4. Discharge the capacitor in the controller by con-
necting a 200-ohm, 2 watt resistor between the B
+ and B- connectors on the controller.
5. Disconnect the control handle wiring harness plug
and the control handle arm prox switch plug loca-
ted on top of the drive motor.
For the following instructions refer to Figure 3.
6. Remove the rubber bumper retaining screw and
wire clamp.
7. If necessary, remove the control handle head.
See the section Electrical System
2200YRM1007, Figure 3.
CAUTION
Discharging the gas spring is a destructive opera-
tion.
8. Discharge and remove the gas spring. Refer to
Gas Spring.
9. Remove setscrews.
10. Remove both threaded control arm pivot pins and
washers.
11. Remove the control arm from the support bracket.
12. Remove two screws from the support bracket and
remove the control handle arm prox switch.
13. If bushings are worn, remove the bushings from
the support bracket pivot pin holes.
INSTALL
1. Install the new gas spring to the control handle
arm. Refer to Gas Spring.
2. If previously removed, install the bushings into the
support bracket pivot pin holes.
NOTE: Install the switch to the bracket with wire to
bottom of the bracket.
3. Install the control handle arm prox switch into the
mounting bracket and mount onto the support
bracket with retaining screws. Leave retaining
screws loose until the control handle arm is instal-
led.
4. Install the bumper and wire clamp with retaining
screw and tighten to 10.5 N•m (93 lbf in).
5. If removed, install the control handle head. See
the section Electrical System 2200YRM1007,
Figure 3.
6. Install the control arm into the support bracket.
Apply Loctite
®
242 to the threaded portion of the
pivot pins and install pivot pins. Torque to 190
±7 N•m (140 ±5 lbf ft).
7. Install and tighten setscrews.
8. Drive the pin through lower end of gas spring to
secure to support bracket.
9. Adjust control handle arm prox switch. Refer to
the section Electrical System 2200YRM1007,
Control Handle Arm Prox Switch - Install.
10. Install the MDU covers and drive unit compart-
ment covers.
11. Connect the battery and test the operation of the
lift truck prior to returning to service.
1600 YRM 1004 Control Handle
3
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