.
Using a small, flat-blade screwdriver, release the
locking finger by moving it away from the socket.
40
2200 SRM 1128 Deutsch Connectors
STEP 4.
Gently pull the wire backward while, at the same
time, releasing the locking finger with the small,
flat-blade screwdriver.
41
Deutsch Connectors 2200 SRM 1128
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.
STEP 6.
Using wire cutters, cut the wire behind the old socket
and discard old socket.
42
2200 SRM 1128 Deutsch Connectors
STEP 7.
Strip the wire to the recommended length shown in
Table 1.
STEP 8.
Using the Deutsch Crimping Tool (HDT 48-00), crimp
the new socket on the wire as shown in How to Crimp
With the Deutsch Crimping Tool.
43
Deutsch Connectors 2200 SRM 1128
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.
44
2200 SRM 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. On 3-way secondary
locks, the arrow on the lock must be oriented toward
the exterior locking mechanism.
1. SEAL
1. SEAL
45
Deutsch Connectors 2200 SRM 1128
STEP 11.
Push the connector plug into the connector receptacle
until the external locking mechanism(s) snap(s) into
place.
46
2200 SRM 1128 Deutsch Connectors
A. TYPE A B. TYPE B
47
Deutsch Connectors 2200 SRM 1128
A. TYPE 1 B. TYPE 2
48
2200 SRM 1128 Deutsch Connectors
STEP 2.
Remove the lock nut and washer retaining the recep-
tacle to the mounting structure. Remove receptacle
from mounting structure.
49
Deutsch Connectors 2200 SRM 1128
STEP 3.
Insert a Deutsch extraction tool over the wire being
removed.
STEP 4.
Push the tool into the connector about 25 mm (1 in.)
until it bottoms on the contact flange.
50
2200 SRM 1128 Deutsch Connectors
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.
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.
51
Deutsch Connectors 2200 SRM 1128
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 re-
ceptacle 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 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 recepta-
cle.
52
2200 SRM 1128 Deutsch Connectors
STEP 2.
Insert a Deutsch extraction tool over the wire being
removed.
53
Deutsch Connectors 2200 SRM 1128
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.
STEP 4.
Hold the tool on the contact flange and pull the wire
and the connection socket out of the connector.
54
2200 SRM 1128 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.
55
Deutsch Connectors 2200 SRM 1128
STEP 6.
Repeat STEP 2 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 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 recepta-
cle.
56
2200 SRM 1128 Deutsch Connectors
STEP 2.
Remove the lock nut and washer retaining the recep-
tacle to the mounting structure. Remove receptacle
from mounting structure.
STEP 3.
Insert a Deutsch extraction tool over the wire being
removed.
57
Deutsch Connectors 2200 SRM 1128
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.
58
2200 SRM 1128 Deutsch Connectors
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.
59
Deutsch Connectors 2200 SRM 1128
STEP 7.
Using wire cutters, cut the wire behind the old pin
and discard old pin.
STEP 8.
Strip the wire to the recommended length shown in
Table 1.
STEP 9.
Using the Deutsch Crimping Tool (HDT 48-00), crimp
the new pin on the wire as shown in How to Crimp
With the Deutsch Crimping Tool.
60
2200 SRM 1128 Deutsch Connectors
STEP 10.
Insert the wires into the back of the new connector re-
ceptacle 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.
STEP 12.
Connect the connector plug to the connector recepta-
cle.
61
Deutsch Connectors 2200 SRM 1128
STEP 2.
Insert a Deutsch extraction tool over the wire being
removed.
62
2200 SRM 1128 Deutsch Connectors
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.
63
Deutsch Connectors 2200 SRM 1128
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.
64
2200 SRM 1128 Deutsch Connectors
STEP 6.
Using wire cutters, cut the wire behind the old socket
and discard old socket.
STEP 7.
Strip the wire to the recommended length shown in
Table 1.
STEP 8.
