YALE E879 GLC60VX LIFT TRUCK Service Repair Manual

GLC/GDC60VX, GLC/GDC70VX (E879)
SERVICE MANUAL CONTENTS
SECTION
PART
NUMBER
YRM
NUMBER
REV
DATE
FRAME............................................................................................................................ 524288189 0100 YRM 1316 08/13
GM 4.3L V-6 ENGINES................................................................................................... 524265337 0600 YRM 1251 05/14
KUBOTA ENGINE REPAIR............................................................................................ 550048607 0600 YRM 1557 03/13
COOLING SYSTEM........................................................................................................ 524223757 0700 YRM 1123 03/13
LPG FUEL SYSTEM GM 4.3L ENGINE WITH PSI........................................................ 550043871 0900 YRM 1556 04/14
THREE-SPEED POWERSHIFT TRANSMISSION REPAIR........................................... 524288194 1300 YRM 1317 03/13
TRANSMISSION REPAIR (DANA SPICER) 2X2........................................................... 524294873 1300 YRM 1343 03/14
DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR (WET BRAKE)................... 524288199 1400 YRM 1318 12/13
STEERING AXLE............................................................................................................ 524223764 1600 YRM 1133 07/13
BRAKE SYSTEM............................................................................................................ 524262279 1800 YRM 1247 03/13
HYDRAULIC GEAR PUMP............................................................................................. 524223766 1900 YRM 1136 04/14
HYDRAULIC CLEANLINESS PROCEDURES............................................................... 550073240 1900 YRM 1620 12/14
MAIN CONTROL VALVE................................................................................................ 524223767 2000 YRM 1137 04/14
CYLINDER REPAIR (MAST S/N A513, A514, A613, A614, B513, B514)..................... 524294878 2100 YRM 1328 02/14
HIGH VOLTAGE SWITCH (HVS) IGNITION.................................................................. 524208014 2200 YRM 1097 05/14
WIRE HARNESS REPAIR.............................................................................................. 524223769 2200 YRM 1128 12/14
USER INTERFACE......................................................................................................... 524223770 2200 YRM 1130 12/14
USER INTERFACE......................................................................................................... 524223771 2200 YRM 1131 12/14
ELECTRICAL SYSTEM.................................................................................................. 524223772 2200 YRM 1142 04/14
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)................................................................................ 524265342 4000 YRM 1250 02/14
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
CALIBRATION PROCEDURES...................................................................................... 524223780 8000 YRM 1134 12/14
PERIODIC MAINTENANCE............................................................................................ 550048616 8000 YRM 1571 11/13
CAPACITIES AND SPECIFICATIONS........................................................................... 550048609 8000 YRM 1572 04/13
DIAGRAMS AND SCHEMATICS.................................................................................... 550055283 8000 YRM 1585 04/14
DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................ 524221866 9000 YRM 1112 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)

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 in-
specting or working near the mast. Additional precau-
tions and procedures can be required when repairing
or removing the mast.
WARNING
Mast parts are heavy and can move. Distances be-
tween 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 in-
stalled. Also make sure that the power is
OFF and the key is removed. Put a DO NOT
OPERATE tag in the operator's compart-
ment. 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 re-
moval of parts and can require removal of
the mast or carriage. Follow the repair pro-
cedures 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 posi-
tion, 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 weld-
ment that moves in outer weldment with cross-
member 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 inter-
mediate 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 mov-
able 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, three-
stage, 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) be-
tween the top or bottom crossmember of the car-
riage bar and a crossmember on the outer weld-
ment.
6. After lowering or restraining the mast, shut off the
power, and remove key.
NOTE: Place a DO NOT OPERATE tag in the opera-
tor's compartment.
7. Disconnect battery and put a tag or lock on bat-
tery connector.
2100 YRM 1328 General
1

A. TWO-STAGE LFL MAST
B. TWO-STAGE FFL MAST
C. THREE-STAGE FFL MAST
D. FOUR-STAGE FFL MAST
1. OUTER WELDMENT
2. INNER WELDMENT
3. INTERMEDIATE WELDMENT
4. HOOK
5. FREE-LIFT CYLINDER
6. CARRIAGE BAR
7. CROSSMEMBER
8. FIRST INTERMEDIATE WELDMENT
Figure 1. Two-Stage LFL, Two-Stage FFL, Three-Stage FFL, and Four-Stage FFL Masts
Safety Procedures When Working Near Mast 2100 YRM 1328
2

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.
NOTE: Insure that the parking brake is applied be-
fore starting the procedure below.
NOTE: Perform Step 1 and Step 2 if mast is installed
on the lift truck.
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)
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
Frame 0100YRM1321 for lift truck models
D878)
GDP175VX36, GLP/GDP190VX) (A909)
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
D879, E879, F879)
GDP135VX, GP/GLP/GDP155VX) (E878)
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.
D878, E878)
D879, E879, F879)
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.
D878, E878)
D879, E879, F879)
2100 YRM 1328 Tilt Cylinder Repair
3

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)
Tilt Cylinder Repair 2100 YRM 1328
4

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. CAPSCREW
2. LOCK NUT
3. ANCHOR PIN
4. TILT PIN
5. FRAME END MOUNT
6. MAST END MOUNT
7. CYLINDER HOSE PORTS
8. ROD END
9. LUBE FITTINGS
10. WASHER
B909)
6. Using a lifting device, remove the tilt cylinder from
the lift truck.
7. Repeat Step 1 through Step 6 for the opposite tilt
cylinder.
DISASSEMBLE
NOTE: Perform only those steps below required to
repair the tilt cylinder.
NOTE: Perform Step 1 for lift truck models:
D878, E878)
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).
NOTE: Note the position of the rod end and number
of turns used to remove the rod end.
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.
D878, E878)
D879, E879, F879)
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
D878, E878)
D879, E879, F879)
4. Remove and discard the O-ring, backup ring,
seal, and wiper ring from the gland. See Figure 4.
5

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

Legend for Figure 3
A. OUTER VIEW B. INNER VIEW
1. TILT PIN
2. CAPSCREW
3. WASHER
4. ANCHOR PIN
5. CYLINDER HOSE PORT
6. FRAME END MOUNT
7. MAST END MOUNT
8. ROD END
9. LUBE FITTING
10. HEX NUT
(A909, B909).
5. Remove and discard the rod wiper, O-rings, rod
seal, and backup ring from the gland. See Fig-
ure 5.
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.
D878, E878)
D879, E879, F879)
B909)
7. Remove O-ring, and if equipped tilt spacer from
rod. Discard O-ring.
D878, E878)
D879, E879, F879)
B909)
8. Remove and discard the wear ring and piston
seal from the piston.
D878, E878)
D879, E879, F879)
B909)
CLEAN
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufactur-
er'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.
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 com-
pressed air.
7

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. SHELL
2. GLAND
3. ROD
4. WIPER RING
5. SEAL
6. BACKUP RING
7. O-RING
8. PISTON
9. PISTON SEAL
10. LOCK NUT
11. WEAR RING
12. BUSHING
13. TILT SPACER*
14. 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)
1. SHELL
2. GLAND
3. ROD WIPER
4. O-RING
5. ROD SEAL
6. BACKUP RING
7. ROD
8. PISTON SEAL
9. WEAR RING
10. PISTON
11. LOCKNUT
12. BUSHING
13. 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)
8

INSPECT
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 surfa-
ces and replace if damaged.
Inspect the rod for damage to the rod surface and en-
sure that the rod is not bent. Replace the rod if found
to be damaged.
Inspect the inner surface of the cylinder shell for dam-
age. If the shell is found to be damaged, replace the
cylinder assembly.
ASSEMBLE
brass tools when installing seals and O-rings.
1. Install a new piston seal and wear ring on the pis-
ton.
D878, E878)
D879, E879, F879)
B909)
2. Install new O-ring, and if equipped, install tilt
spacer onto rod.
D878, E878)
D879, E879, F879)
B909)
NOTE: Perform Step 3, if the piston was removed
from the rod, for lift truck models
D878, E878)
D879, E879, F879)
3. Place the rod in a soft-jaw vise, and install the pis-
ton 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/
(A909, B909).
4. Place the rod in a soft jaw vise and install the pis-
ton onto the rod. See Figure 5.
5. Install locknut onto rod. See Figure 5. Tighten
locknut to 400 to 440 N•m (295 to 325 lbf ft).
D878, E878)
D879, E879, F879)
6. Install a new wiper ring, seal, backup ring, and O-
ring onto gland. See Figure 4.
(A909, B909).
9

