2. Remove the main bulb and reflector,
the spring and the secondary bulb.
3. Remove the three screws
(P/N 65522) and lockwashers
(P/N 54278) that hold the circuit
board in the lamp-housing.
4. Lift the board to expose the wiring.
5. Pull the seven wire pins out of the
board.
Installing the new Main Circuit Board
1. Position the board so that its
straight side is on the same side of
the headpiece as the switch;
a. its pins face up;
b. the flexible circuit board pins
face up.
2. Insert the wires into the pins on the
bottom of the main circuit board.
They must be installed as follows
(the letters are on the top of the
board)
White to W
Orange to O
Black to K
Blue to B
Red to R
Brown to N
Green to G
a. Line up the holes in the board
with the brass inserts into the
lamp-housing and install the
three lockwashers and screws.
Do not over-tighten screws or you
may crack the circuit board.
b. Re-install the main lamp and
reflector assembly, the spring
and the secondary bulb.
c. Re-install the bezel.
Removing the Switch and Wiring
Assembly (P/N 484684)
1. Remove the bezel.
2. Remove the main bulb and reflector,
the spring and the secondary bulb.
3. Remove the main circuit board.
4. Using a wrench, loosen and
remove the boot (P/N 682390).
Keep the boot; it will be used to
secure the new switch. Take care
not to damage the boot material.
5. Pull the switch and wiring out of
the lamp-housing.
Installing the Switch and Wiring
Assembly
1. Position the switch so that the
blue wire is closest to the open
end of the lamp-housing and bend
the wires so that the switch will fit
in the lamp-housing.
Be careful not to bend the switch
terminals. They may break.
2. Insert the switch toggle through
the hole in the lamp-housing.
You may have to move the switch
back and forth to fit the threaded
bushing into the hole.
3. Thread the boot on the switch bush-
ing and tighten, using a wrench.
Take care not to damage the boot.
4. Re-install the main circuit board.
5. Re-install the main bulb and
reflector assembly, the spring and
the secondary bulb.
6. Re-install the bezel.
7. Test the switch operation by push-
ing the toggle forward to light the
main bulb, and back to light the
secondary bulb.
Removing the Cap Hook
(P/N 484687)
1. Use a flatblade screwdriver to
remove the two screws (P/N 65522)
and lockwashers (P/N 51704) that
hold the cap hook to the lamp-
housing.
TAL 998 (L) Rev. 2 - 817184
7
Maintenance
CAUTION
CAUTION
817184 8/13/99 9:43 AM Page 7
