KSE-Lights (UK) LtdHall Farm

Sywell AerodromeSywell

Northampton NN6 0BNTel: 01604 643374

Fax: 01604 670332 sales@kse-lightsuk.comwww.kse-lightsuk.com

Lamps or charging devices may only be opened and repaired by specialists that have been authorised & approved by KSE-LIGHTS (UK)! Unauthorised acccess will invalidate both the certification and warranty cover.

This repair manual is therefore, exclusively for use by KSE authorised & approved repair specialists only.

• Warning!

Repair Manual for LED caplamps (Models KS-7600-M, KS-7610-M, KS-7700-M, KS-7710-M, KS-7700H2-M)

For the following repair procedures the equipment mentioned below (which is included in the approved KSE Repair Kit); is required:

- soldering station (with accessories) - special cordless screwdriver with Torx-inserts - side cutters for electrician - screwdriver Torx T6 - Phillips screwdriver - silicone - electrical engraver

It is strongly recommended to use only the tools mentioned above to ensure a perfect repair!

I. Work process for dismantling the caplamp

Step 1: Opening of lamp - Stab with the bit of the cordless screwdriver through the silicone protection of the 4 openings on the back of the lamp and remove the screws.

- Now you can separate the frontal ring from the rest of the casing.

Step 2: Removing the circuit board and reflector from the casing

a) Remove the two screws that are located on the right and left side of the circuit board.

b) Lift the base of the circuit board slightly and simultaneously push the switch downwards by means of a screw driver. Now the circuit board can be removed from the casing by pulling it forwards.

Step 3: Removing the leads of the battery and the charging connection

- Remove silicone from the soldered points of the battery connection.- Now unsolder the battery leads from the circuit board.- CAUTION: After soldering off the battery; leads must be insulated!- Remove the leads of the charging connection on the other side of the circuit board in exactly the same manner.

Step 4: Removing the battery from the casing of the lamp

- Remove the silicone that laterally attaches the battery in the casing.(Caution: Do not damage the battery when doing this!)

- Now the battery can be removed from the casing.

II. Changing parts

1. Changing the frontal ring

- Carry out step 1 of dismantling.

- Place a new seal in the new frontal ring. If the old ring is used after a repair, a new seal must always be used.

- Fix the frontal ring to the casing of the lamp with screws and seal the screws with silicone.

2. Changing of power switch- Carry out steps 1-3 of dismantling.- Separate the power switch from the circuit board with the side cutter.- Solder the remaining parts of the switch bases off and remove the remains of solder from the holes on the circuit board with solder pump.- Place a new power switch in the holes on the circuit board, solder it on and remove the excess tails.- For re-assembly carry out steps 1-3 of dismantling in reverse order.

- When re-assembling the circuit board, guide the power switch by means of a screwdriver until it enganges correctly into its fitting in the casing.

3. Changing of battery

- Carry out steps 1-4 of dismantling.

- Place the new battery in the casing, apply new insulation material and secure the battery on both sides in the casing with silicone.

- For further re-assembly carry out steps 1-3 of dismantling; in reverse order.

4. Changing the unit of circuit board and reflector

- Carry out steps 1-3 of dismantling.

- Take a new circuit board and carry out steps 1-3 of dismantling; in reverse order.

CAUTION: After replacing the circuit board and reflector, fix and insulate solder points and screws with silicone!

Note: If the original frontal ring is retained, always remove the old seal, clean the groove for sealing ring and replace a new rubber seal!

5. Changing the back of the casing

Changing the back of the casing is recommended if:a) casing is defectiveb) charging connection is defectivec) rubber seal of power switch is defective.

- Carry out steps 1-4 of dismantling.

- Use the electrical engraver to engrave the serial number in the new casing.

-Reassembly of the new casing is carried out in reverse order.