Travel Spring And Pinion - Toyota 7BPUE15 Service Manual

Section 7. Component Procedures
Control Handle
6. Carefully unsolder the harness wires.
Assembly
1. Slide 3/8 in. (9.5 mm) long shrink sleeving
over previously sleeved wires.
2. Solder all electrical components to the
harness. See "Hand Soldering Procedures"
on page 7-22.
3. Shrink sleeving a s necessary.
4. Assemble pot and bracket and install
retaining n u t and lock washer. When
installing the travel pot into the bracket,
leave the mounting n u t finger tight. See
Figure 7-25.
5. Install the gear on the pot shaft, aligning
the set screw with the flat portion of the
shaft.
6. Install the travel pot/bracket assembly
into the enclosure. Engage the travel pot
gear with the shaft gear (there is one large
tooth that is used to align the gears).
Tighten the pot gear set screw and torque
to 3 to 4 in. lb. (0.3 to 0.4 N*m).
It is
very easy to over-torque and ruin
the gear.
7. Tighten the two pan head machine screws
on the back of the enclosure while moving
the handle to ensure there is no binding.
See Figure 7-23.
8. Install the handle in the truck.
9. Adjust the travel pot to the correct voltage
values.
10. Tighten the retaining nut.
11. Install the cover on the travel pot
enclosure with the four hex head cap
screws. See Figure 7-22.

Travel Spring and Pinion

Disassembly
1. Remove the four hex head cap screws from
the front of the travel pot enclosure and
remove cover. See Figure 7-22.
7-2 0
Toyota Orderpicker Model 7BPUE 15 Service Manual
2. Use a pin removal tool and pull pins 3 thru
6 from JC-9. These wires pass through the
shaft to the lift/lower pot and horn switch.
N : The washer and shims can easily slip off
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of the shaft gear. Observe the proper
position of these components before
disassembling them.
3. Remove the button head screw from the
shaft gear and slide shaft out of enclosure.
See Figure 7-24.
4. Carefully rotate the shaft gear assembly to
disengage the spring tangs from the pin.
Remove the shaft gear assembly from the
enclosure.
Assembly
1. Slide the shaft gear assembly back into
enclosure. Engage the travel pot gear with
the shaft gear (there is one large tooth that
is used to align the gears).
a. Make sure the spring tangs straddle the
pin (tangs should be parallel). If the
spirol pins were replaced, make sure
they are installed such that when the
spring is installed, the spring sits on a n
even edge of the pin and not on the gap.
N : Replace the spring if the tangs are not
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parallel. Do not bend the spring.
b. Make sure the washer and shims are
properly aligned to allow the handle
shaft to slide easily through the
enclosure. See Figure 7-26.
7-26.
Figure
00700-CL222-05, 1 5 March 2005