59907-7

Instruction Sheet Retrofit Kits 59907- [ ], 1901775- 1, 1901776- 1, and 1901777- 1 For Hydraulic Handle Control Assemblies 408-- 9809 10 MAR 10 Rev C Faceplate Trigger Micro-- Switches ORIGINAL INSTRUCTIONS Hydraulic Handle Control Assembly (Ref) Switch Mounting Plate Coupler Switch Cover Grip Sleeve Strain Relief Handle Tube RETROFIT KIT HEAVY DUTY HYDRAULIC PUMP RETROFIT KIT 0--59907--7 1--59907--5 2--59907--1 HEAVY DUTY HYDRAULIC PUMP 1901775--1 1901776--1 69120--1 69120--2 1901777--1 1804700--1 1804700--1 1804700--2 2--59907--8 Figure 1 1. INTRODUCTION These instructions cover the procedure for installing the replacement parts contained in the retrofit kits onto the hydraulic handle control assemblies used with the heavy duty hydraulic pumps listed in Figure 1. The retrofit kit is designed to replace the existing trigger and micro--switches on the handle control assembly as well as the mounting hardware. Reasons for reissue of this instruction sheet are provided in Section 4, REVISION SUMMARY. 2. DESCRIPTION The following replacement parts are included in each retrofit kit. — two of Slotted Head Screw 5--21016--6 (10--32¢.38--in. long screws) — Guard 311759--1 — Switch Cover 311761--1 — Green Switch 986290--1 — Red Switch 986290--2 — Yellow Switch 986290--3 3. RETROFIT PROCEDURE The retrofit procedure requires an understanding of electrical wiring and soldering technique. It is recommended that this retrofit be made by a skilled technician in an environment that allows it to be completed on a workbench. 3.1. Disassemble the Handle Control (See Figure 1) 1. Clean the handle control with a soft cloth and a suitable solvent or cleaning fluid which will not harm paint or plastic material. 2. Remove the quick--coupler (part number 311470--1 or 311471--1) and lay aside. 3. Remove the strain relief from the wire as it enters the handle tube by carefully grasping it with a pair of needle--nose pliers and pulling it out of the opening. Take care not to pinch or cut the wire insulation. TOOLING ASSISTANCE CENTER 1-- 800-- 722-- 1111 E2010 Tyco Electronics Corporation, Berwyn, PA PRODUCT INFORMATION 1-- 800-- 522-- 6752 All Rights Reserved TE logo and Tyco Electronics are trademarks. *Trademark. Other product names, logos, or company names might be trademarks of their respective owners. This controlled document is subject to change. For latest revision and Regional Customer Service, visit our website at www.tycoelectronics.com 1 of 3 LOC B 408- 9809 Retrofit Kits 59907- [ ], 1901775- 1, 1901776- 1, and 1901777- 1 4. Slide the grip sleeve approximately one--third of the way down the handle tube. The sleeve is a snug fit and may require some pressure to move it down the tube. 5. Remove the two button head screws securing the faceplate and switch assembly to the handle tube and lay aside (they are required for re--assembly). 6. Remove two screws securing the faceplate and discard. 9. Discard the switch cover, trigger, switch mounting plate, micro--switches, switch base, and faceplate. 3.2. Assemble the Retrofit Kit (Figures 2 and 3) Prior to installing the retrofit kit, the replacement parts should be identified as well as the colors of the leads to be soldered to the replacement switches. Use the standard procedure for preparing leads for soldering then proceed as follows: 1. Place the conductors through the circular opening of the switch cover. 7. Remove the faceplate and switch base (retain one of the 4--40¢.312 screws and the washer). 2. Pull the WHITE conductor through the opening marked RUN. 8. Solder the leads to the micro--switches and remove the micro--switches, switch mounting plate, trigger, and switch cover. 3. Pull the BLUE and ORANGE conductors through the opening marked DUMP. NOTE i It is best if the leads are desoldered; however, they may be cut if they are cut as closely to the solder joint as possible. Re--assembly requires as much lead length as possible. Otherwise, the wrap around the hydraulic hose has to be all removed and then replaced to slide the cable up to the handle control to gain more working length. Green Switch Red Switch 4. Pull the RED and BLACK conductors through the opening marked RESET. 5. Pull one end of the BROWN wire through the opening marked RUN and its other end through the opening marked RESET. 6. Retain the GREEN wire (with the crimped ring terminal) inside the switch cover to attach later to the handle tube (this is a ground wire). Yellow Switch Common the Black Wire on These Tabs WHITE ORANGE BROWN RED BLACK BLUE BROWN Figure 2 2 of 3 Tyco Electronics Corporation Rev C 408- 9809 Retrofit Kits 59907- [ ], 1901775- 1, 1901776- 1, and 1901777- 1 Guard Switch Cover Coupler Figure 3 NOTE i The BROWN wire is a jumper between the RUN and RESET switches. If it is not long enough to be pulled through the two openings to allow easy soldering, substitute it with a length of 0.5mm 2 [20 AWG] stranded wire,preferably with brown insulation. 7. Solder the switches: CAUTION a. Obtain the GREEN switch and solder the WHITE conductor to one of the solder tabs and the BROWN jumper to the other solder tab. ! Take care to ensure that there are no wires in contact with the housing. b. Obtain the RED switch and solder the BLUE conductor to one of the solder tabs and the ORANGE conductor to the other solder tab. 11. Install the guard to the switch cover and secure it with the two slotted head screws provided with the retrofit kit. c. Obtain the YELLOW switch and solder the BLACK conductor to one of the SQUARE solder tabs and to one of the ROUND solder tabs. Solder the BROWN jumper to the other SQUARE solder tab. Then solder the RED conductor to one of the ROUNDED solder tabs. 12. Carefully slide the switch assembly back onto the handle tube and secure it with the two screws removed in Step 3 of Paragraph 3.1. Soldering the BLACK conductor to the two tabs can be best accomplished by stripping enough insulation from the wire to thread the conductor through the holes in the two tabs (thereby commoning them on the conductor) and then soldering them. 14. Slide the grip sleeve up the handle tube until it is butted against the switch cover. NOTE i 8. Check the wiring connections for correct placement and solder joints. 9. Reconnect the green wire (with the ring terminal crimped on it) to the tube handle using the 4--40 screw and washer. 10. Place the switch cover on a solid surface and obtain a piece of 3/8--in. tubing (or something of the Rev C same approximate size that will not press upon the switch itself but will provide an even distribution of pressure on the switch housing) and press--fit the switches into their respective openings. Take care to align the beveled portion of each switch housing with its identifying marking on the switch cover. 13. Apply pipe sealant to the threads of the handle tube and replace the quick--coupler. 15. Carefully install the strain relief removed in Step 3 of Paragraph 3.1, Handle Control Disassembly by fitting it around the wire entering the handle tube and pushing it into the opening in the handle tube until it is seated. 4. REVISION SUMMARY Revisions to this instruction sheet include: S Added “Original Instructions” to page 1 Tyco Electronics Corporation 3 of 3