7. Install new O-rings, backup ring, rod seal, and rod
wiper onto gland. See Figure 5 for specific part or-
der.
8. Install the rod and piston assembly in the cylinder
shell.
D878, E878)
D879, E879, F879)
B909)
NOTE: Perform Step 9 and Step 10 for lift truck mod-
els
D878, E878)
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 cap-
screw 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 out-
board 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/
GLP/GDP190VX) (A909, B909).
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.
NOTE: LEFT TILT CYLINDER SHOWN. TILT CYLIN-
DER 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
10

INSTALL
NOTE: Lock nut should be pointed toward outside of
truck, on lift truck models:
D878, E878)
D879, E879, F879)
1. Using a lifting device, place the tilt cylinder in
mounting point on the lift truck frame end mount.
D878, E878)
D879, E879, F879)
B909)
2. Install the lube fitting in the tilt pin and coat the tilt
pin with grease.
D878, E878)
D879, E879, F879)
B909)
3. Install tilt pin into rod end and frame end mount.
D878, E878)
D879, E879, F879)
B909)
NOTE: Perform Step 4 for lift truck models:
D878, E878)
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
(A909, B909).
NOTE: Lubricate threads on capscrew with multipur-
pose grease prior to installation.
5. Install anchor pin, washer, and capscrew onto rod
end at frame end mount. Tighten capscrew to
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.
D878, E878)
D879, E879, F879)
11

B909)
7. Install lube fitting in tilt pin and coat tilt pin with
grease. Install tilt pin into rod end and mast end
mount.
D878, E878)
D879, E879, F879)
B909)
D878, E878)
D879, E879, F879)
NOTE: Lubricate the threads on the capscrew with
packing lubricant (Yale P/N 504234269).
8. Install anchor pin and capscrew. Tighten cap-
screw to 90 N•m (66 lbf ft). See Figure 2.
(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 un-
til the rod holes line up with the mast tilt anchor
holes.
11. Repeat Step 1 through Step 10 for opposite tilt
cylinder.
12. Install side covers, floor mats, and floor plates.
See Side Covers Install procedures in
D878)
GDP175VX36, GLP/GDP190VX) (A909)
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
D879, E879, F879)
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 opera-
tion 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 cyl-
inders 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,
D879, E879) have internal tilt spacers. See Figure 4.
12

1. Adjust the stroke of the tilt cylinders with or with-
out tilt spacers as follows (see Figure 7).
a. Adjust the rod ends to:
15 mm (0.6 in.) 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)
B909)
b. Slowly tilt the mast backward until one cylinder
rod stops. On the opposite cylinder, loosen the
capscrews on the rod end. Measure the dis-
tance 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 de-
crease, then stop. Repeat this procedure until
both cylinder rods stop at the same position
within
GDP155VX) (C878, D878, E878)
B909)
0.5 mm (0.02 in.) for lift truck models
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
GDP155VX) (C878, D878, E878)
GDC155VX) (C879, D879, E879, F879)
120 to 130 N•m (89 to 96 lbf ft) for lift truck
model
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.
1. MAST
2. ROD END
3. TILT CYLINDER
4. CAPSCREW
5. LOCK NUT
Figure 7. Tilt Cylinder Adjustments
13

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.
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.
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 contin-
ues to tilt SLOWLY forward, the seals on the pis-
ton 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. Re-
move the load from the forks when the checks are
complete.
Table 1. Movement Rates (Maximum) for Tilt Cylinders
Lift Truck Model Hydraulic Oil Temperature/Mast Tilt Rate
20°C (68°F) 60°C (140°F)
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
GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/
GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909,
B909)
1.3 0.51 8.9 0.35
14

Lift Cylinder Repair
REMOVE
WARNING
Before working on or near the mast, see Safety
Procedures When Working Near Mast and Fig-
ure 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, A614,
A702, A703, A704, A705, A706, A707, A751,
A752, B513, B514, B586, B587, B588, B589,
B590, B591, B749, B750, B751, B752, B753,
B754) 4000YRM1250 for lift truck models
D878, E878)
D879, E879, F879)
Mast Repair (S/N A513, A514, A613, A614, A643,
A644, A683, A684) 4000YRM1406 for lift truck
model
B909)
2. On two-stage limited free-lift mast, raise the mast
a few inches and attach safety chain prior to re-
moving lift cylinder.
a. Use safety chains to connect the bottom cross-
member 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 re-
moving lift cylinder.
a. Use safety chains to connect the bottom cross-
member of the intermediate mast section to the
top crossmember of the outer mast section.
Use another safety chain to connect the bottom
crossmember to a crossmember on the inter-
mediate or outer mast section. See Figure 1.
Lower the mast so the safety chains hold the
weight of the mast sections.
WARNING
Be careful when removing or installing snap
rings. These snap rings can come loose during re-
moval 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, re-
move the snap rings at the top of the cylinder.
See Figure 8 and Figure 9 for lift truck models
D878, E878)
D879, E879, F879)
WARNING
Hydraulic oil is hot after system operation and
can cause burns. DO NOT disconnect any hy-
draulic 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 fit-
tings. Retract the rod into the lift cylinder. Discon-
nect and cap the hydraulic lines at the cylinder.
D878, E878)
D879, E879, F879)
See Figure 10 and Figure 11 for lift truck model
B909)
2100 YRM 1328 Lift Cylinder Repair
15

1. BOLT
2. WASHER
3. SHIM
4. SNAP RING
5. LOCK NUT
6. CAPSCREWS
7. HOSE CLAMPS
8. HYDRAULIC FITTINGS
9. LOWERING CONTROL VALVE HOUSING
10. HYDRAULIC LINES
11. HEADER HOSE (FIVE FUNCTION)
12. HEADER HOSE (THREE FUNCTION)
13. HEADER HOSE (FOUR FUNCTION)
14. BRACKET
15. CYLINDER MOUNT
16. CHAIN ANCHOR
17. 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)
Lift Cylinder Repair 2100 YRM 1328
16

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/
17

Legend for Figure 9
1. MAIN CYLINDER (RH)
3. MAIN CYLINDER (LH)
4. LOCK NUT
5. SPACER
6. WASHER
7. CAPSCREW
8. HEADER HOSE (THREE FUNCTION)
10. HEADER HOSE (FOUR FUNCTION)
11. HEADER HOSE (FIVE FUNCTION)
12. CHAIN ANCHOR
13. LOWERING CONTROL VALVE HOUSING
14. SNAP RING
15. CYLINDER MOUNT
16. HOSE CLAMPS
17. HYDRAULIC LINES
18. OUTER MAST
18

1. MAST
2. CARRIAGE
3. HYDRAULIC LINE
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)
19

1. MAST
2. CARRIAGE
3. HYDRAULIC LINE
5. LIFT CYLINDER
6. HOSE CLAMP
Figure 11. Three-Stage Mast, Hydraulic Lines and Fittings for Lift Truck Model GLP/GDP80VX, GLP/
20

