Air Lite 1E Led Flashlight System: Component Maintenance Manual With Illustrated Parts List

Astronics DME
6830 NW 16th Terrace,

Ft. Lauderdale, Florida, 33309
Phone: +1 (954) 975 2100 Fax: +1 (954) 979 3313
COMPONENT MAINTENANCE MANUAL WITH

ILLUSTRATED PARTS LIST
AIR LITE® 1E LED FLASHLIGHT SYSTEM
PART No.: P2-07-0015-001 [mfr?]
P2-07-0015-002 [mfr?]
P2-07-0015-003 [mfr?]
P2-07-0015-004 [mfr?]
P2-07-0015-005 [mfr?]
NOTICE IS HEREBY GIVEN THAT ALL DATA CONTAINED IN, REVEALED BY, OR SHOWN IN THIS DOCUMENT ARE
PROPRIETARY AND BELONG TO ASTRONICS DME, 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 ASTRONICS DME. EXPORT OF THIS
TECHNOLOGY IS CONTROLLED UNDER THE UNITED STATES EXPORT ADMINISTRATION REGULATIONS (EAR) (15 CFR 730-
774). AN EXPORT LICENSE MAY BE REQUIRED BEFORE IT IS USED FOR DEVELOPMENT, PRODUCTION OR USE BY
FOREIGN PERSONS FROM SPECIFIC COUNTRIES. THE CONTROLLER OF THIS DATA HAS THE INDIVIDUAL
RESPONSIBILITY TO ABIDE BY ALL EXPORT LAWS. LICENSE EXCEPTION: NLR ECCN: 9E991
PRINTED IN UNITED
STATES OF AMERICA PUB NO. Y3-01-0147
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COMPONENT MAINTENANCE MANUAL
DOCUMENT No. Y3-01-0147
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THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE.
RECORD OF REVISIONS
Revision Issue Date By Revision Issue Date By

Number Date Inserted Number Date Inserted
RECORD OF REVISIONS
1 Aug 10/07
2 Sep 25/08
3 Feb 03/09
4 May 20/09
5 Mar 09/12
6 Dec 10/13
7 Jul 15/16
8 Dec 14/17
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RECORD OF TEMPORARY REVISIONS
Temporary Issue Date Date Inserted / Date Removed / Date

Revision Inserted By Removed By Incorporated
Number
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SERVICE BULLETIN LIST
Service Bulletin / Issue Date Date Title

Revision Number Incorporated
or No Effect
XX-XXXX N/A SB Title N/A R

e
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1
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LIST OF EFFECTIVE PAGES
SUBJECT PAGE DATE SUBJECT PAGE DATE

LIST OF EFFECTIVE PAGES
TITLE PAGE T-1 Dec 14/17 5002 Blank

T-2 Blank
REPAIR 6001 Dec 14/17
RECORD OF REVISIONS RR-1 Dec 14/17 6002 Dec 14/17
RR-2 Blank
ASSEMBLY 7001 Dec 14/17
RECORD OF TEMPORARY 7002 Blank
REVISIONS RTR-1 Dec 14/17
RTR-2 Blank REMOVAL 12001 Dec 14/17
12002 Blank
SERVICE BULLETIN LIST SBL-1 Dec 14/17
SBL-2 Blank INSTALLATION 13001 Dec 14/17
13002 Dec 14/17
LIST OF EFFECTIVE PAGES LEP-1 Dec 14/17 13003 Dec 14/17
LEP-2 Blank 13004 Blank
TABLE OF CONTENTS TOC-1 Dec 14/17 STORAGE 15001 Dec 14/17

TOC-2 Dec 14/17 15002 Blank
TOC-3 Dec 14/17
TOC-4 Blank ILLUSTRATED PARTS LIST 10001 Dec 14/17
10002 Dec 14/17
INTRODUCTION INTRO-1 Dec 14/17 10003 Dec 14/17
INTRO-2 Dec 14/17 10004 Dec 14/17
INTRO-3 Dec 14/17 10005 Dec 14/17
INTRO-4 Dec 14/17 10006 Dec 14/17
10007 Dec 14/17
DESCRIPTION AND OPERATION 1 Dec 14/17 10008 Dec 14/17
2 Dec 14/17 10009 Dec 14/17
3 Dec 14/17 10010 Dec 14/17
4 Dec 14/17 10011 Dec 14/17
5 Dec 14/17 10012 Dec 14/17
6 Dec 14/17 10013 Dec 14/17
7 Dec 14/17 10014 Dec 14/17
8 Dec 14/17 10015 Dec 14/17
10016 Blank
TESTING AND FAULT FINDING 1001 Dec 14/17
1002 Dec 14/17
1003 Dec 14/17
1004 Blank
DISASSEMBLY 3001 Dec 14/17

