EP 1 Flash Light Component Maintenance Manual

EF-1 FLASHLIGHT
PART NUMBER
P2-07-0001-100 P2-07-0001-211
P2-07-0001-101 P2-07-0001-214
P2-07-0001-201 P2-07-0001-215
P2-07-0001-205 P2-07-0001-400
P2-07-0001-207
COMPONENT MAINTENANCE MANUAL

WITH
ILLUSTRATED PARTS LIST
Originally issued 3/15/89
NOTICE IS HEREBY GIVEN THAT ALL DATA CONTAINED IN, REVEALED BY, OR SHOWN IN THIS DOCUMENT ARE PROPRIETARY AND BELONGS TO DME CORP., FT.
LAUDERDALE, FLORIDA. IT IS FURNISHED AND RECEIVED IN CONFIDENCE SOLELY FOR INFORMATIONAL PURPOSES OF THE RECIPIENT FOR THE PURPOSES
HEREWITH TRANSMITTED. NONE OF THE INFORMATION CONTAINED HEREIN SHALL BE USED FOR ANY OTHER PURPOSES OR DUPLICATED IN WHOLE OR IN
PART WITHOUT PRIOR AUTHORIZATION OF DME CORP.
DME Corporation
6830 N.W. 16 Terrace
Ft. Lauderdale, FL 33309-1518
TEL: 954.975.2100 25-60-02
FAX: 954.979.3313 3/29/04
CAGE: 55827 Y1-03-0007
DME CORPORATION
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RECORD OF REVISIONS
Rev. No. Issue Date Date Inserted By

Original 3/15/89
2 2/28/94
3 12/01/99
4 6/15/02
5 3/29/04
RETAIN THIS RECORD IN FRONT OF MANUAL OR CHAPTER ON RECEIPT OF REVISIONS, INSERT REVISED PAGES IN
MANUAL, AND ENTER REVISION NUMBER, DATE INSERTED, AND INITIALS.
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THIS PAGE INTENTIONALLY LEFT BLANK
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RECORD OF TEMPORARY REVISIONS
Temporary Page Date

Issue Date Insert Date By By
Rev. No. Number Removed
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SERVICE BULLETIN LIST
Service Bulletin Number Revision Date
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SERVICE INFORMATION LETTERS
SIL Number Revision Date
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LIST OF EFFECTIVE PAGES
Section Title Page Date Section Title Page Date

Check * 5001 3/29/04
Title * 3/29/04
* 5002 3/29/04
Record of Revisions * 1/2 3/29/04

Repair * 6001 3/29/04
* 6002 3/29/04
Record of Temporary * 1/2 3/29/04
Revisions
Assembly * 7001 3/29/04
Service Bulletin List * 1/2 3/29/04 * 7002 3/29/04
* 7003 3/29/04
Service Information * 1/2 3/29/04 * 7004 3/29/04
Letters
Fits & Clearances * 8001 3/29/04

List of Effective Pages * 1/2 3/29/04
* 8002 3/29/04
Table of Contents * 1 3/29/04

Special Tools, Fixtures, * 9001 3/29/04
* 2 3/29/04 & Equipment
* 9002 3/29/04
Introduction * 1 3/29/04
* 2 3/29/04 Illustrated Parts List * 10001 3/29/04
* 3 3/29/04 * 10002 3/29/04
* 4 3/29/04 * 10003 3/29/04
* 10004 3/29/04
Description & Operation * 1 3/29/04 * 10005 3/29/04
* 2 3/29/04 * 10006 3/29/04
* 3 3/29/04 * 10007 3/29/04
* 4 3/29/04 * 10008 3/29/04
* 5 3/29/04
* 6 3/29/04
Testing & Fault Isolation * 1001 3/29/04

* 1002 3/29/04
Automatic Test Require- * 2001 3/29/04

ments
* 2002 3/29/04
Disassembly * 3001 3/29/04

* 3002 3/29/04
Cleaning * 4001 3/29/04

* 4002 3/29/04
* Indicates pages changed, added or deleted by current revision.
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TABLE OF CONTENTS
SUBJECT PAGE
Description and Operation 1

Test and Fault Isolation ...........................................................................................................1001
Automatic Test Requirements..................................................................................................2001
Disassembly ............................................................................................................................3001
Cleaning 4001
Check ......................................................................................................................................5001
Repair ......................................................................................................................................6001
Assembly .................................................................................................................................7001
Fits and Clearances ................................................................................................................8001
Special Tools, Fixtures and Equipment ...................................................................................9001
Illustrated Parts List ...............................................................................................................10001
LIST OF FIGURES
FIGURE FIGURE TITLE PAGE
1 Removal/Insertion of Flashlight (shown without Tamper Shields)......................... 5