6. Remove hose clamps securing hoses to lift cylin-
der.
D878, E878)
D879, E879, F879)
See Figure 10 and Figure 11 for lift truck model
B909)
els:
D878, E878)
D879, E879, F879)
7. For lift truck models equipped with a three-stage
full free-lift mast, see Figure 9.
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.
8. For lift truck models equipped with a two-stage
limited free-lift mast, see Figure 8.
a. Remove the lock nuts and bracket and discon-
nect the main lift chain anchor at the cylinder
mount.
b. Remove the bolt, washer, and shims securing
the cylinder mount to the outer mast.
NOTE: Perform Step 9 and Step 10 for lift truck
GLP/GDP190VX) (A909, B909).
full free lift mast, see Figure 12.
a. Remove capscrews, washers, and bracket
from anchor bracket.
b. Remove snap ring and washer at top of lift cyl-
inder.
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.
11. Using a lifting device, remove lift cylinder from
mast.
(A909, B909).
12. Remove convex washer from top of lift cylinder.
See Figure 15.
13. Repeat Step 4 through Step 12 for opposite lift
cylinder.
21

1. MAST
2. LIFT CYLINDER
3. SNAP RING
4. WASHER
5. CONVEX WASHER
6. CAPSCREW
7. WASHER
8. BRACKET
9. ANCHOR BRACKET
10. RETENTION SCREW
Figure 12. Three-Stage Full Free-Lift Mast, Cylinder Installation for Lift Truck Model GLP/GDP80VX, GLP/
22

1. LIFT CYLINDER
2. ANCHOR SCREW
3. WASHER
4. SPACER
5. 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)
1. MAST
2. LIFT CYLINDER
3. RETENTION SCREW
Figure 14. Two-Stage Limited Free-Lift Mast,
Cylinder Installation - Bottom for Lift Truck Model
GDP190VX) (A909, B909)
23

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
Carefully disassemble the main lift cylinders so
the piston rods and sliding surfaces are not dam-
aged.
brass tools when removing seals and O-rings.
1. Loosen gland with a spanner wrench.
D878, E878)
D879, E879, F879)
B909)
D878, E878)
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.
D878, E878)
D879, E879, F879)
NOTE: Perform Step 3 and Step 4 for lift truck model
GDP190VX) (A909, B909).
3. Remove gland from shell. See Figure 18.
4. Remove and discard rod wiper from gland. See
Figure 18.
5. Remove rod and piston assembly from shell.
Drain hydraulic oil into container.
24

D878, E878)
D879, E879, F879)
B909)
els
D878, E878)
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 free-
lift mast. Remove and discard backup ring, seal,
wear ring, and piston ring from piston. See Fig-
ure 17.
(A909, B909).
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 cyl-
inder.
1. SHELL
2. WEAR RING
3. SEAL
4. BACKUP RING
5. ROD AND PISTON ASSEMBLY
6. O-RING
7. WEAR RING
8. ROD SEAL
9. ROD WIPER
10. 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/
GC/GLC/GDC155VX) (C879, D879, E879, F879)
25

1. SHELL
2. PISTON RING
3. WEAR RING
4. SEAL
5. BACKUP RING
7. ROD SEAL
8. ROD WIPER
9. O-RING
10. 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/
GC/GLC/GDC155VX) (C879, D879, E879, F879)
1. ROD WIPER
2. GLAND
3. BLEED-BACK PORT
4. SHELL
5. ROD
6. PISTON
7. O-RING
8. PISTON SEAL
9. PISTON RING
10. BACKUP RING
11. RETENTION SCREW
Figure 18. Lift Cylinder Assembly for Lift Truck
Model GLP/GDP80VX, GLP/GDP80VX9, GLP/
GLP/GDP190VX) (A909, B909)
26

CLEAN
WARNING
CAUTION
components.
pressed air.
INSPECT
seal surfaces. If damaged, replace gland.
ces. If damaged, replace piston.
sure that the rod is not bent. If damaged replace rod.
age. If damaged, replace cylinder assembly.
ASSEMBLE, LIFT TRUCK MODELS GLP/
GDP60VX, GLP/GDP70VX (GP/GLP/
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 lift
cylinders is the correct installation of the seals.
Most lift cylinder maintenance is caused by seal
leaks. DO NOT damage any parts during assem-
bly.
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. 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 free-
lift 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 N•m (277 to 332 lbf ft).
6. Repeat Step 1 through Step 5 for the opposite lift
cylinder.
GDP80VX, GLP/GDP80VX9, GLP/
B909)
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 assem-
bly.
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 Fig-
ure 18.
27

4. Install rod and piston assembly into shell.
5. Install rod wiper onto gland. See Figure 18.
gland threads.
7. Using a spanner wrench, install gland onto piston
rod inside shell. Tighten gland to 350 to
8. Repeat Step 1 through Step 7 for the opposite lift
cylinder.
INSTALL, LIFT TRUCK MODELS GLP/
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 Fig-
ure 8 and Figure 9.
a. Install spacer, capscrew, and lock nut to se-
cure 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 hy-
draulic 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 cylin-
der 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).
WARNING
or installation.
4. If working on a two-stage or three-stage mast, in-
stall 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.
inder.
7. Remove safety chains.
8. Use a lifting device to lower the inner mast (two-
stage limited free-lift) or intermediate mast (three-
stage full free-lift) onto the lift cylinders.
9. Install the carriage as described in the carriage In-
stall 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.
B909)
1. Install convex washer on top of lift cylinder.
2. Using a lifting device, install the lift cylinder in the
mount at the bottom of the outer mast. See Fig-
ure 12 and Figure 15.
3. For lift truck model equipped with a three-stage
a. Install retention screw into mast and bottom of
lift cylinder.
b. Install washer and snap ring onto top of lift cyl-
inder.
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.
28

5. Connect the hydraulic fittings and hydraulic lines
to lift cylinders as tagged during removal. See
Figure 11.
inder.
7. Remove safety chains.
8. Use a lifting device to lower the inner mast (two-
stage limited free-lift) or intermediate mast (three-
stage full free-lift) onto the lift cylinders.
9. Install the carriage as described in the carriage In-
stall procedures. See Mast Repair (S/N A513,
A514, A613, A614, A643, A644, A683, A684)
4000YRM1406.
Free-Lift Cylinder Repair
REMOVE
1. Remove the carriage and load backrest as descri-
bed in the carriage removal procedures in the
section
A702, A703, A704, A705, A706, A707, A751,
A752, B513, B514, B586, B587, B588, B589,
B590, B591, B749, B750, B751, B752, B753,
D878, E878)
D879, E879, F879)
model
B909)
NOTE: Tag hydraulic lines during removal to aid in
installation.
2. Place a drain pan under the free-lift cylinder. Dis-
connect and cap the hydraulic hose and fittings at
the bottom of the cylinder.
D878, E878)
D879, E879, F879)
B909)
els:
D878, E878)
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.
D878, E878)
D879, E879, F879)
B909)
2100 YRM 1328 Free-Lift Cylinder Repair
29

6. Remove hoses from hose sheaves.
D878, E878)
D879, E879, F879)
B909)
(A909, B909).
7. Remove four screws and hose sheave assembly
from chain guard. See Figure 22.
models:
D878, E878)
D879, E879, F879)
8. Remove chain guard from crosshead. See Fig-
ure 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.
11. Remove chain sheave assembly from crosshead.
GLP/GDP190VX) (A909, B909).
12. Remove lock nut from chain anchor; remove
chain anchor from crossmember; remove chain
from chain sheave. See Figure 23.
13. Remove chain sheave from top of free-lift cylinder
by unscrewing. See Figure 24.
models
D878, E878)
D879, E879, F879)
14. Remove two capscrews and washers securing
crosshead to cylinder rod. Remove crosshead.
See Figure 20.
15. Remove two capscrews, lock nuts, lockwashers,
washers, and spacer from inner mast mounting
bracket. With a lifting device, remove free-lift cyl-
inder assembly from inner mast.
D878, E878)
D879, E879, F879)
GLP/GDP190VX) (A909, B909).
16. Remove two screws, two washers, and bracket
from crossmember and free-lift cylinder. See Fig-
ure 25.
17. Remove retention screw from bottom of free-lift
cylinder and mast. See Figure 25.
18. Using a lifting device, remove free-lift cylinder
from inner mast.
(A909, B909).
19. Repeat above steps as required for opposite free-
lift cylinder.
Free-Lift Cylinder Repair 2100 YRM 1328
30

