4. Remove the retaining ring and flat washer
from the shaft.
5. Remove the battery disconnect lever.
Replacement
NOTE
When replacing the battery disconnect lever,
ensure the flange side of the bushing is
toward the frame.
1.
Slide the battery disconnect lever over the
shaft.
2.
Install the flat washer and the retaining ring.
3.
Connect the return spring.
4.
Install the top cover (refer to TOP COVER
Replacement procedure in the FRAME
section).
5.
Make sure the screw is installed in the battery
connector. Connect the battery and test the
disconnect for proper operation.
HORN BUTTON SPRING
Removal
1.
Disconnect the battery and discharge the
capacitors.
2.
Remove the control handle bezel.
3.
Carefully lift the horn button out of the handle
and remove the horn button spring.
Replacement
1.
Install the new horn button spring in the
correct orientation (see Fig. 5.2)
2.
Engage the horn switch to prevent damaging
the arm and install the horn button.
3.
Install the bezel and test the horn button for
proper operation (listen for a click when the
switch closes and opens).
4.
Connect the battery and test the horn, tilt and
sideshift switches.
LIFT AND TRAVEL SPRINGS
Removal & Replacement
Refer
to Fig. 5.3.
1.
Remove the control handle from the truck
and place it on a clean flat work surface (refer
to CONTROL HANDLE Removal procedure
in this section).
CAUTION
Position the control handle so that the
potentiometers, wiring, and other parts of the
control handle and mechanism are not
damaged during removal and installation of
the roll pins.
2.
Remove and replace one spring at a time.
A: Support the stop block in a vise or against
a solid surface or use the roll pin removal
tool, Part # 9660146. Use an appropriate
size pin punch to drive the roll pins out of the
stop block. Slide the stop block and nylon
washer off the cross shaft.
B: Grasp the outer leg of the spring with
pliers and move it to the other side of the
bracket arm to release tension, then remove
the spring.
C: Slide the correct spring onto the shaft so
that the inner leg falls into the notch in the
bracket arm. Grasp the outer leg of the
spring with pliers and pull it to the other side
of the bracket arm until it snaps into the
notch.
D: Slide the nylon washer onto the shaft.
Slide the stop block onto the shaft so that the
leg of the stop block fits between the legs of
the spring.
E: Support the stop block in a vise or against
a solid surface. Drive a 1/4” x 1¼” roll pin
approximately half way into the stop block.
Insert a 5/32” x 3/4” roll pin into the first roll
pin with the open sides 180° apart. Drive the
smaller pin into the larger pin until flush, drive
the assembly the rest of the way in. Insert a
piece of the stainless steel wire through the
roll pin assembly, wrap it around the back of
the stop and twist it together to prevent the
pins from coming out. See Figure 2 for wire
location. Bend the twisted ends back toward
the roll pin to prevent them from catching on
the boot.
E
lectric
C
ounterbalance
H
igh
O
utput
Operator Controls
3/30/00
5.3