7001 Model SE-4 Shield Installation with Reinforcing Straps ...................................7002
7002 Model SE-4 Shield Installation without Reinforcing Straps ..............................7002
IPL 1 Flashlight - Exploded View............................................................................10004
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INTRODUCTION
1. General
This manual contains shop instructions for testing, fault isolation, and repair of the
component listed on the Title Page. Ensure that the part number of the unit is listed on
the Title Page before performing any of these instructions.
The procedures within this manual are to be performed only by qualified shop mechanics
who are familiar with this type of equipment. The contents of this manual have been
verified by the manufacturer by actual performance of disassembly, assembly, and
testing/fault isolation prior to the distribution of printed copies.
2. List of Abbreviations Used
Abbreviation Description
AR as required
EFF effectivity
in inches
kg kilogram
lb pound
mm millimeter
RF reference
3. Sections
A. Front Matter
The front matter of this manual provides component identification and page
update information. The page update information is used to assist the technician
keeping records of data that affect this maintenance manual. This front matter is
divided into separate sections as follows.
(1) Title Page
This page identifies the type of manual, components covered (including

model and part numbers) manufacturer, and publication number.
(2) Record of Revision
This page provides traceability for revisions to the manual. The

publication is kept current throughout the service life by use of revisions.
A revision is issued once the component has been modified.
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(3) Temporary Revisions
This page provides traceability for temporary revisions to the manual. A

temporary revision bridges the gap between permanent revisions and is a rapid
and convenient means of calling attention to critical flaws in procedures or
manufacturing. A temporary revision is issued to prevent injury to personnel and/
or damage to the component.
(4) Service Bulletin/Service Information Letter Lists
This page is provided to list applicable service bulletins and service information
letters affecting the component. A service bulletin or service information letter is
issued when the original design of the component has been changed or modified.
Service bulletins and service information letters, which affect the contents of this
manual, will be superseded by a revision when appropriate.
(5) List of Effective Pages (LOE)
Each page of this manual is listed with a date of issue. Replacement pages from
a revision package will affect this list by changing the date to correspond to the
latest revision. When a revision is issued, an updated list of effective pages will
be included.
(6) Table of Contents (TOC)
The Table of Contents provides page location of primary topic section.
(7) List of Figures (LOF)
The List of figures provides page location of all illustrations.
(8) Introduction
The Introduction of this manual provides the scope of the manual, along with an
explanation of how the manual is configured.
B. MAINTENANCE
(1) DESCRIPTION AND OPERATION (Section 1)
This section provides the description, leading particulars, and operation of the
component.
(2) TESTING AND FAULT ISOLATION (Section 1001)
This section details testing and fault isolation for the component, concentrating
on electrical malfunctions, which can be isolated to components within the
assembly.
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(3) AUTOMATIC TEST REQUIREMENTS (Section 2001)
Not applicable.
(4) DISASSEMBLY (Section 3001)
This section details the disassembly procedures for parts that can be
removed to allow visual inspection of the unit’s components.
(5) CLEANING (Section 4001)
This section details the scheduled cleaning procedures, general cleaning

practices and service intervals which must be performed to maintain the
unit.
(6) CHECK (Section 5001)
This section provides methods of inspecting and maintaining the unit and
individual components to extend service life.
(7) REPAIR (Section 6001)
This section provides a list of all materials required to repair the unit,
along with general repair instructions.
(8) ASSEMBLY (Section 7001)
This section provides assembly procedures for all parts removed in

diassembly (Section 3001). This section also provides storage instructions
for the unit.
(9) FITS AND CLEARANCES (Section 8001)
Not applicable.
(10) SPECIAL TOOLS, FIXTURES, AND EQUIPMENT (Section 9001)
This section contains a list of various special equipment, their description

and source information.
(11) ILLUSTRATED PARTS LIST (Section 10001)
This section contains a complete Illustrated Parts List (IPL) of all spare
parts available for the unit(s). The IPL is preceded by a list of vendor
codes.
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DESCRIPTION AND OPERATION
1.0 General Description
The Model EF-1 Emergency Flashlight System is designed for use in any emergency
standby application demanding a reliable, readily accessible, high-intensity hand-held
flashlight. Special features include automatic activation of the light when removed from
its retention bracket, and a built-in battery/lamp monitoring circuit with a flashing LED
indicator.
Its major components consist of a flashlight body similar in size and shape to a standard
two “D” cell flashlight, a retention bracket designed for mounting on walls or partitions, a
multi-cell battery pack, and an optional anti-tamper shield.
A. Performance
The Model EF-1 Emergency Flashlight can provide approximately four to five
times the beam intensity of a standard two “D” cell flashlight through the use of a
multi-cell battery pack and high-intensity incandescent lamp. A fresh battery pack
provides sufficient energy to enable the unit to remain in the standby mode for an
average of 2.4 years.
B. Battery Pack
The Model #213 battery pack for the system consists of ten alkaline-manganese
primary cells welded in a series-parallel configuration to provide the best
combination of light intensity and capacity needed for a standby emergency
lighting system. The battery pack connects to the flashlight circuit through a
special locking connector. The package configuration of the inter-cell, circuit
connections and battery pack are designed to eliminate the common problems
with flashlights - leakage, corrosion, and poor reliability of contacts.
C. Retention Bracket
The retention bracket is designed for permanent mounting to any solid surface
(wall, partition, or bulkhead) within a static structure or any air/ground/sea
vehicle. The bracket has been tested to provide secure retention of the flashlight
under 16G loading conditions in any attitude, while permitting easy, single-
handed access.
D. Monitoring Circuit
The electronic monitoring circuit incorporated in the flashlight body provides an