NOTE: BOTTOM CROSSMEMBER OF THE INNER MAST HAS BEEN REMOVED FOR CLARITY.
A. REAR VIEW B. FRONT VIEW
1. CAPSCREW
2. LOCK NUT
4. CHAIN
5. HOSE
6. CHAIN ANCHOR
7. INNER MAST
8. 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)
31

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/
32

Legend for Figure 20
1. CAPSCREW
2. WASHER
3. LOCKWASHER
4. HOSE SHEAVE BRACKET
5. SNAP RING
6. HOSE SHEAVE SHAFT
7. HOSE SHEAVE
8. HOSE
10. CHAIN GUARD
11. CHAIN
12. COTTER PIN
13. PIN
14. BEARING
16. CHAIN SHEAVE ASSEMBLY
17. SPACER
18. PIN
19. CROSSHEAD
20. LOCK NUT
21. CHAIN ANCHOR
23. INNER MAST MOUNTING BRACKET
24. CYLINDER ROD
NOTE: MAST CROSSMEMBERS REMOVED FOR
CLARITY.
2. HYDRAULIC HOSE
3. FITTING
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)
1. HOSE SHEAVE ASSEMBLY
2. CHAIN GUARD
3. SCREW
Figure 22. Hose Sheave for Lift Truck Model GLP/
(A909, B909)
33

1. LOCKNUT
2. CHAIN ANCHOR
3. CHAIN
Figure 23. Chain Anchor for Lift Truck Model GLP/
(A909, B909)
1. CHAIN SHEAVE
Figure 24. Chain Sheave for Lift Truck Model GLP/
(A909, B909)
34

A. FRONT VIEW B. REAR VIEW
1. CROSSMEMBER
2. BRACKET
3. SCREW
4. WASHER
5. RETENTION SCREW
6. MAST
Figure 25. Free-Lift Cylinder Mount for Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
35

DISASSEMBLE
CAUTION
Carefully disassemble the free-lift cylinder so the
piston rods and sliding surfaces are not damaged.
brass tools when removing or installing seal and O-
rings.
1. Loosen gland with spanner wrench.
2. Remove gland from shell.
D878, E878)
D879, E879, F879)
B909)
(A909, B909).
3. Remove and discard rod wiper, rod seal, and O-
ring from gland. See Figure 27.
Drain hydraulic oil into container.
D878, E878)
D879, E879, F879)
B909)
models:
D878, E878)
D879, E879, F879)
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
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
GDP190VX) (A909, B909).
8. Remove and discard wear ring from piston. See
Figure 27.
lift cylinder.
36

1. GLAND
2. O-RING
3. ROD WIPER
4. BACKUP RING
5. ROD SEAL
6. WEAR RING
8. PISTON SEAL
9. CHECK VALVE
10. SEAL
11. WASHER
12. SNAP RING
13. 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
D879, E879, F879)
Figure 27. Free-Lift Cylinder Assembly for Lift
Truck Model GLP/GDP80VX, GDP80VX9, GLP/
GLP/GDP190VX) (A909, B909)
37

1. ROD WIPER
2. ROD SEAL
3. GLAND
4. O-RING
5. BLEED SCREW
6. SHELL
7. ROD
8. PISTON
9. WEAR RING
10. RETENTION SCREW
CLEAN
WARNING
CAUTION
Do not allow cleaning solvent to come in contact
components.
pressed air.
INSPECT
seal surfaces. If damaged, replace gland.
ces. If damaged, replace piston.
sure that the rod is not bent. If damaged replace rod.
age. If damaged, replace cylinder assembly.
GDC155VX) (C879, D879, E879, F879)
CAUTION
A difficult and important step in assembling free-
lift cylinders is the correct installation of the
seals. Most cylinders maintenance is caused by
seal leaks. DO NOT damage any parts during as-
sembly.
NOTE: Lubricate all internal parts of the free-lift cylin-
der 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 O-
ring 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 dam-
age to the cylinder.
5. Before installing gland, pour 150 cc (5 oz) of hy-
draulic oil into the cylinder shell.
6. Install gland on rod and piston assembly. See Fig-
ure 26. Tighten gland to 400 to 475 N•m (295 to
350 lbf ft).
lift cylinder.
38

B909)
CAUTION
A difficult and important step in assembling free-
lift cylinders is the correct installation of the
seals. Most cylinders maintenance is caused by
seal leaks. DO NOT damage any parts during as-
sembly.
NOTE: Lubricate all internal parts of the free-lift cylin-
der with clean hydraulic oil.
1. Install new wear ring onto piston. See Figure 27.
2. Carefully install rod and piston assembly into
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).
lift cylinder.
GDC155VX) (C879, D879, E879, F879)
1. Install crosshead onto cylinder rod, then install
two capscrews and lockwashers securing cross-
head to cylinder rod. See Figure 20.
2. Install chain sheave assembly and spacers into
crosshead. See Figure 20.
3. Using a brass drift, install pin through the chain
sheave assembly. See Figure 20.
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).
7. Install chain guard over the chain sheave assem-
bly. 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
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 cylin-
der. 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 Re-
pairs (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.
39

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.
5. Install chain onto chain sheave; install chain an-
chor through crossmember; install locknut onto
chain anchor. See Figure 23.
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 Re-
pair (S/N A513, A514, A613, A614, A643, A644,
A683, A684) 4000YRM1406.
Sideshift Cylinder Repair
REMOVE
WARNING
ure 1.
1. Remove carriage as described in carriage re-
moval 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,
D879, E879, F879)
D878, E878)
See 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/
B909)
D879, E879, F879)
D878, E878)
2. Remove sideshift cylinder from sideshift carriage
as described in disassemble 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,
D879, E879, F879)
D878, E878)
Sideshift Cylinder Repair 2100 YRM 1328
40

WARNING
and wear eye and face protections during removal
or installation.
(A909, B909).
3. Remove four snap rings, two clevis pins, and
sideshift cylinder from carriage. See Figure 28.
1. SIDESHIFT CYLINDER
2. SNAP RING
3. CLEVIS PIN
4. ISS OUTER FRAME
Figure 28. Sideshift Cylinder Removal, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
2100 YRM 1328 Sideshift Cylinder Repair
41

DISASSEMBLE
NOTE: For lift trucks manufactured before August,
2012, perform Step 1 through Step 8 for lift truck mod-
els
D879, E879, F879)
D878, E878)
1. Position cylinder rod in fully extended position and
remove snap ring from retainer. See Figure 29.
2. Push cylinder retainer into cylinder shell approxi-
mately 50 mm (2 in.) until retainer ring is exposed.
3. Remove retainer ring. See Figure 29.
4. Remove rod assembly and retainer from cylinder
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 Fig-
ure 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
D879, E879, F879)
9. Remove the retainer. See Figure 30.
10. Remove rod wiper from retainer. See Figure 30.
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 assem-
bly. See Figure 30. Discard O-rings.
CAUTION
Carefully disassemble the sideshift cylinder so
the piston rods and sliding surfaces are not dam-
aged.
CAUTION
To prevent damage to sealing surfaces use brass
models
14. Loosen gland with spanner wrench. See Fig-
ure 31.
Figure 31.
17. Remove rod and piston assembly from shell. See
Figure 31. Drain hydraulic oil into container.
O-ring from piston. See Figure 31. Discard
backup ring, piston seal, and O-ring.
42

1. SNAP RING
2. RETAINER RING
3. ROD
4. RETAINER
5. CYLINDER SHELL
6. WIPER
7. ROD SEAL
8. BACKUP RING
9. O-RING
10. LOCK NUT
11. PISTON
12. PISTON SEAL
13. 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
43

1. ROD WIPER
2. RETAINER
3. O-RING
4. ROD SEAL
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
44

1. ROD
2. ROD WIPER
3. GLAND
4. PISTON
5. O-RING
6. PISTON SEAL
7. PISTON RING
8. BACKUP RING
9. SHELL
Figure 31. Sideshift Cylinder for Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/
GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)
45

