the screw (6) in the springs (4 and 5) and the
(9) Remove the nut (7) and withdraw the
switch insulation (28). Slide the contact sleeve (30)
s c r e w (11) from the housing (8). Remove the two
o v e r the end of the screw (6) and install the in-
p i e c e s of housing.
( 1 0 ) Remove the two screws (9) and separate
s u l a t o r tube (29) on the screw.
(7) Position the switch lever (25) in the switch
t h e connector cable (12) from the two prongs (10).
i n s u l a t i o n (28) and install the pin (27). Insert the
(11) Disassemble the other connector in the
lamp contact (18) in the insulation tube (17).
same manner as described above.
Insert the insulation tube in the lamp housing (16)
b. Cleaning, Inspection, and Repair.
a n d position the assembly in the lamp insulation
(1) Clean all metal parts with an approved
(15).
c l e a n i n g solvent. Wipe the cable clean with a soft
( 8 ) Position the contact terminal sleeve (26)
c l o t h . Clean the corrosion from the terminals and
o n the lamp contact (18) and secure with the in-
c o n t a c t s . Brush all threaded surfaces free of dirt
sulation washer (21) and nut (22).
a n d all foreign material.
( 2 ) Inspect the tubes and housings for dents,
(9) Line up the grooves in the lamp insulation
( 1 5 ) with the mounting holes of the hook ratchet
c r a c k s , and breaks. Inspect all insulation for wear
( 1 3 ) in the body tube (24) and start the lamp in-
and damage. Inspect all contacts for corrosive
damage and breaks. Inspect the terminals for
s u l a t i o n into the tube.
(10) Line up the switch lever (25) in the switch
b u r r s , bends, and breaks. Inspect the hook ratchet
for bends and damage. Inspect the housings for
insulation (28) with the switch lever opening in the
c r a c k s and breaks.
b o d y tube (24). Slide the two assemblies into the
tube, moving them progressively until the lamp
(3) Repair minor insulation damage to the
i n s u l a t i o n (15) clears the tube.
cable with tape. Straighten out all dents and bends.
Remove all burrs with a fine file. Rechase threaded
(11) Position the ends of the hook ratchet (13)
surfaces having minor thread damage or wear.
i n the mounting holes in the body tube (24). Back
Replace all defective parts that cannot be repaired.
up and position the two assemblies in the body tube
and secure with the screws (3) and (23).
c.
Reassembly.
CAUTION
( 1 ) Position the bare tips of one end of the
c a b l e (1, fig. 4-5) in the mounting holes in two of
Be careful not to bend the contact
t h e prongs (10). Install the two screws (9).
spring (5)
when moving the two
( 2 ) Place the prongs (10) in the housing (8).
assemblies
backward and forward
Position a second housing over the first and install
w i t h i n the body tube (24).
the screw (11) and nut (7).
(12) Twist the cover (31) backward the
( 3 ) Assemble the second connector (2) in the
n u m b e r of turns required to engage it in the body
s a m e manner as described avove.
tube (24). This will put a reverse twist on the two
(4) Place the cover (31) on the cable (1).
wires which make up the cable (1). Screw the cover
Position the long end of the cable (1) in the switch
i n t o the tube.
i n s u l a t i o n (28) and solder the contact sleeve (30)
(13) Install a lamp (19) in the lamp
housing
a n d the contact terminal sleeve (26) to the cable
(16) and install the shade tube (20).
end.
4-12. Electrical Illumination Assembly
( 5 ) Install the connector plug (2) on the free
a.
Disassembly.
e n d of the cable (1) according to the instructions
(1) Remove the nut (7, fig. 4-6) and lamp
outlined in paragraph 2-30.
holder (8) from the electrical illumination assembly
( 6 ) Position the contact spring (5) and spring
cover (17).
(4) in the slot in the switch insulation (28). Install
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