Using the Deutsch Crimping Tool (HDT 48-00), crimp
the new socket on the wire as shown in How to Crimp
With the Deutsch Crimping Tool.
65
Deutsch Connectors 2200 SRM 1128
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 recepta-
cle.
SEALING PLUGS
All empty contact cavities must be filled with a sealing plug. See Figure 24.
66
2200 SRM 1128 Deutsch Connectors
STEP 1.
Hold the sealing plug with the large diameter end
away from the connector.
STEP 2.
Insert the sealing plug into the connector contact
cavity. Gently apply downward pressure to force the
sealing plug into the cavity.
67
Metri-Pack Connectors 2200 SRM 1128
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 Se- REMOVE AND INSTALL
ries 150. These may be used at the coolant sensor and
TBI units. 1. Slide the seal back on the wire.
They are also called pull-to-seat terminals because to 2. Hold the wire and use it to push the terminal to
install a terminal on a wire, the wire is first inserted its forward position in the connector body. Hold
through the seal and connector. The terminal is then the terminal in this position. See Figure 25.
crimped on the wire and the terminal pulled back
3. Find the lock tab for the terminal in the connec-
into the connector to seat it in place.
tor channel. Push a removal tool (pick) of the
correct size into the connector channel. See Fig-
ure 26 and Figure 27.
68
2200 SRM 1128 Metri-Pack Connectors
69
Micro-Pack Connectors 2200 SRM 1128
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 Micro-Pack connectors are the same as
the Metri-Pack connectors. Refer to the section
Metri-Pack Connectors for the repair procedures.
70
2200 SRM 1128 Weather-Pack Connectors
Weather-Pack Connectors
A Weather-Pack connector can be identified by a rub- Make certain that the connectors are properly seated
ber seal at the rear of the connector. This connector, and all of the sealing rings are in place when connect-
which is used in the engine compartment, protects ing leads. The hinge-type flap provides a backup or
against moisture and dirt which could create oxida- secondary locking feature for the connector. They are
tion and deposits on the terminals. This protection used to improve the connector reliability by retaining
is important because of the very low voltage and cur- the terminals if the small terminal lock tabs are not
rent levels found in the electronic system. positioned properly.
1. FEMALE CONNECTOR
2. MALE CONNECTOR
3. SECONDARY LOCK HINGE
STEP 2.
Remove terminal, using tool.
1. TERMINAL
2. TOOL
71
Wire Repair 2200 SRM 1128
STEP 3.
Cut wire immediately behind cable seal.
1. WIRE
2. SEAL
STEP 4.
Replace terminal.
STEP 5.
Push terminal and connector onto wire and engage locking tabs.
STEP 6.
Close secondary lock hinge.
1. SEAL
Wire Repair
WIRE SPLICING REQUIREMENTS 4. 12 to 14 Gauge wire in area allowing 12.7 mm
(0.5 in.) diameter × 63.5 mm (2.5 in.) long splice
Refer to the following for determining which proce- - use Deutsch jiffy splice.
dure to use for wire repairs.
5. 14 to 20 Gauge wire in area allowing 9.78 mm
1. 8 Gauge or heavier wire - no splicing, replace full (0.385 in.) diameter × 62.74 mm (2.47 in.) long
length of wire or replace harness. splice - use Deutsch jiffy splice.
2. Wires not meeting requirements of Step 3
DEUTSCH JIFFY SPLICE
through Step 5 - no splicing, replace full length
of wire or replace harness. This splicing procedure adds 19.05 mm (0.75 in.) to
the length of the wire and may be used when slight
3. 10 to 20 Gauge wire in area allowing use of a heat
lengthening of the wire is desired.
gun - repair using Del-City crimp-solder-shrink
splice.
72
2200 SRM 1128 Wire Repair
Assemble
STEP 1.
Strip both wire ends to the specifications in Table 1.
STEP 2.