indication of battery pack readiness and lamp integrity through a flashing light-
emitting-diode (LED) located on the head of the flashlight. The LED continues
to flash at intervals of 3 - 6 seconds until the battery pack reaches a cut-off
voltage of approximately 6.75 volts or until the lamp filament is broken. Flashing
intervals between 6 and 10 seconds indicates low battery power which will result
in reduced operational life of the flashlight. Battery pack replacement is required
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when the LED flash interval increases to beyond 10 seconds or dims to the point
that it is not easily detected in ambient light conditions. Lamp replacement is
required when the LED stops flashing, the lamp is not functioning, and the battery
pack voltage is greater than 6.75 volts.
E. Materials and Construction
The major components of the Model EF-1 Emergency Flashlight are made from
injection molded, high-impact, flame-retardant ABS material. The lens is stamped
from clear polycarbonate. The reflector is made from metalized, stamped
aluminum for durability and heat resistance. All openings to the interior of the
flashlight body are sealed to ensure water resistance. There are no sharp edges
to cause secondary injury to the user.
F. Lanyard
The Model EF-1 Emergency Flashlight is provided with a breakaway lanyard

coiled in the bottom end cap that allows the unit to be secured to the user in
an emergency situation while leaving both hands free. The lanyard will break
away from the flashlight when unreasonable force is exerted on it. This prevents
secondary injury to the user if the unit is snagged or caught.
G. Optional Shield
The system can be configured using one or two tamper shields (model SE-4)
designed to deter theft and casual use of the flashlight. These tamper shields are
attached to the retention bracket that has tamper shield mounting provisions. The
retention bracket tamper shield mounting provisions allow the tamper shield to be
easily removed during an emergency.
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TECHNICAL DATA
MODEL EF-1 EMERGENCY FLASHLIGHT SYSTEM
MATERIAL (FLASHLIGHT & BRACKET) ....................................... High impact, flame-retardant ABS

material conforming to FAR
25.853(b)
POWER SUPPLY ........................................................................... Multi-cell alkaline manganese

dioxide battery pack. Welded
construction. 7.5 VDC (nominal)
OPERATING TEMPERATURES .................................................... -40°C to 70°C (-40°F to 158°F)
LAMP ........................................................................................... PR-18; 0.55 AMPS AT 7.2 VDC
BATTERY OPERATIONAL LIFE .................................................... 2.4 years nominal on monitor

circuit drain only (fresh battery)
BATTERY SHELF LIFE .................................................................. 4 years maximum at +20°C (69°F).

Operational life is affected by ...
storage time and conditions
PEAK BEAM CANDLEPOWER (with fresh battery)....................... 4700 candlepower at 7.0 VDC
CANDLEPOWER AT END OF BATTERY OPERATIONAL LIFE.... 2000 candlepower at 5.7 VDC
DISCHARGE LIFE (with fresh battery)........................................... 240 minutes (nominal) to 4.5 VDC
(approx. 750 candlepower)
DISCHARGE LIFE AT END OF BATTERY OPERATIONAL LIFE... 30 minutes (nominal) to 4.5 VDC
(approx. 750 candlepower)
BEAM DIAMETER AT 7.62M (25 feet) ........................................... 1.1 meter (3.6 feet) nominal
DIMENSIONS................................................................................. Flashlight length - 20.8 cm

(8.19 in)
Flashlight grip 4.6 cm (1.8 in)
diameter
Bracket length - 25.7 cm (10.1 in)
Bracket width - 7.0 cm (2.76 in)
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2.0 Operation
The flashlight is turned ON automatically when removed from the retention bracket, and
turned OFF automatically when properly returned to the bracket. (See Figure 1).
A. Flashlight Insertion
The flashlight is installed in the retention bracket by first orienting the “fins” on the
flashlight body towards the slotted recesses in the retention bracket, with the LED
facing away from the retention bracket. The lamp end of the flashlight is inserted
into the top portion of the retention bracket and the bottom of the flashlight is
firmly snapped into the retaining clips. As the flashlight body is captured by the
clips, the “fins” on the flashlight body assure proper alignment of the flashlight
body to the retention bracket.
CAUTION: The fins on the flashlight body must be aligned with the recesses on the retention
bracket if the magnetic switch in the flashlight body is to turn the flashlight lamp
off. If the fins on the flashlight are not properly mated with the retention bracket
recesses the lamp will remain on and this condition may not be immediately
apparent. If the lamp remains “ON,” the power unit will be discharged and there
may be localized distortion of the flashlight lens and retention bracket caused by
the lamp heat.
After installation, the LED flash interval should be verified and the tamper
shield(s) installed using the screws provided with the retention bracket (See
Assembly Section, heading 2.0B for tamper shield(s) installation instructions.), as
applicable.
B. Flashlight Removal
If no shield is installed, the flashlight is removed from the retention bracket by