CLEAN
WARNING
CAUTION
components.
1. Clean all metal parts in solvent and dry with com-
pressed air.
INSPECT
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
tools when installing seals and O-rings.
els
D879, E879, F879)
D878, E878)
NOTE: Lubricate all internal parts of the cylinder with
clean hydraulic oil prior to assembly.
1. Install new piston seal and backup ring onto pis-
ton. 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.
6. Push retainer into cylinder shell until retainer ring
groove is exposed.
7. Install retainer rig into groove of cylinder shell.
See Figure 29.
8. Pull rod and piston out of cylinder shell until re-
tainer stops on retainer ring and snap ring groove
is exposed. See Figure 29.
9. Install snap ring onto retainer. See Figure 29.
models
GDC135VX, GC/GLC/GDC155VX) (E879,
F879)
10. Install new O-ring on fittings and install fittings in
cylinder. See Figure 30.
11. Install rod seal in retainer. See Figure 30.
12. Install O-ring on retainer. See Figure 30.
13. Install rod wiper in retainer. See Figure 30.
14. Install retainer onto cylinder assembly. See Fig-
ure 30.
46

CAUTION
tools when installing seal and O-rings.
model
clean hydraulic oil prior to assembly.
See Figure 31.
Figure 31.
ure 31.
18. Install rod and piston assembly into shell. See
Figure 31.
gland threads.
21. Install gland onto shell. See Figure 31. Tighten
gland to 350 to 400 N•m (258 to 295 lbf ft).
INSTALL
D879, E879, F879)
D878, E878)
1. Install sideshift cylinder as described in install pro-
cedure in section
A702, A703, A704, A705, A706, A707, A751,
A752, B513, B514, B586, B587, B588, B589,
B590, B591, B749, B750, B751, B752, B753,
D879, E879, F879)
D878, E878)
WARNING
and wear eye and face protections during removal
or installation.
(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
A702, A703, A704, A705, A706, A707, A751,
A752, B513, B514, B586, B587, B588, B589,
B590, B591, B749, B750, B751, B752, B753,
D879, E879, F879)
D878, E878)
model
B909)
2100 YRM 1328 Fork Positioner Cylinder Repair
47

Fork Positioner Cylinder Repair
REMOVE
WARNING
ure 1.
D879, E879, F879)
D878, E878)
1. Remove fork positioner cylinder as described in
Hang On Sideshift Carriage Repair removal pro-
cedures 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.
model
2. Remove carriage as described in carriage re-
moval procedures located in the section Mast Re-
pair (S/N A513, A514, A613, A614, A643, A644,
A683, A684) 4000YRM1406.
NOTE: The following step to be performed for both
upper and lower fork positioner cylinders.
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 posi-
tioner cylinder from carriage.
7. Repeat Step 4 through Step 6 for upper fork posi-
tioner cylinder.
DISASSEMBLE
CAUTION
Carefully disassemble the fork positioner cylin-
ders so the piston rods and sliding surfaces are
not damaged.
els
D879, E879, F879)
D878, E878)
1. Unscrew cylinder rod retainer. See Figure 34.
CAUTION
2. Remove piston, rod, and cylinder rod retainer as
an assembly from cylinder shell. See Figure 34.
3. Remove cylinder rod retainer from cylinder rod.
See Figure 34.
4. Remove spacer from cylinder rod. See Figure 34.
5. Remove and discard rod wiper, rod seal, backup
rings, and O-rings from cylinder rod retainer. 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.
Fork Positioner Cylinder Repair 2100 YRM 1328
48

1. CARRIAGE
2. FORK POSITIONER CYLINDER
4. HYDRAULIC LINE
Figure 32. Hydraulic Connections Fork Positioner Cylinder
49

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. SCREW
7. WASHER
8. BUSHING
9. NUT
Figure 33. Fork Positioner Cylinder Mount
50

1. CYLINDER ROD
2. ROD SEAL
3. ROD WIPER
4. CYLINDER ROD RETAINER
5. BACKUP RING
6. O-RING
7. SPACER
8. CYLINDER SHELL
9. PISTON
10. PISTON SEAL
11. 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 cylin-
ders so the piston rods and sliding surfaces are
not damaged.
CAUTION
To prevent damage to sealing surfaces use brass
models
GDC135VX, GC/GLC/GDC155VX) (D879,
E879, F879)
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 car-
rier lug towards manifold and remove half-ring
keepers. Move cylinder rod to fully retracted posi-
tion shown in Figure 35.
10. Using retainer socket tool (see Special Tools), un-
screw cylinder retainer to remove cylinder assem-
bly 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.
51

1. ANCHOR PLUG
2. HALF-RING KEEPERS
3. FORK CARRIER LUG
4. RETAINER SOCKET TOOL
5. CYLINDER RETAINER
6. CYLINDER ROD
7. HEAD TIGHTENING TOOL
8. CYLINDER SHELL
Figure 35. Fork Positioner Assembly for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
NOTE: DO NOT scratch seal grooves. Use brass
seal removal tools to pry items from grooves.
13. Remove all seals, O-ring, wear rings and bearings
from components as shown in Figure 36.
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.
model:
16. Loosen gland with spanner wrench. See Fig-
ure 37.
Figure 37.
Drain hydraulic oil into container. See Figure 37.
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 po-
sitioner cylinder.
52

A. RETAINER B. PISTON C. FORK CARRIER LUG
1. RETAINER
2. MANIFOLD
3. CYLINDER SHELL
4. CYLINDER ROD
5. FORK CARRIER LUG
6. INTERNAL SPACER (IF RE-
QUIRED)
7. HEAD END/MOUNTING
FOOT
8. O-RING
9. U-CUP PRESSURE SEAL
10. WIPER SEAL
11. WEAR RING
12. TWO-PIECE PRESSURE SEAL
13. WIPERS
14. BEARINGS
Figure 36. Fork Positioner Cylinder for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
53

Figure 37. Fork Positioner Cylinder
1. ROD WIPER
2. GLAND
3. SHELL
4. ROD
5. PISTON
6. O-RING
7. PISTON SEAL
8. PISTON RING
9. BACKUP RING
CLEAN
WARNING
CAUTION
components.
1. Clean all metal parts in solvent and dry with com-
pressed air.
INSPECT
1. Inspect gland for damage to threads and seal sur-
faces. 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.
54

ASSEMBLE
CAUTION
tools when installing seal and O-ring.
clean hydraulic oil during assembly.
els
D879, E879, F879)
D878, E878)
1. Install new O-rings, backup rings, rod seal, and
rod wiper onto cylinder rod retainer. See Fig-
ure 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.
models
D879, E879, F879)
GDP135VX, GP/GLP/GDP155VX) (D878,
E878)
NOTE: If necessary, use 400-grit emery cloth to
break any sharp edge on the piston, retainer and cyl-
inder shell chamfer angles and threads to prevent
seal damage.
6. If the cylinder head end was removed during dis-
assembly, 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 re-
spective 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. SEAL
2. ROD
3. RETAINER
4. PIN PUNCH
5. 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
55

