Wire Harness Repair-2200SRM1128 - (05-2005) - US-EN

WIRE HARNESS REPAIR
S30FT, S35FT, S40FTS [E010];

H1.6FT, H1.8FT, H2.0FTS
(H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177]
PART NO. 1580517 2200 SRM 1128

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use 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.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
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.......................................................................................................... 12
Connector Plug Replacement.................................................................................................................... 18
Connector Receptacle Pin Replacement................................................................................................... 23
Connector Plug Socket Replacement........................................................................................................ 30
HD Series Connectors ................................................................................................................................... 37
Connector Receptacle Replacement.......................................................................................................... 39
Connector Plug Replacement.................................................................................................................... 43
Connector Receptacle Pin Replacement................................................................................................... 46
Connector Plug Socket Replacement........................................................................................................ 51
Sealing Plugs ................................................................................................................................................. 55
Metri-Pack Connectors ...................................................................................................................................... 57
Remove and Install........................................................................................................................................ 57
Micro-Pack Connectors ...................................................................................................................................... 59
Weather-Pack Connectors ................................................................................................................................. 59
Weather-Pack Terminal Repair .................................................................................................................... 60
Wire Repair ........................................................................................................................................................ 61
Wire Splicing Requirements ......................................................................................................................... 61
Deutsch Jiffy Splice ....................................................................................................................................... 61
Assemble .................................................................................................................................................... 61
Disassemble ............................................................................................................................................... 63
Del-City Crimp-Solder-Shrink Splice ........................................................................................................... 65
Twisted/Shielded Cable and Leads Repair ....................................................................................................... 66
Twisted/Shielded Cable Repair ..................................................................................................................... 66
Twisted Leads Repair .................................................................................................................................... 67
Special Tools ....................................................................................................................................................... 68
This section is for the following models:
S30FT, S35FT, S40FTS [E010];

H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177]
©2005 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"
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.
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 con-

tact size. Measure strip length from end of wire
as shown in Figure 1.
Figure 2. Stripped Wire
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.
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.
Figure 3. Strip Length Measurement
Verification
1
Deutsch Crimping Tool 2200 SRM 1128
Table 1. Wire Strip Length Specifications
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. 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.
1. LOCK NUT
2. ADJUSTING SCREW
Figure 5. Adjusting Screw and Lock Nut
4. Insert the contact into the crimping tool. See Fig-

ure 6.
5. Turn the adjusting screw clockwise until the con-

tact is flush or slightly above flush with the in-
dentor cover (cover around insertion point). See
Figure 6. Tighten the lock nut.
Figure 4. Selector Knob
2
2200 SRM 1128 Deutsch Crimping Tool
d. There are no frayed wires or wires not enter-

ing the contact barrel.
1. INSERTION POINT
2. INDENTOR COVER
Figure 6. Insertion Point 1. INSPECTION HOLE

2. CRIMP
6. Insert the wire into the contact. There should be 3. INSULATION GAP, 0.635 to 2.54 mm (0.025 to
no loose strands. All strands should be contained 0.100 in.)
in the contact barrel. The contact must be cen-
tered between indicators. See Figure 7. Figure 8. Proper Crimp
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 pro-
cedures. The G454 testing tool is for use with the
Deutsch hand crimping tool only. See Figure 9.
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 follow-

ing:
a. The conductor is inserted to the proper depth

and is visible through the inspection hole.
See Figure 8. 1. GO END (GREEN)
2. NO-GO END (RED)
b. There is about 0.635 to 2.54 mm (0.025 to
0.100 in.) of conductor between the contact Figure 9. G454 Testing Tool
and the insulator.
c. There are no damaged wire strands.
3
Deutsch Crimping Tool 2200 SRM 1128
NOTE: Testing for all wire sizes should be #20 wire