grasping the hand grip of the flashlight body and pulling the bottom end of the
flashlight body firmly out of the retaining clip at the base of the retention bracket.
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If a tamper shield is installed it must first be removed before the flashlight can
be removed from the retention bracket. Two types of tamper shields have
been fielded. The Model SE-2 tamper shield is a rectangular panel with a red
pull handle attached to the shield. The rectangular panel of the Model SE-2
shield covers the entire hand grip area of the flashlight body and is removed by
grasping the red pull handle and pulling the shield from the retention bracket. The
Model SE-2 shield is obsolete and has been replaced by the Model SE-4 tamper
shield. The Model SE-4 shield is a thin strip of plastic material that forms a loop
around the flashlight body but does not cover the hand grip area of the flashlight
body. One or two Model SE-4 shields can be installed on the retention bracket
and each shield is removed by grasping the loop of plastic material and pulling
the shield from the retention bracket. Alternatively, the exposed hand grip can be
grasped and the bottom of the flashlight body pulled from the retaining clip at the
base on the retention bracket until the bottom tamper shield separates from the
retention bracket. The top tamper shield will separate as the flashlight body is
pulled further away from the retention bracket.
LED
Fins
Retaining
Clip
Figure 1. Removal/Insertion of Flashlight (shown without Tamper Shields)
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TESTING AND FAULT ISOLATION
1.0 GENERAL
The following chart is provided to enhance the ability of field maintenance personnel to identify
and react to certain indications that can exist in the field. Maintenance personnel should be
able to isolate and identify the malfunctioning element of the system by checking the function
of the suspected element with parts that are known to be operating properly. If the fault can not
be isolated using these methods, then the entire system should be returned to the factory for
further evaluation.
Table 1000-1
SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION
LED is not flashing 1. Battery is depleted 1. Replace battery at next

opportunity
2. Lamp is burned out 2. Replace lamp
3. LED is inoperative 3. Return unit for service
4. Defective Bracket. 4. Return entire system to

Flashlight did not turn off factory for check
when installed in bracket
LED is flashing at interval of 10 1. Battery is at or beyond cut- 1. Replace battery within 10

seconds or greater off point days
Flashlight does not turn on when 1. Unauthorized use of 1. Replace battery

removed from bracket flashlight. Battery depleted
2. Lamp is burned out 2. Replace lamp
3. Battery pack not installed 3. Check battery and

or connected connection
4. Broken contacts in 4. Return flashlight for

flashlight body service
5. Defective bracket. 5. Return entire system to

Flashlight did not turn off factory for check
when installed in bracket
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AUTOMATIC TEST REQUIREMENTS
There are no automatic test requirements. Refer to the Testing and Fault Isolation section in this
manual for testing procedures.
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DISASSEMBLY
1.0 General
See Testing and Fault Isolation to establish the condition of the component or the
possible cause of its malfunction. This is to determine the extent of disassembly
required without complete disassembly and rebuilding of the component. Refer to the
Illustrated Parts List (IPL) for disassembly and assembly relationships. The number in
parentheses after the noun name of a part refers to the item number in the IPL Figure.
2.0 Flashlight Disassembly (Ref. IPL Figure 1)
A. Flashlight Removal from Bracket Assembly
1. Remove two or four screws (15) from bracket assembly (13) and lift off
(one or two) tamper shields (16) respectively, if installed.
2. Pull flashlight assembly (17) out of bracket assembly (13).
B. Flashlight Disassembly
1. Remove bottom end cap (3) by rotating it counterclockwise and then