NOTE: DO NOT use a pin punch with sharp edges.
10. Lubricate seal and force partially into grove using
15 mm (0.6 in.) pin punch. See Figure 38.
NOTE: Make sure piston seal is not damaged by cyl-
inder shell threads during installation.
11. Use flat brass O-ring tool to seat seals fully into
groove. See Figure 38.
12. Slide fork carrier lug onto cylinder shell with the
plug heads facing outwards. See Figure 35.
13. Align cylinder assembly to manifold and engage
opposite cylinder rod into fork carrier. Install exter-
nal spacer on cylinder rod, if required. Install cyl-
inder retainer through opposite side of manifold
and screw partially into cylinder shell. See Fig-
ure 35.
14. Make sure cylinder is properly oriented with re-
strictor 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
tools when installing seal and O-ring.
models
clean hydraulic oil during assembly.
See Figure 37.
Figure 37.
ure 37.
20. Install rod and piston assembly into shell. See
Figure 37.
gland threads.
23. Install gland onto shell. Tighten gland to 350 to
24. Repeat Step 17 through Step 23 for other fork po-
sitioner cylinder.
INSTALL
D879, E879, F879)
D878, E878)
1. Install fork positioner cylinder and carriage as de-
scribed in Hang On Sideshift Carriage Repair in-
stallation 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.
model
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 Fig-
ure 33.
5. Connect hydraulic fittings and lines onto upper
fork positioner cylinder. See Figure 32.
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.
7. Install nut onto lower fork positioner cylinder shell
end. See Figure 33.
56

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 sys-
tem, 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.
2. Put mast in vertical position and raise carriage
and load 2.5 m (8 ft).
If carriage slowly lowers when control valve is in
NEUTRAL position, there are leaks in hydraulic
system. The maximum speed the carriage is al-
lowed to lower is 100 mm (4 in.) per 10 minutes
when hydraulic oil is at normal operating tempera-
ture.
3. Check lift cylinders for internal leaks. Remove
load from forks. Install valve in supply line be-
tween 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 fit-
tings. If no leaks are found, main control valve
can be worn or damaged. Remove load from
forks.
Seal Kit Installation
EXTERNAL INSTALLATION (SEAL AND
BACK-UP RING)
NOTE: It is recommended that seal is heated in hy-
draulic oil prior to installation to make it more flexible
and pliable.
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.
4. Install back-up ring into piston rod groove. See
Figure 39.
5. Slide seal over external installation sleeve and
into piston rod groove. See Figure 39.
6. Remove external installation sleeve.
INTERNAL INSTALLATION (PISTON ROD
ASSEMBLY)
1. Insert internal installation sleeve into end of cylin-
der 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.
2100 YRM 1328 Lift Cylinder Leak Check
57

1. PISTON ROD ASSEMBLY
2. WEAR RING
3. EXTERNAL INSTALLATION SLEEVE
4. BACK-UP RING
5. SEAL
Figure 39. Cylinder External Seal Installation
1. PISTON ROD ASSEMBLY
2. BACK-UP RING
3. SEAL
4. INTERNAL INSTALLATION SLEEVE
5. CYLINDER TUBE
6. WEAR RING
Figure 40. Cylinder Internal Installation
SPECIAL TOOLS
Special Tool Cascade Part Number
6075028
6075087
Cylinder Repair (Mast S/N A513, A514, A613, A614, B513, B514) 2100 YRM 1328
58

Torque Specifications
FOR LIFT TRUCK MODELS GLC/
GDC60VX, GLC/GDC70VX (GC/GLC/
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)
Tilt Cylinder Gland
400 to 440 N•m (295 to 325 lbf ft)
Tilt Cylinder Rod End to Rod Locknut- Mast End
90 N•m (66 lbf ft)
Tilt Cylinder Rod End to Rod Capscrew - Frame
End
90 N•m (66 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)
Lift Cylinder Mount to Outer Mast Lock Nut
135 N•m (100 lbf ft)
Lift Cylinder Chain Anchor Lock Nuts
370 N•m (273 lbf ft)
Lift Cylinder Mounting Bolts to Outer Mast
555 N•m (410 lbf ft)
Free- Lift Cylinder Gland
400 to 475 N•m (295 to 350 lbf ft)
Free- Lift Cylinder Mount Lock Nut to Inner Mast
370 N•m (273 lbf ft)
Free- Lift Cylinder Chain Anchor to Cylinder
Mount Lock Nuts
135 N•m (100 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)
FOR LIFT TRUCK MODEL GLP/GDP80VX,
GLP/GDP80VX9, GLP/GDP90VX (GLP/
GDP190VX) (A909, B909)
Tilt Cylinder Piston Rod Nut
400 to 440 N•m (295 to 325 lbf ft)
Tilt Cylinder Gland
400 to 500 N•m (295 to 325 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)
Tilt Cylinder Rod End to Rod Capscrew - Frame
End
66 N•m (49 lbf ft)
Tilt Cylinder Anchor Pin Capscrew
90 N•m (66 lbf ft)
Lift Cylinder Gland
350 to 400 N•m (258 to 295 lbf ft)
Fork Positioner Cylinder Gland
350 to 400 N•m (258 to 295 lbf ft)
Sideshift Cylinder Gland
350 to 400 N•m (258 to 295 lbf ft)
2100 YRM 1328 Torque Specifications
59

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 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 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 3. Strip Length Measurement Verification
2200 YRM 1128 General
1

Table 1. Wire Strip Length Specifications
Contact Part Number Type Wire Gauge Range Recommended Strip Length
580039516 Pin 20 AWG (0.5 mm2
) 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 Pin 20 AWG (0.5 mm2
) 4.0 to 5.5 mm (0.157 to 0.217 in.)
505972554 Pin 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 Pin 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 Pin 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 Pin 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.)
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 Fig-
ure 4.
3. Loosen lock nut and turn adjusting screw until it
stops. See Figure 5.
Figure 4. Selector Knob
Deutsch Crimping Tool 2200 YRM 1128
2

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.
1. INSERTION POINT
2. INDENTOR COVER
Figure 6. Insertion Point
5. Turn the adjusting screw clockwise until the con-
tact is flush or slightly above flush with the inden-
tor cover (cover around insertion point). See Fig-
ure 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 cen-
tered between indicators. See Figure 7.
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.
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. INSPECTION HOLE
2. CRIMP
3. INSULATION GAP, 0.635 TO 2.54 mm (0.025 TO
0.100 in.)
Figure 8. Proper Crimp
2200 YRM 1128 Deutsch Crimping Tool
3

10. If any of the conditions in Step 9 are not met, dis-
card 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.
1. GO END (GREEN)
2. NO-GO END (RED)
Figure 9. G454 Testing Tool
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. SELECTOR SET AT #20 WIRE SIZE, SELEC-
TOR NUMBER 4
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 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.
Deutsch Crimping Tool 2200 YRM 1128
4

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 No-
Go 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 FUR-
THER
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 man-
ner.
For examples of the DT connectors, see Figure 14 for
the different connector receptacles, Figure 15 for the
different connector receptacle secondary locks, Fig-
ure 16 for the different connector plugs, and Figure 17
for the different connector plug secondary locks.
For examples of the DTM and DTP connectors, see
Figure 18 for the different connector receptacles, Fig-
ure 19 for the different connector receptacle secon-
dary locks, Figure 20 for the different connector plugs,
and Figure 21 for the different connector plug secon-
dary locks.
2200 YRM 1128 Deutsch Crimping Tool
5

NOTE: ALL CONNECTOR RECEPTACLES ARE SHOWN WITH THE SECONDARY LOCK INSTALLED.
A. CONNECTOR TYPE AA
B. CONNECTOR TYPE AB
C. CONNECTOR TYPE AC
D. CONNECTOR TYPE AD
E. 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
Deutsch Connectors 2200 YRM 1128
6

A. SECONDARY LOCK TYPE BA
B. SECONDARY LOCK TYPE BB
C. SECONDARY LOCK TYPE BC
D. SECONDARY LOCK TYPE BD
E. SECONDARY LOCK TYPE BE
F. SECONDARY LOCK TYPE BF
G. SECONDARY LOCK TYPE BG
H. SECONDARY LOCK TYPE BH
Figure 15. DT Connector Receptacle Secondary Locks
2200 YRM 1128 Deutsch Connectors
7

NOTE: ALL CONNECTOR PLUGS ARE SHOWN WITH THE SECONDARY LOCK INSTALLED.
A. CONNECTOR TYPE CA
B. CONNECTOR TYPE CB
C. CONNECTOR TYPE CC
D. 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
8