3002 Blank
CLEANING 4001 Dec 14/17

4002 Blank
INSPECTION/CHECK 5001 Dec 14/17
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TABLE OF CONTENTS
Page
INTRODUCTION
1. General INTRO-1
A. Instructions INTRO-1
2. List of Abbreviations Used INTRO-1

A. The acronyms and abbreviations used in this manual are provided in Table 1 of INTRO-1
3. Manual Sections INTRO-2

A. Front Matter INTRO-2
B. Maintenance INTRO-3
DESCRIPTION AND OPERATION

1. General Description 1
A. Performance 2
B. Battery 2
C. Flashlight Mounting Bracket 2
D. Monitoring Circuit 2
E. Optical Assembly 3
F. Materials and Construction 3
G. Lanyard 3
H. Tamper Shield (Optional) 3
2. Technical Data 4
3. Operation 5
4. Handling 8
TESTING AND FAULT FINDING

1. General 1001
A. This section contains specific tests and procedures required to determine the condition
of the Air Lite 1E LED flashlight system, and return it to service. 1001
2. Testing 1001
3. Fault Isolation 1001
DISASSEMBLY
1. General 3001
2. Air Lite 1E LED Flashlight System Disassembly (See IPL Figures 1, 1A, 1B, and 1C) 3001
CLEANING
1. General Cleaning 4001
A. Cleaning Priority 4001
INSPECTION/CHECK
1. General 5001
A. Checks 5001
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TABLE OF CONTENTS (CONTINUED)

Page
REPAIR
1. General 6001
2. Repair Procedures (See IPL Figures 1, 1A, 1B, and 1C) 6001
ASSEMBLY
1. General 7001
2. Assembling the Handlight (Battery Pack Installation) (See IPL Figures 1, 1A, 1B, and 1C) 7001
REMOVAL
1. General 12001
INSTALLATION
1. Handlight to Bracket 13001
2. Bracket to Aircraft 13003
STORAGE
1. General 15001

1. Function 10001
A. General 10001
2. To Use this Section 10001

A. General 10001
B. Fig/Item Column 10001
C. Part Number Column 10001
D. Airline Part Number Column 10002
E. Nomenclature Column 10002
F. Effectivity Column 10004
G. Units per Assembly Column 10004
LIST OF ILLUSTRATIONS
Figure Page
1 Air Lite® 1E LED Flashlight System P2-07-0015-001 10007

1A Air Lite® 1E LED Flashlight Systems P2-07-0015-002 through -005 10009
1B HANDLIGHT ASSEMBLY P2-07-002-001 10012
1C HANDLIGHT ASSEMBLY P2-07-0020-002 AND P2-07-0020-003(P2-07-0020-002
USED ON P2-07-0015-002 AND P2-07-0015-003)(P2-07-0020-003 USED ON P2-07-
0015-004 AND P2-07-0015-005) 10014
LIST OF TABLES
Table Page
1. List of Abbreviations and Acronyms INTRO 1
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LIST OF TABLES (CONTINUED)