remove bottom cap O-ring (7) from case assembly (1).
2. Disconnect the battery connector and slide battery (12) out of case
assembly (1).
3. Remove top end cap (2) by rotating it counterclockwise and then remove
top cap O-ring seal (6) from case assembly (1).
4. Remove reflector/lamp retainer (9) and lamp (11) from reflector (8).
5. Lift reflector (8), lens (4), and lens seal (5) from top end cap (2).
6. Remove lanyard (10) from bottom end cap (3) by removing the knot in
lanyard and pulling it out of bottom end cap (3).
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CLEANING
1.0 General Cleaning
When required, the components of the Model EF-1 system should be cleaned only with a damp,
soft rag, or if necessary, a mild detergent solution. Under no circumstances should the plastic
portions of the system, including the lens, be cleaned with solvents, abrasive compounds or
chemical cleaning solutions. The reflector should be cleaned only with a soft, dry cloth.
2.0 Storage
The Model EF-1 system and its components should be stored in dry, ventilated areas but not
in direct sunlight. The battery pack should be stored under controlled temperature conditions
of 20°C ±3°C (68°F ±5°F). Storage at lower temperatures is beneficial since battery loss due to
aging is retarded. The battery pack should be removed from the flashlight if the aircraft is being
stored for more than 10 days under desert conditions.
3.0 Handling
The Model EF-1 system, despite its rugged construction, houses some delicate components.
Care should be taken not to drop or abuse the flashlight
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CHECK
1.0 General
When left in the standby mode with no unauthorized or casual use, the Model EF-1
Emergency Flashlight will remain in a constant state of readiness for an average of 2.4
years before maintenance is required. The built-in monitoring circuit with the flashing
LED indicator provides a ready method of checking the system at regular intervals.
2.0 Monitoring Circuit Operation
The flashlight is designed to have sufficient battery capacity reserves to ensure its utility
up to ten days after the LED monitoring circuit has either turned off or its flash interval
exceeds ten seconds. When left in the standby mode, the LED goes from: a bright
flash at approximately five second intervals, to a dim flash at approximately ten second
intervals, to an OFF condition over 2.4 years.
3.0 Inspection/Check Intervals
Check the LED function two to four times a month. If the monitoring circuit flash is dim or
the interval exceeds ten seconds, replacement of the battery pack at the next convenient
opportunity (not to exceed ten days) is recommended.
4.0 Inspection
A. Check that the bracket is mounted in such a manner that it is readily accessible
and visible to designated users.
B. Check that the flashlight can be easily removed and reinserted in the bracket.
Removal of the flashlight may require removal of the tamper shield, if installed.
C. Remove the flashlight bottom end cap and ensure that the battery pack is
installed, connected, and the lamp is functional.
D. Check that the flashlight is properly installed in the bracket with the flashing LED
oriented outward, away from the bracket.
E. Ensure the flashlight is off when installed in the bracket. If the unit is on, light will
be visible between the flashlight head and the bracket; if the light is on, refer to
the Test and Fault Isolation section of this manual.
F. Ensure the LED is flashing at an interval of approximately five seconds and that it
can easily been seen in normal cabin lighting conditions.
G. If applicable, ensure the tamper shield is mounted and secured properly.
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5.0 In-service Inspection
A. If applicable, ensure the tamper shield is mounted and secured properly.
B. Ensure the LED is flashing at an interval of approximate five seconds, and that it
can be seen easily in normal lighting conditions.
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REPAIR
1.0 General
Disassembly and repair of the Model EF-1 Flashlight System is limited to those
procedures which allow replacement of seal, lens, end caps, reflector, lamp, and battery
pack. Field repairs of the LED monitoring circuit are not authorized and will void factory
warranty. Disassembly instructions are provided below, but should not be performed
unless required.
2.0 Lamp Replacement
A. Unscrew top end cap from flashlight body. Remove and replace O-ring seal.
B. Remove reflector/lamp assembly. Remove and replace lens and/or lens seal if
required.
C. Unscrew plastic lamp retainer from reflector.
D. Remove and replace lamp.
E. Replace retainer. Install reflector assembly in the top end cap and screw the
assembly back onto the flashlight.
3.0 Battery Pack Replacement
A. Unscrew bottom end cap from flashlight body. Remove and replace O-ring seal,
if required.
B. Disconnect battery/flashlight connector.
C. Remove and replace battery pack.
D. Mate flashlight and battery connections. Note that the connector locking feature
allows the connection to be made only one way, thus ensuring that polarity is
observed.
E. Replace bottom end cap.
F. Place flashlight back into the bracket to turn-off the flashlight. Reinstall tamper
shield, if installed.
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ASSEMBLY
1.0 Flashlight Bracket Installation
The retention bracket is designed for two point mounting to any secure surface such
as a wall, partition, bulkhead, or larger items of equipment. The bracket is designed to
accept attachment hardware with a counter-sunk head in a No. 10 (0.190 DIA) size. The
mounting method will vary with the surface to which the unit will be mounted.
The bracket should be mounted in such a manner and position that the system is readily
accessible and available to individuals in an emergency situation. Special consideration
should be given in the mounting to the dynamics of the flashlight removal and insertion
procedure so that these operations can be easily accomplished, unencumbered by
awkward positioning or interference with other structures and appliances.
The following suggestions are given to guide the selection of installation hardware:
MOUNTING STRUCTURE DESCRIPTION.. SUGGESTED MOUNTING

