SERVICE MANUAL, HEADSET TOP AND HEAD
Contents
1. SERVICE MANUAL Document Number SS 040 00066 Form Instructions Operation Description Sub Assembly Removal and Replacement Machine Occup Cycle Time Setup Time Batch Qty Standards Equipment Manufacturer Equipment List 1 Headset Top Assembly T3 Motion 2 Head Light Assembly T3 Motion 3 5 32 inch Allen Hex key or driver Any 4 7 16 inch open end or box wrench Any Document Description Document Description Reference Docs Related Files enor sones OOOO T3MOTION INC PROPRIETARY INFORMATION ALL TEXT AND GRAPHICS This document is the sole property of T3MOTION Inc The release of data COMPUTER GENERATED DO contained in this document and the reproduction of this document in whole SHEET 1 of 12 NOT REVISE MANUALLY or in part without the written permission of T3MOTION Inc is prohibited Form 040 00066 Rev 1 SERVICE MANUAL ent rane ern fy 023 00021 Headset top assembly 2 023 00022 Head light assembly 1 T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contained on this sheet is D subject to the restriction on the cover or title page of this 040 00066 1 document SERVICE MANUAL Serious electrical shock can occur if precautions are not followed e ALWAYS TURN OFF POWER BREAKER IN GLOVE BOX AND REMOVE POWER MODULES BEFORE PERFORMING ANY ELECTRICAL WORK Power breaker in glove box Power modules e ALSO SET THE PARKING BRAK2. E PRIOR TO ANY WORK Parking brake T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contained on this sheet is 3 subject to the restriction on the cover or title page of this 040 00066 1 document SERVICE MANUAL WORK INSTRUCTIONS 1 0 Recommended tools for replacing the headset top and head light assemblies see equipment table above for the details Close up of Allen or hex style driver tips 2 0 Headset top assembly 2 1 Head light assembly T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contained on this sheet is A subject to the restriction on the cover or title page of this 040 00066 1 document SERVICE MANUAL 3 0 Remove the two Allen head screws on the front of the headset under the headlight 3 1 Remove the two Allen head screws on the rear of the headset T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contained on this sheet is 5 subject to the restriction on the cover or title page of this 040 00066 1 document SERVICE MANUAL 4 0 Gently lift the headset top up from the front You can use the headlight as a handle Do not force pry or pull hard on the wiring 7 a t ray 4 1 There is enough slack in the wiring to gently rest the headset top on the headset housing as shown below cy T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or dis
3. L 10 0 Reconnect the wires to the terminals that match the labels Make note of the locking tabs to insure proper connections sae eee eee eee Te Remove the tape labels after making the proper conde Tons 11 0 Test the installation Set parking brake Turn breaker and power switches On T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contained on this sheet is 11 subject to the restriction on the cover or title page of this 040 00066 1 document SERVICE MANUAL 12 0 Final assembly Turn power Off Attach headset top and headlight assembly to headset housing using the four Allen head screws Start all four screws about halfway then tighten them up until snug do not over tighten Y lf all functions do not work properly check the connections and the battery levels lf problems persist contact T3 Motion at 714 619 3600 T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contained on this sheet is 12 subject to the restriction on the cover or title page of this 040 00066 1 document
4. closure of data contained on this sheet is 6 subject to the restriction on the cover or title page of this 040 00066 1 document SERVICE MANUAL 5 0 This is the circuit board as viewed from the front of the vehicle Notice that the smaller connectors are labeled on the circuit board as to their functions i F CT EF UCL Erde gt fi ak Trt Bl eB BR rh ara Di tii i oe 2 Note that all of the connector plugs have locking tabs that must be pressed to release the plugs See photo in Step 7 0 for a close up 5 1 Unplug the two larger connectors on the right one top one black bottom r 5 2 Using tape label five of the remaining wires with the corresponding names printed on the circuit board before unplugging them They are the HI LOW SWITCH BRAKE SWITCH THROTTLE POWER SWITCH and BATTERY TRAY There is no need to unplug or label the HEAD LIGHT wire at this time 5 3 Once the five labeled wires are unplugged the headset top can be removed from the vehicle T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contained on this sheet is 7 subject to the restriction on the cover or title page of this 040 00066 1 document SERVICE MANUAL 6 0 Remove the two 7 16 bolts holding the head light assembly to the headset top 6 1 Genily spread one side of the headset top from the head light to allow the head light to slip out Only a little pressure is re
5. quired to free the head light T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contained on this sheet is 8 subject to the restriction on the cover or title page of this 040 00066 1 document SERVICE MANUAL 7 0 Release and unplug the HEAD LIGHT connector from the circuit board L ETE m Ta i Ma a gt l Te ma PEL pA ka tE Re oN H me T 7 1 Push the grommet through the hole to allow clearance for the connector The Allen wrench or a small screwdriver can be used to help push the grommet through the hole T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contained on this sheet is 9 subject to the restriction on the cover or title page of this 040 00066 1 document SERVICE MANUAL 8 0 Depending on your service requirements you will either install a new head light in the headset top or re install the head light you just removed into a new headset top Start by feeding the head light connector into the hole from the front and then seat the grommet in the hole a 9 0 Slide the head light back in place and thread the 7 16 bolts back in Snug them down but do not over tighten them T3MOTION PROPRIETARY INFORMATION Document No Revision Sheet Use or disclosure of data contained on this sheet is 10 subject to the restriction on the cover or title page of this 040 00066 1 document SERVICE MANUA
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