Table Page
4001. Cleaning Consumables 4001

5001. Check of the Air Lite 1E LED Flashlight System 5001
7001. Handlight Assembly Consumables 7001
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INTRODUCTION
1.
TASK1 General
A. Instructions
NOTE: During the course of this manual, Air LiteW 1E LED flashlight system (Air Lite® 1E LED
flashlight system) may be written with or without the registration mark. All rights reserved.
(1) This manual contains shop instructions for testing, fault isolation, cleaning, check, repair,
disassembly, and assembly of the Air Lite® 1E LED flashlight system part number (PN) P2-
07-0015-001, -002, -003, -004, and -005 manufactured by Astronics DME, Ft. Lauderdale,
Florida.
The procedures in this manual must be performed by qualified shop personnel who are
familiar with the Air Lite 1E LED flashlight system. This manual may use MTOSS.
Dates of Shop Verification by Actual Performance:
• Testing and Fault Isolation Verified Jan 15/09-
• Disassembly Verified Jan 15/09
• Assembly Verified Jan 15/09
• Engineering Technical Review Completed Jan 15/09
2.
TASK2 List of Abbreviations Used
A. The acronyms and abbreviations used in this manual are provided in Table 1 of 2.A.
List of Abbreviations and Acronyms
Table 1. List of Abbreviations and Acronyms
Abbreviation/Acronym Definition
ATA Air Transport Association
ABS Acrylontrile Butadiene Styrene
Cd Candela
ESD Electrostatic Discharge
FC Foot Candles
IEC International Electro-Technical

Commission
LED Light Emitting Diode
MTOSS Maintenance Task Oriented Support

System
PN Part Number
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3.
TASK3 Manual Sections
A. Front Matter
NOTE: The front matter in this manual provides component identification as well as listing
changed pages, service bulletins, and service information letters that affect the support of
the Air LiteW 1E LED flashlight system. The front matter is divided into the following
separate sections.
(1) TITLE PAGE
This page identifies the type of manual, the component covered by the manual, the
component part number and model number (if applicable), the publication date, the latest
revision number and revision date, the manufacturer, and the manual ATA number.
(2) RECORD OF REVISIONS
The information in this manual is kept current by revisions issued whenever the component
or the instructions pertaining to it have been modified. The record of revision page remains in
the manual and is updated by the person incorporating the revision pages in the manual.
This provides traceability for the revisions.
(3) RECORD OF TEMPORARY REVISIONS
If it is necessary to provide changed or additional information before a permanent revision

can be completed a temporary revision is issued. The changed pages are added to the
manual in the same manner as a permanent revision, and the person incorporating the
temporary revision updates the Record of Temporary Revisions page. When the permanent
revision that includes the information provided in the temporary revision is incorporated, the
temporary revision pages are removed, and the person inserting the permanent revision
pages updates both the Record of Revisions page and the Record of Temporary Revisions
page.
(4) SERVICE BULLETIN LIST
When the information from a service bulletin has been incorporated into the manual by a
permanent revision, the service bulletin list page includes the following information:
•The service bulletin number

•The service bulletin or service bulletin revision publication date
•The date of the permanent revision that incorporates the service bulletin information
(5) SERVICE INFORMATION LETTERS
When the information from a service information letter has been incorporated into the manual
by a permanent revision, the service information letter list page includes the following
information:
•The service information letter number