size, selector number 4. This ensures proper calibra-
tion 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.
1. GO END (GREEN)
2. GO END COMPLETEY 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.
1. SELECTOR SET AT #20 WIRE SIZE, SELECTOR The No-Go end (red) should not insert. If it does
NUMBER 4 insert, the calibration is incorrect and the crimp
tool must be replaced. See Figure 13.
Figure 10. Selector Test Setting
2. Squeeze the handles of the crimp tool completely

together. See Figure 11.
Figure 11. Insertion Point
3. Insert the Go end (green) of the G454 testing tool

into the insertion point of the crimp tool while 1. NO-GO END (RED)
2. NO-GO END SHOULD NOT INSERT ANY
the handles are completely closed. The Go end FURTHER
(green) should insert easily. If it does not in-
sert, the calibration is incorrect and the crimp Figure 13. No-Go End Test
tool must be replaced. See Figure 12.
4
2200 SRM 1128 Deutsch Connectors
Deutsch Connectors
DT, DTM, AND DTP SERIES CONNECTORS Figure 17 for the different connector plug secondary
locks.
All Deutsch DT, DTM, and DTP series pin- and
socket-type connectors are repaired in the same For examples of the DTM and DTP connectors, see
manner. Figure 18 for the different connector receptacles,
Figure 19 for the different connector receptacle sec-
For examples of the DT connectors, see Figure 14 ondary locks, Figure 20 for the different connector
for the different connector receptacles, Figure 15 for plugs, and Figure 21 for the different connector plug
the different connector receptacle secondary locks, secondary locks.
Figure 16 for the different connector plugs, and
NOTE: ALL CONNECTOR RECEPTACLES ARE SHOWN WITH THE SECONDARY LOCK INSTALLED.
A. CONNECTOR TYPE AA G. CONNECTOR TYPE AB-A (SIMILAR TO
B. CONNECTOR TYPE AB TYPE AB)
C. CONNECTOR TYPE AC H. CONNECTOR TYPE AB-B (SIMILAR TO
D. CONNECTOR TYPE AD TYPE AB)
E. CONNECTOR TYPE AE I. CONNECTOR TYPE AB-C (SIMILAR TO
F. CONNECTOR TYPE AF TYPE AB)
Figure 14. DT Connector Receptacles
5
Deutsch Connectors 2200 SRM 1128
A. SECONDARY LOCK TYPE BA E. SECONDARY LOCK TYPE BE

B. SECONDARY LOCK TYPE BB F. SECONDARY LOCK TYPE BF
C. SECONDARY LOCK TYPE BC G. SECONDARY LOCK TYPE BG
D. SECONDARY LOCK TYPE BD H. SECONDARY LOCK TYPE BH
Figure 15. DT Connector Receptacle Secondary Locks
6
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
Figure 16. DT Connector Plugs
7
A. SECONDARY LOCK TYPE DA E. SECONDARY LOCK TYPE DE

B. SECONDARY LOCK TYPE DB F. SECONDARY LOCK TYPE DF
C. SECONDARY LOCK TYPE DC G. SECONDARY LOCK TYPE DG
D. SECONDARY LOCK TYPE DD H. SECONDARY LOCK TYPE DH
Figure 17. DT Connector Plug Secondary Locks
Legend for Figure 18

A. DTP CONNECTOR TYPE EA D. DTP CONNECTOR TYPE ED
B. DTM CONNECTOR TYPE EB E. DTM CONNECTOR TYPE EE
C. DTM CONNECTOR TYPE EC F. DTM CONNECTOR TYPE EF
8
Figure 18. DTM and DTP Connector Receptacles
9
A. DTP SECONDARY LOCK TYPE FA D. DTP SECONDARY LOCK TYPE FD

B. DTM SECONDARY LOCK TYPE FB E. DTM SECONDARY LOCK TYPE FE
C. DTM SECONDARY LOCK TYPE FC F. DTM SECONDARY LOCK TYPE FF
Figure 19. DTM and DTP Connector Receptacle Secondary Locks
10
A. DTM CONNECTOR TYPE GA E. DTM CONNECTOR TYPE GF

