T3 Motion 020-00012 User manual

Rev Description Date ECO#
1 SERVICE MANUAL 2/14/2008 00239
Document Number:
040-00068
Form Instructions
Title SERVICE MANUAL, POWER SOCKET / LIGHT BOARD REPLACEMENT
Operation
Description Sub Assembly
Man Occup. Machine Occup. Cycle Time Setup Time Batch Qty
Standards
Equipment Manufacturer Qty
1- P/S Light Control T3 Motion 1
2- Phillips screw driver (small) Any 1
3- ¼ inch nut driver Any 1
4- 1/8 inch Allen wrench Any 1
5- Wire cutters Any 1
6- Blade screwdriver (small) Any 1
Equipment
List
Reference
Docs
Document #
Description
Document #
Description
Related
Files
RESP
ENGR Mark Jones
ALL TEXT AND GRAPHICS
COMPUTER GENERATED, DO
NOT REVISE MANUALLY
T3MOTION, INC. PROPRIETARY INFORMATION
This document is the sole property of T3MOTION, Inc. The release of data
contained in this document and the reproduction of this document in whole
or in part, without the written permission of T3MOTION, Inc. is prohibited.
SHEET 1 of 12
Form 040-00068 Rev.1

SERVICE MANUAL
T3MOTION PROPRIETARY INFORMATION
Use or disclosure of data contained on this sheet is
subject to the restriction on the cover or title page of this
document.
Document No
040-00068
Revision
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Sheet
2
Item# Part # Description Qty
1
020-00012 P/S Light Control Assembly 1

SERVICE MANUAL
T3MOTION PROPRIETARY INFORMATION
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Document No
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•ALWAYS TURN OFF POWER BREAKER IN GLOVE BOX AND REMOVE POWER
MODULES BEFORE PERFORMING ANY ELECTRICAL WORK.
Power breaker in glove box Power modules
•ALSO SET THE PARKING BRAKE PRIOR TO ANY WORK.
Parking brake
Serious electrical
shock can occur
if precautions are
not followed.

SERVICE MANUAL
T3MOTION PROPRIETARY INFORMATION
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WORK INSTRUCTIONS:
1.0 Recommended tools for replacing the power socket / light board assembly.
See equipment table above for the details.
1.1 New power socket / light board.
2.0 Remove the pannier bag from the T3 unit by releasing the four plastic clasps.
2- Phillips screwdriver
3- ¼ inch nut driver
4- 1/8 inch Allen wrench
5- Wire cutters
6- Blade screwdriver

SERVICE MANUAL
T3MOTION PROPRIETARY INFORMATION
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2.1 Squeeze tangs to release the clasps.
3.0 Using the 1/8 inch Allen wrench, remove the four fasteners that attach the access
panel. Remove the bottom two first.
3.1 Remove access panel.

SERVICE MANUAL
T3MOTION PROPRIETARY INFORMATION
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4.0 Remove the two small Phillips head screws holding the red/pink board in place.
4.1 Gently lower the hinged panel. Do not force, if it does not open all the way
easily, carefully guide the wires to allow for some slack in them.
4.2 If you cannot get enough slack in the wires, check to see if clipping a nylon wire
tie is necessary. Not all units need to have this done.

SERVICE MANUAL
T3MOTION PROPRIETARY INFORMATION
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4.3 This is a view of the fully exposed board from the left hand side of the vehicle.
5.0 Unplug the four connectors positioned along the left side of the board. Take your
time and be sure to release the locking tabs on them.
5.1 If any of the connectors are too tight to release by hand, a small screwdriver can
be carefully used to separate them.
.
Locking tabs

SERVICE MANUAL
T3MOTION PROPRIETARY INFORMATION
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5.2 Remove the two Phillips head screws holding this metal connector in as shown.
5.3 Unplug the connector.
6.0 Using the ¼ inch nut driver loosen the four nylock nuts fastening the board
down. Leave them finger tight and on the studs for now so you can remove
them by hand to lessen the chance of dropping them.

SERVICE MANUAL
T3MOTION PROPRIETARY INFORMATION
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6.1 After removing the nylock nuts, washers and grommets from the four studs, lift
the board out. You may have to use a screwdriver to help lift it off the studs.
7.1 Install the new P/S light board. Carefully align it on the four studs as shown.
7.2 Place a grommet, then a washer, then a nylock nut on each stud and snug them
down with the nut driver.
Be sure to leave the
grommets under the board
on the studs.
Nylock nut
Washer
Grommet

SERVICE MANUAL
T3MOTION PROPRIETARY INFORMATION
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subject to the restriction on the cover or title page of this
document.
Document No
040-00068
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10
7.3 Do not over tighten the nylock nuts. They only need to be snug. Do not over
compress the grommets. They are for shock absorption.
8.0 Reattach the metal connector with the two Phillips head screws.
8.1 Plug the four connectors on the left side into their receptacles.
Note slight
compression of
grommets.
A screwdriver for
support can be
helpful here.

SERVICE MANUAL
T3MOTION PROPRIETARY INFORMATION
Use or disclosure of data contained on this sheet is
subject to the restriction on the cover or title page of this
document.
Document No
040-00068
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11
9.0 Close the hinged red/pink panel.
9.1 Install the two small Phillips head screws to secure it.
10.0 Re-install access panel. Align holes of panel with threaded holes.

SERVICE MANUAL
T3MOTION PROPRIETARY INFORMATION
Use or disclosure of data contained on this sheet is
subject to the restriction on the cover or title page of this
document.
Document No
040-00068
Revision
1
Sheet
12
10.1 Hold panel in place and hand thread fasteners to start.
10.2 Once all four fasteners are hand threaded, tighten them down with the Allen
wrench. Do not over tighten; they only need to be snug.
10.3 Re-install pannier bag by securing all four plastic clasps.
For addition information, contact T3 Motion at: (714)-619-3600.