•The service information letter or service information letter revision publication date
•The date of the permanent revision that incorporates the service bulletin information
(6) LIST OF EFFECTIVE PAGES
Each page in the manual is listed in this section and provided with the effective date. At
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original issue, all pages have the original issue date. A revised List of Effective Pages is
provided in each subsequent revision. If a page changes because of revision, the date of the
revision is applied to the changed page and also to the page listing in the list of effective
pages. This allows the user to verify that all information in the manual is current.
(7) TABLE OF CONTENTS
The Table of Contents lists each section by title and provides the page location for each.
(8) LIST OF FIGURES
The List of Figures also appears on the Table of Contents page, and provides the figure
number, title, and page location for each illustration in the manual.
(9) INTRODUCTION
The Introduction section lists the component covered in the manual, provides the scope of
the manual, and describes how the manual is configured.
B. Maintenance
NOTE: The maintenance sections of this manual provide the information needed for periodic,
preventive, and corrective maintenance for the Air LiteW 1E LED flashlight system. The
content and purpose of each section are described below.
(1) DESCRIPTION AND OPERATION
This section provides the physical description and operation and includes a table of leading
particulars.
(2) TESTING AND FAULT ISOLATION
This section provides testing and fault isolation procedures.
(3) DISASSEMBLY
This section provides disassembly instructions. The Air LiteW 1E LED flashlight system can
be disassembled for inspection, cleaning, and corrective maintenance.
(4) CLEANING
This section provides scheduled cleaning information as well as general cleaning practices.
(5) CHECK
This section provides instructions and inspection intervals.
(6) REPAIR
This section provides instructions for replacing components that are damaged or have failed.
(7) ASSEMBLY
This section provides assembly instructions.
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(8) REMOVAL
This section provides removal information.
(9) INSTALLATION
This section provides installation information.
(10) STORAGE
This section provides storage information.
(11) ILLUSTRATED PARTS LIST
This section provides an illustrated parts list to the level of disassembly practical for the Air
LiteW 1E LED flashlight system.
TASK4
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DESCRIPTION AND OPERATION
1.
TASK1 General Description
NOTE: The Air Lite 1E LED flashlight system part number P2-07-0015-001, -002, -003, -004, and
-005 (refer to Figures 1 and 2) is a high-intensity, hand-held light for use in emergency
situations. The handlight turns on automatically when it is removed from its mounting bracket.
The principal components of the flashlight system are the bulkhead mounted bracket, the
handlight, and the replaceable battery pack.
The LED flashlight uses microprocessors in the handlight and the bracket, therefore
Electrostatic Discharge (ESD) precautions need to be adhered to when performing
maintenance on these components.
The configurations of the Air Lite 1E LED flashlight system part number -001, -002, -003,
-004, and -005 are as follows:
(1) 001 (Gray) consists of:
Handlight - PN P2-07-0020-001
Bracket - PN P2-07-0019-001
Battery Pack (Alkaline) - PN P2-07-0021-002
Tamper Shield (Optional) - PN A1-26-0086-001
Bracket - PN P2-07-0019-002 - obsolete after 15 July 2015
Bracket - PN P2-07-0019-102 - replacement part effective 15 July 2015
(4) 004 (Beige) consists of:
(5) 005 (Beige) consists of:
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Refer to the figures in the Illustrated Parts List to note the physical differences of the dash numbers.
A. Performance
(1) The Air Lite 1E LED flashlight system part number P2-07-0015-001, -002, -003, -004, and
-005 provides high intensity light using a three-cell, 4.5-volt, sealed battery pack. The
flashlight system can remain in-service (in-service is defined as handlight on the bracket but
system is off) for 5 years on a fresh battery pack.
B. Battery
(1) The Air Lite 1E LED flashlight system uses three 1.5-volts Alkaline AAA cells sealed in a
flame retardant ABS case (battery pack part number P2-07-0021-002). The battery pack
design prevents leakage and corrosion, and provides reliable electrical contact. The battery
pack is connected to the handlight using spring contacts. Battery pack in-service life is 5
years in service, and a shelf life of 5 years in storage at 25° C (77° F) ambient temperature.
Air Lite 1E LED flashlight systems kept in storage for more than 5 years shall have the
battery pack verified before placing it into service).
The Air Lite 1E LED flashlight system is shipped in an operational state. The battery pack is
connected and no maintenance action is required to activate the system.
Only the Astronics DME Battery Pack PN P2-07-0021-002 will work in the Air Lite 1E LED
flashlight system Handlight PN P2-07-0020-001, -002, -003, -004 and -005. The battery pack
and handlight execute a ‘handshake’ between the two components.
C. Flashlight Mounting Bracket
(1) The mounting bracket has two mounting holes to mount it to flat surfaces such as walls,
panels, or bulkheads. The P2-07-0019-001 mounting holes are 4.98 mm (0.196 in.) diameter
with a counter sink of 9.65 mm (0.380 in.) x100°.
The P2-07-0015-002, -003, -004, -005, -102, -103, -104 and -105 mounting holes are 5.18
mm (0.204 in.) diameter with a counter sink of 9.65 mm (0.380 in.) x100°.
D. Monitoring Circuit
WARNING: FAILURE TO REPLACE THE BATTERY PACK MAY RESULT IN NO USABLE

