408-9809 Datasheet, PDF (3/3 Pages) Tyco Electronics – Reasons for reissue of this instruction sheet are provided in Section 4, REVISION SUMMARY.

Retrofit Kits 59907- [ ], 1901775- 1, 1901776- 1, and 1901777- 1
Coupler
Guard
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 0.5mm²
[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.
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.
CAUTION
!
Take care to ensure that there are no wires in
contact with the housing.
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.
NOTE
i
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.
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
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.
4. REVISION SUMMARY
Revisions to this instruction sheet include:
S Added “Original Instructions” to page 1
Rev C
Tyco Electronics Corporation
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