B. DTM CONNECTOR TYPE GB F. DTM CONNECTOR TYPE GE
C. DTM CONNECTOR TYPE GC G. DTP CONNECTOR TYPE GG
D. DTP CONNECTOR TYPE GD H. DTM CONNECTOR TYPE GH
Figure 20. DTM and DTP Connector Plugs
11
A. DTM SECONDARY LOCK TYPE HA F. DTM SECONDARY LOCK TYPE HF

B. DTM SECONDARY LOCK TYPE HB G. DTM SECONDARY LOCK TYPE HG
C. DTM SECONDARY LOCK TYPE HC H. DTP SECONDARY LOCK TYPE HH
D. DTP SECONDARY LOCK TYPE HD I. DTM SECONDARY LOCK TYPE HJ
E. DTM SECONDARY LOCK TYPE HE
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.
12
STEP 1. (Cont)
STEP 2.
Using a small hook end tool or needle nose pliers, re-
move the secondary lock from the connector recepta-
cle.
13
STEP 3.
Using a small, flat-blade screwdriver, 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,
flat-blade screwdriver.
14
STEP 4. (Cont)
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.
15
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.
STEP 8.
Install the secondary lock. Push the lock straight in
until the lock snaps into place.
16
STEP 8. (Cont)
STEP 9.
Push the connector plug into the connector receptacle
until the external locking mechanism(s) snap(s) into
place.
17
Connector Plug Replacement

STEP 1.
STEP 2.
Using a small, flat-blade screwdriver, remove the sec-
ondary lock from the connector plug.
18
STEP 2. (Cont)
STEP 3.
locking finger by moving it away from the socket.
19
STEP 4.
STEP 5.
20
STEP 5. (Cont)
STEP 6.
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.
21
NOTE: Verify that the seal is in place on the connec-

tor plug before installing the secondary lock.
STEP 8.
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.
place.
22
STEP 9. (Cont)
Connector Receptacle Pin Replacement

STEP 1.
23
STEP 2.
Using a small hook end tool or needle nose pliers, re-
move the secondary lock from the connector recepta-
cle.
STEP 3.
locking finger by moving it away from the pin.
24
STEP 3. (Cont)
STEP 4.
25
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.
26
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 pin on the wire as shown in How to Crimp
With the Deutsch Crimping Tool.
27
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
tag.
STEP 10.
until the lock snaps into place.
28
STEP 10. (Cont)
STEP 11.
place.
29
Connector Plug Socket Replacement

STEP 1.
STEP 2.
Using a small, flat-blade screwdriver, remove the sec-
ondary lock from the connector plug.
30
STEP 2. (Cont)
STEP 3.
locking finger by moving it away from the socket.
31
STEP 4.
STEP 5.
If more than one socket is being removed, tag the wire
removed.
32
STEP 5. (Cont)
STEP 6.
Using wire cutters, cut the wire behind the old socket
and discard old socket.
STEP 7.
Table 1.
33
STEP 8.
the new socket on the wire as shown in How to Crimp
STEP 9.
Insert the wire into the back of the new connector
connector plug. Push the wire straight into the back
of the plug until a click is felt. Slightly tug the wire
tag.
34
NOTE: Verify that the seal is in place on the connec-

tor plug before installing the secondary lock.
STEP 10.
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
35
STEP 11.
place.
36
HD SERIES CONNECTORS For examples of the HD connectors, see Figure 22 for

the different connector receptacles and Figure 23 for
All Deutsch HD series pin-type connectors are re- the different connector plugs.
paired in the same manner.
A. TYPE A B. TYPE B
Figure 22. HD Connector Receptacles
37
A. TYPE 1 B. TYPE 2
Figure 23. HD Connector Plugs
38
Connector Receptacle Replacement

STEP 1.
Separate the connector plug from the connector re-
ceptacle.
STEP 2.
Remove the lock nut and washer retaining the recep-
tacle to the mounting structure. Remove receptacle
from mounting structure.
39
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.
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.
40
STEP 5.
Hold the tool on the contact flange and pull the wire
and the connection pin out of the connector.
STEP 6.
41
STEP 7.
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.
42
Connector Plug Replacement