LIGHT.
(1) The battery pack monitoring circuit that is part of the flashlight mounting bracket uses a push-
to-test button and a red/green LED to indicate the battery pack status.
If the LED illuminates green (flashes green once) when the push-to-test button is pressed,
the battery pack charge is satisfactory, and can remain in service. There is a 4 second sleep
period after the button is initially pressed to prevent the user from continually pressing the
monitor circuit. This is to help maintain the overall battery life in the handlight.
If the LED illuminates red (flashes red once) when the push-to-test button is pressed, the
battery pack charge is low and should be changed at earliest possible service. The
monitoring circuit continues to check the battery every ten seconds and emit a red flash until
the battery is replaced. The operator has approximately three weeks to replace the battery.
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NOTE: Temperature has an impact on the internal resistance of the battery pack and
temperature changes will cause the unit to flash red and then change to green or
go from green to red depending on battery state and temperature. This type of
condition is normal with temperature changes and is not viewed as a failure, but
as an indication that the battery pack needs to be replaced.
NOTE: If the LED does not illuminate, refer to fault isolation and repair section.
E. Optical Assembly
(1) The optical assembly is an integral part that has the 'automatic on' circuitry, the LED drive
circuitry and the photometric components. The top cap (head assembly) is bonded to the
handlight and is not removable. The optical assembly uses a circuit board that has the drive
circuitry, 'automatic ON' circuitry, the LED and is mated to an optical reflector.
The automatic on feature utilizes a magnetic reed switch. The magnet is in the bracket and
holds the circuit in the off condition. Removing the handlight from the bracket automatically
turns the handlight on.
The LED drive circuitry controller is a voltage controlled current limiting circuit, which
maximizes the light output of the LED.
F. Materials and Construction
(1) The handlight body and end caps are made of flame-retardant ABS, and the lens is
polycarbonate. All openings are sealed with O-rings.
The flashlight mounting bracket is molded from flame-retardant ABS.
G. Lanyard
(1) The handlight end cap assembly includes a lanyard that hooks to the handlight body when
stowed or not in use. The lanyard is used to secure the handlight to the user when it is
necessary to have both hands free.
H. Tamper Shield (Optional)
(1) The Air Lite 1E LED flashlight system part numbers P2-07-0015-001, -002, and -004 can use
an optional tamper shield part number A1-26-0086-001 for the P2-07-0015-001 and
A1-26-0086-002 for the P2-07-0015-002 and -004. The tamper shield, which is mounted by
adhesive, deters theft and unauthorized use of the handlight. Removal of the tamper shield is
self-evident. See IPL Fig. 1 Sheet 1 and IPL Fig. 1A Sheet 1.
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2.
TASK2 Technical Data
AIR LITE 1E LED FLASHLIGHT SYSTEM

PART NUMBERS P2-07-0015-001 THRU P2-07-0015-005
Material (Handlight PN P2-07-

0020-001,-002, and -003; and
Bracket PN P2-07-0019-001, -
High impact, flame-retardant ABS
002, -003, -004, and -005
conforming to FAR 25.853(a)
before 15 July 2015; PN P2-07-
0019-102, -103, -104, and -105
after 15 July 2015)
Battery Pack Three 1.5-volt AAA alkaline cells in a

(PN P2-07-0021-002) welded 4.5-volt pack
Operating Temperature Range -40°C to 70°C (-40°F to 158°F)
Light Source White LED
Battery Operational Life* (In- 5-years nominal when installed in the

service Life) handlight
Battery Shelf Life 5 years at 25°C m 2°C (77°F)
Light Intensity 2100 Ca
Discharge Life (to the end of

3.4 hours (nominal)
battery pack operational life)
Center spot diameter: 330.2 mm (13 in.)

Beam Diameter at 84 inches
Outer diameter: 2819.4 mm (111 in.)
Flashlight System Dimensions Length: 204.9 mm (8.07 in.)

P2-07-0015-001 Height: 61.2 mm (2.41 in.)
(handlight in bracket) Width: 44.5 mm (1.75 in.)
Flashlight System Dimensions Length: 204.5 mm (8.05 in.)