A. SECONDARY LOCK TYPE DA
B. SECONDARY LOCK TYPE DB
C. SECONDARY LOCK TYPE DC
D. SECONDARY LOCK TYPE DD
E. SECONDARY LOCK TYPE DE
F. SECONDARY LOCK TYPE DF
G. SECONDARY LOCK TYPE DG
H. SECONDARY LOCK TYPE DH
Figure 17. DT Connector Plug Secondary Locks
9

Figure 18. DTM and DTP Connector Receptacles
10

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
11

A. DTM CONNECTOR TYPE GA
B. DTM CONNECTOR TYPE GB
C. DTM CONNECTOR TYPE GC
D. DTP CONNECTOR TYPE GD
E. DTM CONNECTOR TYPE GF
F. DTM CONNECTOR TYPE GE
G. DTP CONNECTOR TYPE GG
H. DTM CONNECTOR TYPE GH
Figure 20. DTM and DTP Connector Plugs
12

A. DTM SECONDARY LOCK TYPE HA
B. DTM SECONDARY LOCK TYPE HB
C. DTM SECONDARY LOCK TYPE HC
D. DTP SECONDARY LOCK TYPE HD
E. DTM SECONDARY LOCK TYPE HE
F. DTM SECONDARY LOCK TYPE HF
G. DTM SECONDARY LOCK TYPE HG
H. DTP SECONDARY LOCK TYPE HH
I. 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.
13

STEP 2.
Using a small hook end tool (Yale Part No.
150121838), or needle nose pliers, remove the sec-
ondary lock from the connector receptacle.
14

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, flat-
blade screwdriver (Yale P/N 150121838).
15

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.
16

STEP 7.
Insert the wires into the new connector receptacle
according to the number or letter on the tag and con-
nector 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.
17

STEP 9.
Push the connector plug into the connector recepta-
cle until the external locking mechanism(s) snap(s)
into place.
18

Connector Plug Replacement
STEP 1.
STEP 2.
150121838), remove the secondary lock from the
connector plug.
19

STEP 3.
away from the socket.
20

STEP 4.
STEP 5.
21

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.
22

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.
into place.
23

Connector Receptacle Pin Replacement
STEP 1.
24

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.
away from the pin.
25

STEP 4.
26

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.
27

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 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.
28

STEP 10.
until the lock snaps into place.
29

STEP 11.
into place.
Connector Plug Socket Replacement
STEP 1.
30

STEP 2.
150121838), remove the secondary lock from the
connector plug.
31

STEP 3.
away from the socket.
STEP 4.
32

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.
33

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
STEP 8.
150121900), crimp the new socket on the wire as
shown in How to Crimp With the Deutsch Crimping
Tool.
34

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 to
verify the wire is properly locked in place. Remove
tag.
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
35

1. SEAL
STEP 11.
into place.
HD SERIES CONNECTORS
All Deutsch HD series pin-type connectors are re-
paired 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.
36

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 re-
ceptacle to the mounting structure. Remove recepta-
cle 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.
39

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.
40

STEP 6.
STEP 7.
STEP 8.
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.
41

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 recep-
tacle.
Connector Plug Replacement
STEP 1.
ceptacle.
42

STEP 2.
removed.
STEP 3.
NOTE: If pin is difficult to remove, remove the extraction tool, turn the extraction tool 90 degrees, and reinsert the
tool into the connector.
43

STEP 4.
and the connection socket out of the connector.
STEP 5.
STEP 6.
44

STEP 7.
of the plug until a click is felt. Slightly tug each wire
tags.
STEP 8.
tacle.
Connector Receptacle Pin Replacement
STEP 1.
ceptacle.
45

STEP 2.
Remove the lock nut and washer retaining the re-
ceptacle to the mounting structure. Remove recepta-
cle from mounting structure.
STEP 3.
removed.
46

STEP 4.
STEP 5.
and the connection pin out of the connector.
STEP 6.
If more than one wire is being removed, tag the wire
was removed.
47

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
48

STEP 9.
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.
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.
49

STEP 12.
tacle.
Connector Plug Socket Replacement
STEP 1.
ceptacle.
STEP 2.
removed.
50

STEP 3.
STEP 4.
and the connection socket out of the connector.
51

STEP 5.
If more than one wire is being removed, tag the wire
was removed.
52

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
STEP 8.
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.
53

STEP 9.
of the plug until a click is felt. Slightly tug wire to ver-
ify the wire is properly locked in place. Remove tags.
STEP 10.
tacle.
54

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.
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 open-
ing.
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.
56

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. TOOL (PICK)
2. LOCK TAB
3. TERMINAL
4. CONNECTOR BODY
Figure 26. Metri-Pack Push-to-Seat Connector
1. TOOL (PICK)
2. LOCK TAB
3. TERMINAL
4. CONNECTOR BODY
Figure 27. Metri-Pack Pull-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.
2200 YRM 1128 Metri-Pack Connectors
57

1. TERMINAL
2. LOCK TAB
3. TOOL KIT
4. CONNECTOR BODY
5. SEAL
Figure 28. Metri-Pack Pull-to-Seat Terminal
Removal
CAUTION
Work carefully and do not use enough force to
damage the terminal or the connector.
5. Inspect the terminal and connector for damage.
See Figure 29.
NOTE: THE GREATER DISTANCE D, A FAULT CAN
OCCUR IN THE CONNECTION.
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.
7. Push the terminal into the connector channel.
Make sure that the lock tab correctly locks the ter-
minal in position.
8. Push the seals into their position and install any
secondary locks.
Metri-Pack Connectors 2200 YRM 1128
58

Micro-Pack Connectors
The Micro-Pack connector is shown in Figure 30. This
connector is normally used to connect the wire har-
ness to the ECM. The repair procedures for the Micro-
Pack connectors are the same as the Metri-Pack con-
nectors. Refer to the section Metri-Pack Connectors
for the repair procedures.
1. CABLE
2. TERMINAL
3. LOCKING TAB
4. TOOL KIT (YALE P/N 150121852
Figure 30. Micro-Pack Connector
Weather-Pack Connectors
A Weather-Pack connector can be identified by a rub-
ber 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 im-
portant because of the very low voltage and current
levels found in the electronic system.
Repair of a Weather-Pack terminal is shown in
Weather-Pack Terminal Repair. Use the tool kit to re-
move the pin and sleeve terminals. See Special
Tools.
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.
Make certain that the connectors are properly seated
and all of the sealing rings are in place when connect-
ing 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.
Weather-Pack connections cannot be replaced with
standard connections. Instructions are provided with
Weather-Pack connector and terminal packages.
2200 YRM 1128 Micro-Pack Connectors
59

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.
Weather-Pack Connectors 2200 YRM 1128
60

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 in-
serts, two anvils, an insulation crimp adjustment lever,
a contact support, a locator, an ejector, and a CERTI-
CRIMP ratchet. The contact is inserted into the
FRONT of the tool. The wire is inserted into the
BACK of the tool. See Figure 31.
2200 YRM 1128 Weather-Pack Connectors
61

Figure 31. AMP Hand Crimping Tool
A. FRONT OF TOOL
B. BACK OF TOOL
1. UPPER INSERT
2. ANVIL
3. INSULATION CRIMP ADJUSTMENT LEVER
4. CONTACT SUPPORT
5. LOCATOR
6. CERTI-CRIMP RATCHET
7. STRIPPED WIRE
The insulation adjust lever regulates the crimp height.
See Insulation Crimp Adjustment.
The contact support prevents the contact from bend-
ing 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 CERTI-
CRIMP ratchet releases. This is a design feature
that ensures maximum electrical and tensile per-
formance of the crimp DO NOT readjust the
ratchet.
The CERTI-CRIMP ratchet assures full crimping of
the contact. Once engaged, the ratchet will not re-
lease until the handles have been fully closed.
Stripping Wire for Use with AMP Hand
Crimping Tool
used.
2. See Table 2 for recommended strip length.
AMPSEAL Crimping Tools 2200 YRM 1128
62