HARDWARE
Wall board, sheet rock................................. Plastic or metal toggle insert
Masonry....................................................... Lead inserts
Sheet Metal ................................................. Sheet metal screws
Honeycomb panel ....................................... Potted inserts and screws
Wood Panel................................................. Metal “butterfly” inserts
Figures 7001 and 7002 depict the installation of the Model SE-4 Tamper Shield for
the EF-1 retention brackets with the old reinforcing strips (Figure 7001) and the EF-1
retention bracket without the reinforcing strips (Figure 7002).
Ensure that the printing on the shield is properly oriented. Secure the tabs of the shield
to the threaded inserts closest to the top of the flashlight using the reinforcing strips and
the four screws shown in Figure 7001 or using two of the screws without the reinforcing
strips as shown in Figure 7002.
If two shields are to be installed, ensure that the printing on the shields is properly
oriented. Secure the tabs on one side of each shield to the threaded inserts on one side
of the retention bracket using one retaining strip and two screws shown in Figure 7001 or
the two screws without the retaining strips as show in Figure 7002. Repeat the process
for the other side of the retention bracket.
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SE-4 Tamper Shield Screws

(4 req’d.)
Reinforcing Strip
NOTE: A second SE-4 Tamper Shield can be installed at

the lower ends of the
reinforcing strips
Figure 7001. Model SE-4 Shield Installation With Reinforcing Strips
SE-4 Tamper Shield

Screws
(2 or 4 req’d.)
NOTE: A second SE-4 Tamper Shield can be installed at

the lower end
Figure 7002. Model SE-4 Shield Installation Without Reinforcing Strips
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2.0 Assembly Procedures (Ref. IPL Figure 1)
A. Flashlight Assembly
1. Attach lanyard (10) to bottom end cap (3) by threading it through the hole
in the bottom end cap (3) and then tieing a knot in the end of the lanyard
(10).
2. Insert lens seal (5), lens (4), and reflector (8) into top end cap (2).
3. Insert lamp (11) and reflector/lamp retainer (9) into reflector.
CAUTION: Ensure that the center lamp and reflector contacts are not shorted
when re-installing the reflector assembly. If shorted, the monitoring circuit can be
damaged.
4. Place top cap O-ring seal (6) and top end cap (2) onto case assembly (1).
5. Slide battery (12) into case (1) and connect battery (12) to connector in
flashlight.
6. Install bottom cap O-ring (7) and bottom end cap onto case assembly (1).
B. Flashlight Installation Into Bracket Assembly
1. Insert flashlight assembly (17) into bracket assembly (13).
2. Place tamper shield (16) over bracket assembly and install two or four
screws (15) into bracket assembly (13), if used.
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FITS AND CLEARANCES
(Not Applicable)
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SPECIAL TOOLS, FIXTURES & EQUIPMENT
No special tooling, fixtures, or equipment are required for maintenance, assembly/

disassembly or repair of the Model EF-1 system.
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ILLUSTRATED PARTS LIST
1.0 General
A. The Illustrated Parts List (IPL) is a breakdown of assemblies, subassemblies,

and detailed parts of the unit indicated on the title page. Index numbers on the
exploded view illustration normally indicate the general order of disassembly.
Component parts are indented to show subordinate relationship to the complete
assembly. The IPL also contains a Numerical Index and a Detailed Parts List,
which consist of illustrations and a breakdown of component part numbers and
names.
B. Use of the IPL:
(1) When Part Number (P/N) is known:
Locate the P/N in the Numerical Index List. The Figure and item
numbers listed in the column to the right of the P/N will show where the
part appears. Go to the IPL Figure and locate the item number. The
corresponding item number in accompanying parts list will give P/N,
description, assembly relationship, and quantity required for the particular
application.
(2) When P/N is not known:
Look through the IPL Figures and find the assembly for which the
component is used as a part; or, look through the IPL Figures and identify
the part by its appearance. Note the item number shown on the Figure.
Check the corresponding item number accompanying the IPL to find the
P/N, description, and quantity required for the application.
2.0 Numerical Index
A. The purpose of the Numerical Index is to enable the user to locate any part by
the P/N. The Figure(s) and item number(s) in which the part is used are listed,
as well as the total quantity required in the particular Figure. Parts are listed in
alphanumeric order (ascending letters followed by ascending numbers).
B. The sequence of each numbered part begins at the extreme left-hand position
and continues left-to-right (one position at a time) until the location of each
part number is determined. Letters “A” through “Z” are followed by numbers “0”
through “9.” In the second column and in all succeeding positions, the order of
procedure is: first, a blank space (blank column) or a dash “-”; if present, the
letters “A” through “Z”; then, numbers “0” through “9.” The letter “O” is treated as
the number “0.”
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3.0 Detailed Parts List
The Detailed Parts List provides the user with a numerical listing of the parts and
information as shown on the accompanying Figure(s). Part designations are as follows:
A. Item Numbering
Item numbers on the illustrations accompanying each parts list correspond to the
FIG. ITEM column of the Parts List. The FIG. ITEM of the Parts List is used with
the accompanying Figure to show the location of the individual parts in relation
to assembly or subassembly of any equipment. The number at the start of the
Detailed Parts List indicates the IPL Figure on which it is used. Any item number
after the first ITEM number, prefixed with a hyphen (-), indicates the part is not
illustrated on the Figure.
B. Part Numbering and Identification
The PART NUMBER and NOMENCLATURE columns of the Parts List are used
to identify each part. Component parts are indented in the Nomenclature column
to show the subordinate relationship to the complete assembly or subassembly.
When an equipment designator has been assigned to any electrical component,
the designator will be shown in the NOMENCLATURE column. The vendor code
number is shown in parentheses, following the part description, and is prefixed
with the capital letter “V.” In the NOMENCLATURE column, ATTACHING
PARTS indicates that items following are used for attachment. Asterisks (*)
indicate the end of the ATTACHING PARTS segment.
The standard P/Ns are prefixed as follows:
AN — Army-Navy Standard
MIL — Military Specification
MS — Military Standard
NAS — National Aerospace Standard
C. Effectivity
If variations exist between similar assemblies or subassemblies, and only one