P2-07-0015-002,-003,-004, and Height: 62.2 mm (2.45 in.)
-005 (handlight in bracket) Width: 51.3 mm (2.02 in.)
LED Handlight Dimensions

Length: 181.4 mm (7.14 in.)
P2-07-0020-001, -002, and - Diameter: 42.9 (1.69 in.)
003
Flashlight System Weight
P2-07-0015-002, -003, -004, Max.: 270g (9.6 oz.)

and -005
* Battery operational life is defined as pressing the 'Press to Test' button 8

times per day over a period of 5 years.
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AIR LITE 1E LED FLASHLIGHT SYSTEM

PART NUMBERS P2-07-0015-001 THRU P2-07-0015-005
Handlight Weight
P2-07-0020-001, -002, and Max.: 110 g (3.9 oz.)

-003 (without battery pack)
Bracket Weight:
Max.: 75 g (2.6 oz.)
P2-07-0019-001
Bracket Weight:
P2-07-0019-002, -003, -004,

Max.: 85 g (3.0 oz.)
and -005
P2-07-0019-102, -103, -104,

Max.: 95 g (3.4 oz.)
and -105
Battery Pack Weight

Max.: 65 g (2.3 oz.)
P2-07-0021-002
* Battery operational life is defined as pressing the 'Press to Test' button 8

times per day over a period of 5 years.
3.
TASK3 Operation
WARNING: FAILURE TO REPLACE THE BATTERY PACK MAY RESULT IN NO USABLE LIGHT.
The handlight turns ON automatically when it is removed from its mounting bracket and turns OFF
automatically when it is properly reinserted in the bracket.
When the handlight is mounted in the bracket the condition of the battery pack can be checked by pressing
the push-to-test button on the mounting bracket. The system can be checked 8 times a day over a period
of 5 years before the system is degraded. A two-function LED will provide battery pack condition,
illuminating green if the battery pack charge is satisfactory, and red if the battery pack is low. If there is no
indication on the LED, refer to Section 1001, Testing and Fault Finding. This Built-In Test only tests the
battery voltage.
There is a 4 second sleep period after the button is initially pressed to prevent the user from continually
pressing the monitor circuit and to help maintain the overall battery life in the handlight.
If the LED emits a red flash, the monitoring circuit continues to check the battery every ten seconds and
emits a red flash until the battery is replaced. The operator has approximately three weeks to replace the
battery.
A. Handlight Removal
(1) Grasp the handlight body and pull the handlight from the mounting bracket. It will turn ON
automatically.
NOTE: REGARDING HANDLIGHTS with TAMPER SHEILD - The tamper shield part
number A1-26-0086 -001 or -002 is retained on the mounting bracket by adhesive.
The handlight can be removed from the mounting bracket by peeling the tamper
shield from the bracket and removing the handlight. The tamper shield can also be
fractured by grasping the handlight body and pulling the handlight from its
mounting bracket. The tamper shield is designed to be self-evident when it has
been peeled off or fractured, so that it cannot be re-affixed. The handlight will turn
ON automatically when removed from mounting bracket.
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B. Handlight Installation - P2-07-0015-001

[1] Position the handlight, see Figure 1, using the handlight position icon on the mounting
bracket as a guide.
[2] Orient the handlight so the lanyard hook is outward and the contacts are facing the bracket.
Install the handlight into the mounting bracket, making sure the contacts engage the pogo pin
rivets on the mounting bracket.
[3] To check a proper installation, press the push-to-test button and verify the test LED
illuminates green. If it does not, rotate the handlight in the bracket to correctly mate the
contacts with the pogo pins. Again, this is ensured by pressing the push-to-test button and
verifying the test LED light illuminates green.
NOTE: The anti-rotation tabs aid in ensuring the contacts are aligned properly to the pogo
pins.
Handlight Installation (P2-07-0015-001) Fig. Sheet 1
Contacts
Anti-Rotation
Tabs
Handlight Position Icon
Charge Indicator
Pogo Pin Rivets
Push to Test Button
Figure 1 Handlight Installation (P2-07-0015-001)

C. Handlight Installation - P2-07-0015-002 thru P2-07-0015-005
NOTE: The alignment tab aids in ensuring the contacts are aligned properly to the pogo pins.
Model 002 and -004 have an orientation placard on the mounting bracket as a guide.
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Rev. 8 Dec 14/17
[1] Orient the handlight so the alignment tab and contacts are facing the bracket. Position the
handlight as shown in Figure 2.
[2] Install the handlight into the mounting bracket, making sure the alignment tab on the
handlight goes into the recessed slot and the contacts engage the pogo pin rivets on the
mounting bracket.
[3] Double-check this by pressing the push-to-test button and verifying the test LED illuminates
green. If it does not, rotate the handlight in the bracket to correctly mate the contacts with the
pogo pins. Again, this is ensured by pressing the push-to-test button and verifying the test
LED light illuminates green.
Fig. Sheet 2
Contacts
Alignment Tab
Pogo Pin Rivets