On one wire, crimp the appropriate pin onto the wire
using the Deutsch Crimping Tool (HDT 48-00). See
How to Crimp With the Deutsch Crimping Tool.
STEP 3.
On second wire, crimp the appropriate socket onto
the wire using the Deutsch Crimping Tool (HDT
48-00). See How to Crimp With the Deutsch Crimp-
ing Tool.
STEP 4.
Insert the wire with the socket contact into one end
of the jiffy splice.
73
Wire Repair 2200 SRM 1128
STEP 5.
Push the contact into the jiffy splice until a positive
stop is felt. An audible snap will occur when correctly
installed. Slightly tug the wire to verify the wire is
properly locked in place.
STEP 6.
Insert the wire with the pin contact into opposite end
of the jiffy splice.
STEP 7.
Push the contact into the jiffy splice until a positive
stop is felt. An audible snap will occur when correctly
installed. Slightly tug the wire to verify the wire is
properly locked in place.
74
2200 SRM 1128 Wire Repair
Disassemble
STEP 1.
Insert appropriate Deutsch extraction tool over the
wire being removed.
STEP 2.
Push the tool into the splice connector about 25 mm
(1 in.), until it bottoms on the contact flange.
75
Wire Repair 2200 SRM 1128
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 3.
Hold the tool on the contact flange and pull the wire
and the connection socket or pin out of the connector.
STEP 4.
Repeat STEP 1 through STEP 3 on opposite end.
STEP 1.
Strip approximately 9.525 mm (0.375 in.) from both
wire ends.
76
2200 SRM 1128 Wire Repair
CAUTION
Do not crimp solder sleeve in the center of the connector. This will make the connector unservice-
able.
STEP 2.
Insert one wire into the connector. Make sure wire
is properly seated and crimp the connector using an
insulated connector crimping tool nest that matches
the color or gauge of the connector.
1. SOLDER SLEEVE
CAUTION
Do not crimp solder sleeve in the center of the connector. This will make the connector unservice-
able.
STEP 3.
Insert the second wire into the opposite end of the
connector. Make sure wire is properly seated and
crimp the connector using an insulated connector
crimping tool nest that matches the color or gauge of
the connector.
STEP 4.
Using a heat gun, apply heat evenly, to approx-
imately 135 C (275 F), around the length of the
tubing (including the crimp area) from the center
out to the ends until the tubing fully recovers and
adhesive flows.
77
Twisted/Shielded Cable and Leads Repair 2200 SRM 1128
STEP 2.
Unwrap aluminum mylar tape. Do not remove mylar
tape.
1. DRAIN WIRE
2. OUTER JACKET
3. MYLAR
STEP 3.
Untwist conductors and strip insulation as necessary.
STEP 4.
Splice wires using splice clips and rosin core solder.
Wrap each splice to insulate.
STEP 5.
Splice the drain (uninsulated) wire using splice clip and rosin core solder.
STEP 6.
Wrap with mylar and drain (uninsulated) wire.
1. DRAIN WIRE
78
2200 SRM 1128 Twisted/Shielded Cable and Leads Repair
STEP 7.
Apply electrical tape over whole bundle to secure.
STEP 2.
Splice the two wires using splice clips and rosin core
solder.
STEP 3.
Cover splice with electrical tape to insulate from other wires.
STEP 4.
Twist and tape with electrical tape.
79
Special Tools 2200 SRM 1128
Special Tools
Illustration Tool Description
Not Illustrated Deutsch Connector Kit
Hyster Part No. 866410
Not Illustrated Deutsch Connector/ Crimp/ Stripper Kit
Hyster Part No. 867892
Not Illustrated Wire Stripper
Hyster Part No. 866411
Used for stripping wires.
Not Illustrated Wire Stop for Wire Stripper
Hyster Part No. 866412
Wire Crimping Pliers
Used for crimping connectors. (Except
Deutsch Connectors)
80
2200 SRM 1128 Special Tools
Heat Gun
Used to repair connector wires.
81
NOTES
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