Figure is illustrated, the differences are indicated by an effectivity code listed
in the EFF CODE column; this column uses the capital letters A, B, C, etc. The
lettered EFF CODE refers to the first indented item(s) similarly coded for the
particular Figure of the IPL. When the EFF CODE column is left blank, the parts
listed are common to all assemblies.
D. Units Per Assembly
The UNIT PER ASSY column of the IPL indicates the quantity of each part
required for the next higher assembly. When RF appears in this column, the
part item is listed for reference purposes only, and the quantity will appear on
another drawing. When the quantity is shown as NP, the item is nonprocurable
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and is used for reference only. All NP items in the electrical IPLs are located in
the Description and Operation section of this manual. The quantity listed as A/R
indicates a bulk item material; quantity is “as required.”
4.0 Vendor List
As referenced above, the code number prefixed by a “V” in the Nomenclature column
of the Detailed Parts List represents the assigned Commercial and Government
Entity (CAGE) Code Numbers, formerly referred to as the Federal Supply Code for
Manufacturers (FSCM) Code Numbers. The following is a list of manufacturers’ names
and addresses (sorted by their respective CAGE codes) that are used in this IPL:
Cage Name & Address

Number
V55827 DME Corporation, 6830 NW 16th Terrace, Ft. Lauderdale. FL 33309-1518
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5
4
11
15
17
16
12
10
Figure IPL1. Flashlight - Exploded View
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Fig. Part Number Airline Nomenclature Eff. Units per

Item Part Code Assy.
Number
1-17 P7-02-0001-100 Flashlight System, Beige, w/ Illumination Port, w/o A
Tamper Shield, Bracket w/o Tamper Shield Provision,
Airline Specific (V55827)
17 P2-07-0001-101 Flashlight System, Beige, w/o Illumination Port, w/o B

Tamper Shield, Bracket w/o Tamper Shield Provision
(V55827)
17 P2-07-0001-201 Flashlight System, Beige, w/o Illumination Port, w/o C

Tamper Shield, Bracket w/ Tamper Shield Provision
(V55827)
17 P2-07-0001-205 Flashlight System, Beige, w/ Illumination Port, w/ D

Tamper Shield, Bracket w/ Tamper Shield Provision,
17 P2-07-0001-207 Flashlight System, Beige, w/o Illumination Port, w/ E

17 P2-07-0001-211 Flashlight System, Beige, w/o Illumination Port, w/ F

-17 P2-07-0001-214 Flashlight System, Beige, w/o Illumination Port, w/ G

Tamper Shield, Bracket w/ Tamper Shield Provision
(V55827)
-17 P2-07-0001-215 Flashlight System, Gray, w/o Illumination Port, w/ H

17 P2-07-0001-400 Flashlight System, Gray, w/o Illumination Port, w/ I

20 P2-07-0003-001 Flashlight Assembly, Beige (V55827) B,C,G 1
20 P2-07-0003-005 Flashlight Assembly, Beige (V55827) D 1
20 P2-07-0003-007 Flashlight Assembly, Beige (V55827) E 1
20 P2-07-0003-011 Flashlight Assembly, Beige (V55827) F 1
20 P2-07-0003-100 Flashlight Assembly, Beige (V55827) A 1
20 P2-07-0003-215 Flashlight Assembly, Gray (V55827) H 1
20 P2-07-0003-400 Flashlight Assembly, Gray (V55827) I 1
1 A3-06-0163 Case Assembly, Beige (V55827) A, B, C, 1

D, E, F, G
1 A3-06-0163-400 Case Assembly, Gray (V55827) I 1
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Number
1 A3-06-0163-200 Case Assembly, Gray (V55827) H 1
2 A1-18-0068-200 Top End Cap, Gray (V55827) H 1
2 A1-18-0068-300 Top End Cap, Beige(V55827) A, B. C, 1

D, E, F, G
2 A1-18-0068-400 Top End Cap, Gray, Airline Specific (V55827) I 1
3 A1-18-0067-200 Bottom End Cap, Gray (V55827) H 1
3 A1-18-0067-300 Bottom End Cap, Beige, Airline Specific (V55827) A. B, C, 1