Recessed Slot
Orientation Placard
(002/004 ONLY)
Charge Indicator
Push to Test Button
Figure 2 Handlight Installation (P2-07-0015-002 thru P2-07-0015-05)

D. Tamper Shield Installation (Optional)
NOTE: Make sure the surface to which the tamper shield will be applied is free of contamination
and old adhesive before applying the new tamper shield.
(1) Verify that the handlight is correctly positioned in the mounting bracket, with the lanyard
seated over the lanyard stowage hook on the handlight tube.
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(2) Peel the backing from the adhesive side of the tamper shield.
(a) P2-07-0015-001 : Position the tamper shield so the clearance hole is over the lanyard
storage hook.
(b) P2-07-0015-002 and -004: Position the tamper shield as shown in IPL Figure 1A.
(3) Working from the center of the tamper shield to the ends, press the tamper shield firmly
against the mounting bracket. This will avoid wrinkles in the shield material and assure a tight
fit against the handlight tube.
4.
TASK4 Handling
CAUTION: AVOID DROPPING THE HANDLIGHT AND DO NOT SUBJECT IT TO UNNECESSARY

ABUSE.
A. Handle the handlight carefully. Although the handlight is of rugged construction and is intended for
use in all types of emergencies, it does contain electronic circuits on a printed wiring board.
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Rev. 8 Dec 14/17
TESTING AND FAULT FINDING
1.
TASK1 General
A. This section contains specific tests and procedures required to determine the condition of the Air
Lite 1E LED flashlight system, and return it to service.
• The test procedure for the Air Lite 1E LED flashlight system is provided in paragraph 2.
• Refer to the Fault Isolation table in paragraph 3 to determine the cause and corrective action
for faults discovered during testing or observed during inspection or use.
NOTE: When returning a defective component to the repair station, a detailed failure
description is required to accompany the component, to ensure the proper
troubleshooting procedures and repairs are accomplished.
2.
TASK2 Testing
WARNING: FAILURE TO REPLACE THE BATTERY PACK MAY RESULT IN NO USABLE LIGHT.
A. With the handlight correctly positioned in its mounting bracket, refer to Section 7001 Assembly,
press the push-to-test button momentarily and release.
B. Check the mounting bracket LED.
(1) If the LED is illuminated green, the battery pack is above minimum voltage and can remain in
service.
(2) If the LED is illuminated red, the battery pack is below minimum voltage and must be
replaced at earliest opportunity. The operator has approximately three weeks to replace the
battery.
NOTE: Temperature has an impact on the internal resistance of the battery pack and
temperature changes will cause the unit to flash red and then change to green or
go from green to red depending on battery state and temperature. This type of
condition is normal with temperature changes and is not viewed as a failure, but as
an indication that the battery pack needs to be replaced.
(3) If the LED does not illuminate, refer to the Fault Isolation table in paragraph 3.
C. Remove the handlight from the mounting bracket. The handlight must turn ON immediately. If the
handlight does not turn ON, refer to the Fault Isolation table in paragraph 3.
3.
TASK3 Fault Isolation
NOTE: If the handlight or flashlight system fails the tests or a fault is observed during inspection or
use, refer to the Fault Isolation table to discover the cause and corrective action.
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SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION
Battery pack is depleted Remove the handlight from the

or has failed. mounting bracket. If the
handlight does not turn ON
immediately, remove and
replace the battery pack.
After replacing the battery

pack, verify that the handlight
is ON when the handlight is not
in the mounting bracket.
Reinsert the handlight in the
mounting bracket and verify
that the LED turns on green
when the push-to-test button is
pressed.
Electrical failure in If changing the battery pack