STEP 1.
ceptacle.
STEP 2.
removed.
43
STEP 3.
NOTE: If pin is difficult to remove, remove the extraction tool, turn the extraction tool 90 degrees, and reinsert
STEP 4.
and the connection socket out of the connector.
STEP 5.
44
STEP 5. (Cont)
STEP 6.
Repeat STEP 2 through STEP 5 for the removal of
the remaining wires.
STEP 7.
of the plug until a click is felt. Slightly tug each wire
tags.
STEP 8.
cle.
45
Connector Receptacle Pin Replacement

STEP 1.
ceptacle.
STEP 2.
Remove the lock nut and washer retaining the recep-
tacle to the mounting structure. Remove receptacle
from mounting structure.
STEP 3.
removed.
46
STEP 3. (Cont)
STEP 4.
STEP 5.
and the connection pin out of the connector.
47
STEP 6.
If more than one wire is being removed, tag the wire
removed.
48
STEP 7.
Using wire cutters, cut the wire behind the old pin
and discard old pin.
STEP 8.
Table 1.
STEP 9.
the new pin on the wire as shown in How to Crimp
49
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.
cle.
50
Connector Plug Socket Replacement

STEP 1.
ceptacle.
STEP 2.
removed.
51
STEP 3.
STEP 4.
and the connection socket out of the connector.
STEP 5.
If more than one wire is being removed, tag the wire
removed.
52
STEP 5. (Cont)
STEP 6.
Using wire cutters, cut the wire behind the old socket
and discard old socket.
STEP 7.
Table 1.
53
STEP 8.
the new socket on the wire as shown in How to Crimp
STEP 9.
of the plug until a click is felt. Slightly tug wire to
verify the wire is properly locked in place. Remove
tags.
STEP 10.
cle.
54
SEALING PLUGS
All empty contact cavities must be filled with a sealing plug. See Figure 24.
A. 6 AWG (DARK RED) C. 12 TO 18 AWG (WHITE)

B. 8 AWG (CLEAR WHITE) D. 20 AWG (RED)
Figure 24. Sealing Plugs
STEP 1.
Hold the sealing plug with the large diameter end
away from the connector.
55
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.
56
2200 SRM 1128 Metri-Pack Connectors
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
into the connector to seat it in place.
1. FEMALE TERMINAL 4. CONNECTOR BODY

2. LOCKING TAB 5. SEAL
3. TOOL KIT
Figure 25. Metri-Pack Terminal Removal
3. Find the lock tab for the terminal in the connec-

tor channel. Push a removal tool (pick) of the
correct size into the connector channel. See Fig-
ure 26 and Figure 27.
1. TOOL (PICK) 4. CONNECTOR

2. LOCK TAB BODY
3. TERMINAL
Figure 27. Metri-Pack Pull-to-Seat Connector
4. Use the removal tool to move the lock tab to re-

lease the terminal from its seat.
1. TOOL (PICK) 4. CONNECTOR Push-to-Seat - Gently pull the wire to remove
2. LOCK TAB BODY
3. TERMINAL the terminal from the back of the connector.
Figure 26. Metri-Pack Push-to-Seat Connector Pull-to-Seat - Gently push the wire to remove
the terminal through the front of the connector.
See Figure 28.
57
Metri-Pack Connectors 2200 SRM 1128
NOTE: THE GREATER DISTANCE D, A FAULT CAN

OCCUR IN THE CONNECTION.
1. CONTACT TAB
1. TERMINAL 4. CONNECTOR
2. LOCK TAB BODY
3. TOOL KIT 5. SEAL Figure 29. Metri-Pack Terminal Inspection
Figure 28. Metri-Pack Pull-to-Seat Terminal NOTE: If reusing the terminal, reshape the locking
Removal tab.
6. If the terminal will be used again, make sure the