D, E, F, G
3 A1-18-0067-400 Bottom End Cap, Gray, Airline Specific (V55827) I 1
4 A1-18-0010 Lens (V55827) ALL 1
5 A1-25-0002 Lens Seal (V55827) ALL 1
6 A1-25-0015 Top End Cap Seal (V55827) ALL 1
7 A1-25-0014 Bottom End Cap Seal (V55827) ALL 1
8 A1-17-0031 Reflector (V55827) ALL 1
9 A1-18-0015 Lamp Retainer (V55827) ALL 1
10 A2-18-0001-003 Lanyard (V55827) ALL 1
11 A1-14-0001-002 Lamp (V55827) ALL 1
12 P4-01-0021 Battery Pack, Model 213 (V55827) * ALL 1
13 P2-07-0004-002 Bracket Assembly, Beige, w/ Illumination Port, w/ D 1

Tamper Shield Provision (V55827)
13 P2-07-0004-100 Bracket Assembly, Beige, w/ Illumination Port, w/o A 1

13 P2-07-0004-101 Bracket Assembly, Beige, w/o Illumination Port, w/o B 1

13 P2-07-0004-201 Bracket Assembly, Beige, w/o Illumination Port, w/ C,E,F,G 1

13 P2-07-0004-215 Bracket Assembly, Gray, w/o Illumination Port, w/ H 1

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Number
Bracket Assembly, Gray Airline Specific, w/o
13 P2-07-0004-400 Illumination Port, w/ Tamper Shield Provision I 1
(V55827)
15 MS51957-13 Tamper Shield Machine Screw, PNH, 4-40 x 0.25 C, D, E, 4
F, G, H, I
16 A1-18-1030 Tamper Shield, Model SE-4 (V55827) * D, E, F, 1

G, H, I
14 Y1-03-0007 Manual, CMM, Model EF-1 (V55827) ALL 1
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EP 1 Flash Light Component Maintenance Manual

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EP 1 Flash Light Component Maintenance Manual

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EF-1 FLASHLIGHT

COMPONENT MAINTENANCE MANUAL

Originally issued 3/15/89

Rev. No. Issue Date Date Inserted By

THIS PAGE INTENTIONALLY LEFT BLANK

RECORD OF TEMPORARY REVISIONS

Temporary Page Date

THIS PAGE INTENTIONALLY LEFT BLANK

SERVICE BULLETIN LIST

Service Bulletin Number Revision Date

THIS PAGE INTENTIONALLY LEFT BLANK

SERVICE INFORMATION LETTERS

SIL Number Revision Date

THIS PAGE INTENTIONALLY LEFT BLANK

LIST OF EFFECTIVE PAGES

Section Title Page Date Section Title Page Date

Record of Revisions * 1/2 3/29/04

Fits & Clearances * 8001 3/29/04

Table of Contents * 1 3/29/04

Testing & Fault Isolation * 1001 3/29/04

Automatic Test Require- * 2001 3/29/04

Disassembly * 3001 3/29/04

Cleaning * 4001 3/29/04

* Indicates pages changed, added or deleted by current revision.

THIS PAGE INTENTIONALLY LEFT BLANK

Description and Operation 1

FIGURE FIGURE TITLE PAGE

1 Removal/Insertion of Flashlight (shown without Tamper Shields)......................... 5

THIS PAGE INTENTIONALLY LEFT BLANK

2. List of Abbreviations Used

(1) Title Page

This page identifies the type of manual, components covered (including

(2) Record of Revision

This page provides traceability for revisions to the manual. The

(3) Temporary Revisions

This page provides traceability for temporary revisions to the manual. A

(4) Service Bulletin/Service Information Letter Lists

(5) List of Effective Pages (LOE)

(6) Table of Contents (TOC)

The Table of Contents provides page location of primary topic section.

(7) List of Figures (LOF)

The List of figures provides page location of all illustrations.

(1) DESCRIPTION AND OPERATION (Section 1)

(2) TESTING AND FAULT ISOLATION (Section 1001)

(3) AUTOMATIC TEST REQUIREMENTS (Section 2001)

(4) DISASSEMBLY (Section 3001)

(5) CLEANING (Section 4001)

This section details the scheduled cleaning procedures, general cleaning

(6) CHECK (Section 5001)

(7) REPAIR (Section 6001)

(8) ASSEMBLY (Section 7001)

This section provides assembly procedures for all parts removed in

(9) FITS AND CLEARANCES (Section 8001)

(10) SPECIAL TOOLS, FIXTURES, AND EQUIPMENT (Section 9001)

This section contains a list of various special equipment, their description

(11) ILLUSTRATED PARTS LIST (Section 10001)

THIS PAGE INTENTIONALLY LEFT BLANK

DESCRIPTION AND OPERATION

1.0 General Description

The electronic monitoring circuit incorporated in the flashlight body provides an

E. Materials and Construction

The Model EF-1 Emergency Flashlight is provided with a breakaway lanyard

MATERIAL (FLASHLIGHT & BRACKET) ....................................... High impact, flame-retardant ABS