Table 2. Wire Size (AWG)
Wire Size
(AWG)
Insulation Diameter
Range
Tool Wire
Size Mark-
ing
Contact Wire Strip Length
16 1.7 to 2.7 mm (0.067
to 0.106 in.)
16 Yale P/N 520202601 5.5 mm (0.215 in.)
20 - 18 20 - 18 4.7 mm (0.185 in.)
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.
NOTE: SEE TABLE 2 FOR WIRE STRIP LENGTH.
1. STRIPPED WIRE
2. LOCATOR SLOT
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.
Maintenance and Inspection for AMP Hand
Crimping Tool
AMP Hand Crimping Tool
1. Perform maintenance and inspections as speci-
fied 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.
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.
2200 YRM 1128 AMPSEAL Crimping Tools
63

Figure 33. AMP Crimp Tool Inspection
A. CRIMP HEIGHT - SEE TABLE 3
1. TOOL CRIMP SECTION MARKING
2. WIRE SLOT IN LOCATOR
3. WIRE BARREL
4. LOCATOR SLOT IN CONTACT
5. MODIFIED ANVIL ON MICROMETER
Table 3. Crimp Height
Contact Part No Wire Size (AWG) Tool Crimp Section Mark-
ing
Crimp Height
Yale P/N 520202601
20 20-18 1.22 ±0.05 mm (0.048
±0.002 in.)
18 20-18 1.22 ±0.05 mm (0.048
±0.002 in.)
16 16 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. Posi-
tion contact as shown in Figure 34.
64

1. BACK OF TOOL
2. STRIPPED WIRE
3. WIRE BARREL
4. CONTACT
5. 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 han-
dles 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 crim-
ped contact from tool.
AMP PRO-CRIMPER II TOOL
Description
This tool has a tool frame with stationary jaw and han-
dle, 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.
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.
A. TOOL FRONT
B. TOOL BACK
1. STATIONARY JAW
2. STATIONARY HANDLE
3. MOVING JAW
4. MOVING HANDLE
5. DIE ASSEMBLY
6. 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 assem-
bly.
1. Close tool handles until ratchet releases.
2. Remove nut, locator assembly, upper and lower
die retaining screws, and upper and lower die re-
taining pins. See Figure 36.
3. Slide wire anvil, insulation anvil, wire crimper, and
insulation crimper out of tool frame. See Fig-
ure 36.
65

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 com-
pletely. See Figure 36.
7. Insert wire crimper and insulation crimper into sta-
tionary 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 station-
ary 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 assem-
bly in place while allowing the locator to slide up
and down. See Figure 36.
1. UPPER DIE RETAINING SCREW
2. LOWER DIE RETAINING SCREW
3. WIRE ANVIL
4. INSULATION ANVIL
5. LOWER DIE RETAINING PIN
6. WIRE CRIMPER
7. INSULATION CRIMPER
8. UPPER DIE RETAINING PIN
9. LOCATOR ASSEMBLY
10. NUT
11. LOCATOR
12. TOOL FRAME
Figure 36. Die Set and Locator Assembly
Stripping Wire for Use With AMP PRO-
CRIMPER II Tool
used.
2. See Table 4 for recommended strip length.
Table 4. Strip Length for PRO-CRIMPER II Tool
Wire Size
(AWG)
Wire Insulation Di-
ameter
Strip Length
16 1.7 to 2.7 mm (0.07
to 0.11 in.)
5.1 ±0.4 mm (0.20
±0.02 in.)18-20
CAUTION
DO NOT cut or nick the wire strands.
3. Strip wire to recommended strip length. See Fig-
ure 37.
66

1. CONTACT
2. LOCATOR (IN WIRE STOP SLOT)
3. WIRE (INSERTED TO STOP)
4. STRIP LENGTH
Figure 37. Contact and Wire Strip
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.
3. Insert contact and wire into tool as shown in Fig-
ure 37. Close tool handles until the ratchet rea-
ches the sixth clip or the contact support touches
the contact.
4. Loosen the nut, slightly, that holds the locator as-
sembly onto the tool frame. See Figure 38.
5. Move the contact support to eliminate bending the
contact.
6. Tighten the nut and squeeze handles until ratchet
releases.
7. Remove and inspect the contact.
8. Make another sample crimp. If the contact is
straight, tighten the adjustment screw. If the con-
tact is bent, repeat Step 2 through Step 8.
1. ADJUSTMENT SCREW
2. CONTACT SUPPORT
3. LOCATOR
4. WIRE
5. BACK OF TOOL
Figure 38. Contact Support Adjustment
Crimp Height Adjustment
1. Remove lockscrew from ratchet adjustment
wheel. See Figure 39.
2. Using screwdriver, adjust ratchet wheel as indica-
ted in Step 3 or Step 4.
3. To tighten crimp, rotate ratchet adjustment wheel
COUNTERCLOCKWISE. See Figure 39.
4. To loosen crimp, rotate ratchet adjustment wheel
CLOCKWISE. See Figure 39.
5. Replace lockscrew onto ratchet adjustment
wheel. See Figure 39.
6. Make a sample crimp and measure the crimp
height.
67

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 en-
sure they are not worn or damaged. If crimp sec-
tions are flattened, chipped, worn or broken re-
place tool.
Crimp Height Inspection
1. This inspection requires the use of a micrometer
with a modified anvil as shown in Figure 40.
A. POSITION POINT ON CENTER OF WIRE BAR-
REL OPPOSITE SEAM.
1. MODIFIED ANVIL ON MICROMETER
2. CRIMP HEIGHT, SEE TABLE 5
Figure 40. Crimp Height
2. Refer to Table 5 to select wire for each crimp sec-
tion listed.
Table 5. Crimp Measurement
Wire Size (AWG) Crimp Height
18 1.22 ±0.05 mm (0.048
±0.002 in.)
16 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 pro-
cedure.
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.
68

HOW TO USE AMP PRO-CRIMPER II
TOOL
1. Strip insulation from wire. See Stripping Wire for
Use With AMP PRO-CRIMPER II Tool procedure.
2. Hold PRO-CRIMPER II tool so BACK side (wire
side) is facing you.
3. Squeeze tool handles together, then allow to fully
open.
4. Holding contact by mating end, insulation barrel
first, insert contact through front of tool and into
appropriate crimp section.
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.
NOTE: Make sure neither wire barrel nor insulation
barrel are damaged.
6. Hold contact in position and squeeze tool handles
until ratchet engages enough to hold contact.
7. Insert stripped wire into contact insulation and
wire barrels until butted against wire stop.
8. Squeeze tool handles, while holding wire in posi-
tion, until ratchet releases.
9. Allow tool handles to open and remove crimped
contact from tool.
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.
69

1. HOUSING
2. WEDGE LOCK
3. WIRE SEAL
4. MATING SEAL
5. DIAPHRAGM
6. CONTACT
7. RETENTION FINGERS
Figure 41. AMPSEAL Plug Connector
For current ratings of special use connectors, AMP-
SEAL, refer to Table 6.
Table 6. Current Rating
Single Cir-
cuit Plating
Wire Size
(AWG)
Current Rating
(Max.)
Tin 16, 18, and 20 8A
Gold 16 14.5A
18 13A
20 11.5A
Seal Plug
All circuits are sealed by a diaphragm in the rubber
wire seal. When assembling the connector, the dia-
phragm is pierced as the contact passes through it.
Unused circuit cavities will remain sealed unless per-
forated 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 usu-
ally required for this procedure. See Figure 42.
1. PLUG CONNECTOR
2. SEAL PLUG
3. CIRCUIT CAVITY
Figure 42. Seal Plug
Contact Crimping
Information on contact crimping can be found in AMP-
SEAL Crimping Tools.
AMPSEAL Connector Assemblies 2200 YRM 1128
70

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 DIREC-
TION OF ARROW.
A. CLOSED POSITION
B. OPEN POSITION
1. WEDGE LOCK TAB
2200 YRM 1128 AMPSEAL Connector Assemblies
71

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