CAUTION lock tab is correctly bent so that the terminal will
Work carefully and do not use enough force to be locked in the connector again.
damage the terminal or the connector.
7. Push the terminal into the connector channel.
5. Inspect the terminal and connector for damage. Make sure that the lock tab correctly locks the
See Figure 29. terminal in position.
8. Push the seals into their position and install any

secondary locks.
58
2200 SRM 1128 Weather-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 Micro-Pack connectors are the same as
the Metri-Pack connectors. Refer to the section
Metri-Pack Connectors for the repair procedures.
1. CABLE 3. LOCKING TAB

2. TERMINAL 4. TOOL KIT
Figure 30. Micro-Pack Connector
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.
Repair of a Weather-Pack terminal is shown in Weather-Pack connections cannot be replaced with

Weather-Pack Terminal Repair. Use the tool kit to standard connections. Instructions are provided
remove the pin and sleeve terminals. See Special with Weather-Pack connector and terminal pack-
Tools. ages.
If removal is attempted with an ordinary pick, there

is a good chance that the terminal will be bent or de-
formed. Unlike standard blade-type terminals, these
terminals cannot be straightened once they are bent.
59
Weather-Pack Connectors 2200 SRM 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.
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.
60
2200 SRM 1128 Wire Repair
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.
Assemble
STEP 1.
Strip both wire ends to the specifications in Table 1.
61
Wire Repair 2200 SRM 1128
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.
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.
62
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.
Disassemble
STEP 1.
Insert appropriate Deutsch extraction tool over the
wire being removed.
63
Wire Repair 2200 SRM 1128
STEP 2.
Push the tool into the splice 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
STEP 3.
and the connection socket or pin out of the connector.
STEP 4.
Repeat STEP 1 through STEP 3 on opposite end.
64
DEL-CITY CRIMP-SOLDER-SHRINK SPLICE

Refer to Table 2 for the correct splice part number for the wire gauge being repaired.
Table 2. Wire Splice Size
Part Number Wire Gauge Range

866417 10 to 12 AWG (5.0 to 3.0 mm 2)
866418 14 to 16 AWG (2.0 to 1.0 mm 2)
866419 18 to 20 AWG (0.8 to 0.5 mm 2)
STEP 1.
Strip approximately 9.525 mm (0.375 in.) from both
wire ends.
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
65
Twisted/Shielded Cable and Leads Repair 2200 SRM 1128
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.
Continue distributing the heat over the solder sleeve

until solder flows into the terminal barrel. Remove
from the heat and let cool for ultimate connection per-
formance.
Twisted/Shielded Cable and Leads Repair

TWISTED/SHIELDED CABLE REPAIR
STEP 1.
Remove outer jacket.
STEP 2.
Unwrap aluminum mylar tape. Do not remove mylar
tape.
1. DRAIN WIRE
2. OUTER JACKET
3. MYLAR
66
2200 SRM 1128 Twisted/Shielded Cable and Leads Repair
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.
1. SPLICE AND SOLDER
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
STEP 7.
Apply electrical tape over whole bundle to secure.
TWISTED LEADS REPAIR

STEP 1.
Locate damaged wire and remove insulation as re-
quired.
67
Special Tools 2200 SRM 1128
STEP 2.
Splice the two wires using splice clips and rosin core
solder.
1. SPLICE AND SOLDER
STEP 3.
Cover splice with electrical tape to insulate from
other wires.
STEP 4.
Twist and tape with electrical tape.
Special Tools
Illustration Tool Description
Not Illustrated Deutsch Connector Kit
Hyster Part No. 866410
Not Illustrated Deutsch Connector/ Crimp/ Stripper Kit
Not Illustrated Wire Stripper
Used for stripping wires.
Not Illustrated Wire Stop for Wire Stripper
Wire Crimping Pliers
Used for crimping connectors. (Except
Deustch Connectors)
68
2200 SRM 1128 Special Tools

