Retrofit Kits 59907- [ ], 1901775- 1,
1901776- 1, and 1901777- 1
For Hydraulic Handle Control Assemblies
Hydraulic Handle Control Assembly (Ref)
Faceplate
Coupler
Switch Cover
Trigger
Micro-- Switches
Switch Mounting
Plate
Instruction Sheet
10 MAR 10 Rev C
408-- 9809
ORIGINAL INSTRUCTIONS
Grip Sleeve
Handle Tube
HEAVY DUTY
HYDRAULIC PUMP
Strain
Relief
RETROFIT KIT
1901775--1
HEAVY DUTY
HYDRAULIC PUMP
RETROFIT KIT
0--59907--7
1--59907--5
2--59907--1
2--59907--8
69120--1
69120--2
1901776--1
1901777--1
Figure 1
1804700--1
1804700--1
1804700--2
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.
— 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.
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.tycoelectronics.com
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
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.
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LOC B
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.
7. Remove the faceplate and switch base (retain
one of the 4--40¢.312 screws and the washer).
8. Solder the leads to the micro--switches and
remove the micro--switches, switch mounting plate,
trigger, and switch cover.
NOTE
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
408- 9809
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.
2. Pull the
WHITE
conductor through the opening
marked
RUN.
3. Pull the
BLUE
and
ORANGE
conductors
through the opening marked
DUMP.
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
i
WHITE
ORANGE
BROWN
RED
BLACK
BLUE
BROWN
Figure 2
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Tyco Electronics Corporation
Rev
C
Retrofit Kits 59907- [ ], 1901775- 1, 1901776- 1, and 1901777- 1
Guard
Coupler
Switch Cover
408- 9809
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.
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.
CAUTION
Take care to ensure that there are no wires in
contact with the housing.
7. Solder the switches:
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.
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.
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.
NOTE
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.
!
11. Install the guard to the switch cover and
secure it with the two slotted head screws provided
with the retrofit kit.
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.
13. Apply pipe sealant to the threads of the handle
tube and replace the quick--coupler.
14. Slide the grip sleeve up the handle tube until it
is butted against the switch cover.
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.
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
4. REVISION SUMMARY
Revisions to this instruction sheet include:
S
Added “Original Instructions” to page 1
Tyco Electronics Corporation
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