➢Repairing the headpiece
TOOLS:
G & D type spares and tools kit –206008
D type Headpiece fastening & cable lock kit -
201536
The switch should be placed in the off position and
the battery fuse removed (see section “cap lamp
system”) before disassembly of the headpiece.
➢Replacing Cable
1. Remove the cable from the battery terminals.
2. Cut the cable tie around the cable under the
battery cover and pull the cable out from the
battery cover gland.
3. Unscrew the M3 socket head mushroom screw
from the headpiece cable lock.
4. Use a small screw driver to “flick” the cable lock
off the retaining boss. Take care not to lose the
o-ring under the boss as this is required for
reassembly.
5. Replace the mushroom head socket screw.
This is important to ensure the circuit board
support in the headpiece does not become
loose.
6. Hold the lens glass down while unscrewing the
bezel ring.
7. Remove the lens glass and reflector.
8. Unscrew the 2 off M3 slotted screws.
9. Remove the cable
10. To replace the cable reverse the above
procedure.
Note:- Always ensure that one screw is fixed
into the positive cable terminal or the cable
lock. This ensures the circuit board support
does fall out of position.
WARNING
It is essential that all contacts in the headpiece
are tight, so that no electrical resistance is
incurred which might increase the time
necessary to obtain an efficient charge or
possibly reduce the light output of the lamp.
➢Replacing the reflector
1. Remove the bezel ring and lens.
2. Remove the reflector
3. Remove gasket around reflector.
4. Place the gasket around the new reflector.
The reflector is located by two projections
which fit either side of the main LED; the hole
in the reflector goes over the secondary LED
.
The bezel ring should be screwed down firmly
while holding the glass down with your thumb.
5. Reassemble the lens and bezel ring (see
“Reassembling the bezel ring”).
➢Replacing the circuit board
The LE CC driver circuit board can be replaced in
the event of damage to the switch or electronic
failure of the board. This procedure should be
carried out by a person with experience of
soldering on small circuit boards.
1. Remove the cable as described above
2. De-solder the wire connections to the LED at
the circuit board.
3. Carefully bend the cables away from the
circuit board.
4. Use an open ended spanner 206002 to
remove the nut securing the switch. Remove
the washer and rubber backed sealing
washer.
5. Pull the old circuit board out from the front of
the main housing.
6. Put a 10mm spacer in the positive hole
before replacing the board.