Deutsch Hand Crimping Tool
Used for crimping pins and sockets for
Deutsch connectors.
Yellow Extracting Tool

Used to repair Deutsch HD 12 to 14
AWG connectors.
Orange Extracting Tool (E-Seal)

Extra thin wall tool. Used to repair Deutsch
HD 12 to 14 AWG connectors.
Light Blue Extracting Tool

AWG connectors.
Dark Blue Extracting Tool (E-Seal)

Extra thin wall tool. Used to repair Deutsch
HD 16 to 18 AWG connectors.
69
Special Tools 2200 SRM 1128

Red Extracting Tool
AWG connectors.
Deutsch G454 Testing Tool

Used to check calibration of Deutsch
Hand Crimping Tool
Heat Gun
Used to repair connector wires.
Tool Kit for Terminal Repair

Terminals cannot be removed from their
connectors or repaired without special tools.
This kit has the special removal and installation
tools and crimping tools required to make repairs
in Micro-Pack, Metri-Pack, and Weather-Pack
connectors. This repair kit does not have
the terminals or the connectors.
70
TECHNICAL PUBLICATIONS
2200 SRM 1128 5/04 (12/04) Printed in U.S.A.

Wire Harness Repair-2200SRM1128 - (05-2005) - US-EN

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WIRE HARNESS REPAIR

S30FT, S35FT, S40FTS [E010];

PART NO. 1580517 2200 SRM 1128

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

This section is for the following models:

S30FT, S35FT, S40FTS [E010];

©2005 HYSTER COMPANY i

Deutsch Crimping Tool

2. See Table 1 for recommended strip length for con-

Figure 2. Stripped Wire

5. Measure the exposed strands to verify strip

Figure 1. Strip Length Measurement

3. Strip the wire to the recommended strip length.

4. Check for any broken strands or for a nick in the

Table 1. Wire Strip Length Specifications

1. Strip the insulation from the wire. See How to

2. Raise the selector knob and rotate until arrow

Figure 5. Adjusting Screw and Lock Nut

4. Insert the contact into the crimping tool. See Fig-

5. Turn the adjusting screw clockwise until the con-

Figure 4. Selector Knob

d. There are no frayed wires or wires not enter-

Figure 6. Insertion Point 1. INSPECTION HOLE

10. If any of the conditions in Step 9 are not met,

CALIBRATION TEST FOR THE DEUTSCH

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 follow-

a. The conductor is inserted to the proper depth

c. There are no damaged wire strands.

NOTE: Testing for all wire sizes should be #20 wire

1. Set the Deutsch hand crimp tool to #20 wire size,

Figure 12. Go End Test

4. Insert the No-Go end (red) of the G454 testing

2. Squeeze the handles of the crimp tool completely

Figure 11. Insertion Point

3. Insert the Go end (green) of the G454 testing tool

Figure 14. DT Connector Receptacles

A. SECONDARY LOCK TYPE BA E. SECONDARY LOCK TYPE BE

Figure 15. DT Connector Receptacle Secondary Locks

Figure 16. DT Connector Plugs

A. SECONDARY LOCK TYPE DA E. SECONDARY LOCK TYPE DE

Figure 17. DT Connector Plug Secondary Locks

Legend for Figure 18

Figure 18. DTM and DTP Connector Receptacles

A. DTP SECONDARY LOCK TYPE FA D. DTP SECONDARY LOCK TYPE FD

Figure 19. DTM and DTP Connector Receptacle Secondary Locks

A. DTM CONNECTOR TYPE GA E. DTM CONNECTOR TYPE GF

Figure 20. DTM and DTP Connector Plugs

A. DTM SECONDARY LOCK TYPE HA F. DTM SECONDARY LOCK TYPE HF

Figure 21. DTM and DTP Connector Plug Secondary Locks

Connector Receptacle Replacement

Connector Plug Replacement

NOTE: Verify that the seal is in place on the connec-

Connector Receptacle Pin Replacement

STEP 10. (Cont)

Connector Plug Socket Replacement