Mounting handlight electronics. does not turn the handlight
Bracket LED ON, there is an electrical
does not failure in the handlight
illuminate electronics. Refer to REPAIR
when the for repair procedures or
push-to-test continue troubleshooting
button is symptoms.
pressed...
Electrical failure in If the handlight turns ON when
mounting bracket it is removed from the
electronics. mounting bracket, there is an
electrical failure in the
mounting bracket. Replace the
mounting bracket. Return
defective unit to repair station.
Pogo contacts not Rotate and ensure pogo

making contact. contacts are making contact.
Refer to ASSEMBLY for
handlight installation
procedures.
Battery pack installed Install battery correctly. Refer

incorrectly. to ASSEMBLY for handlight
installation procedures.
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Rev. 8 Dec 14/17
SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION
Battery pack is depleted Replace the battery pack. After

or has failed. replacing the battery pack,
verify that the handlight is ON
when the handlight is not in the
mounting bracket. Reinsert the
handlight in the mounting
Handlight bracket and verify that the LED
does not turn turns on green when the push-
ON when it is to-test button is pressed.
removed from
the mounting Electrical failure in If changing the battery pack
bracket... handlight electronics. does not turn the handlight
ON, there is an electrical
failure in the handlight
electronics. Refer to REPAIR
for repair procedures or
continue troubleshooting
symptoms.
Failure in mounting If the handlight does not turn

bracket or electrical OFF when it is returned to the
failure in handlight head mounting bracket, there may
assembly electronics. be a failure in the mounting
bracket. Insert another
Handlight handlight in the mounting
does not turn bracket. If that handlight does
OFF when not turn OFF, the failure is in
returned to its the mounting bracket. Replace
mounting the mounting bracket.
bracket... If the second handlight turns
OFF when it is inserted in the
mounting bracket, the
electrical failure is in the
handlight head assembly
electronics. Replace handlight.
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25-60-13 Page 1004
DISASSEMBLY
1.
TASK1 General
NOTE: Disassemble the Air Lite 1E LED flashlight system according to the instructions provided
below. Limit disassembly to removing only the components necessary to accomplish the task
being performed.
2.
TASK2 Air Lite 1E LED Flashlight System Disassembly (See IPL Figures 1, 1A, 1B, and 1C)
A. LED Flashlight System
(1) If the handlight is retained in the mounting bracket by a tamper shield, remove the tamper
shield. Do not use sharp or hard objects to remove the shield, as this may damage the
handlight housing. Remove the tamper shield adhesive using a clean, lint-free cloth
moistened with isopropyl alcohol. Exposure to isopropyl alcohol should be kept as brief as
possible. When removing the adhesive, temperature shall be less than 40L C (104L F).
CAUTION: THE BRACKET CONTAINS A MICROPROCESSOR; THEREFORE ESD
PRECAUTIONS SHALL BE FOLLOWED WHEN PERFORMING MAINTENANCE.
(2) Grasp the handlight by the barrel and pull outward to remove it from the mounting bracket.
(3) Removal of the mounting bracket is aircraft specific. Refer to the aircraft’s maintenance
manual for this procedure.
B. Handlight Battery Pack Removal
(1) Remove the bottom cap assembly and the O-ring. Discard the O-ring.
(2) Remove the battery pack from the barrel tube assembly.
NOTE: The top cap (head assembly) is bonded to the tube and cannot be removed.
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CLEANING
1.
TASK1 General Cleaning
A. Cleaning Priority
(1) Clean the Air Lite 1E LED flashlight system components as described below. Table 4001
below describes the consumables used for general cleaning.
NOTE: Under normal circumstances, only the tamper shield (if installed), the external
surfaces of the handlight, and the exposed surface of the mounting bracket will
require cleaning.
Cleaning Consumables
Table 4001. Cleaning Consumables
ITEM DESCRIPTION SPECIFICATION
Cloth Clean, Lint Free N/A
Detergent Mild (if required) N/A
CAUTION: DO NOT USE SOLVENTS, CLEANING COMPOUNDS WITH ABRASIVES, OR

CHEMICAL CLEANING COMPOUNDS ON ANY HANDLIGHT COMPONENTS,
MOUNTING BRACKET COMPONENTS OR BATTERY PACK.
(1) Remove the battery pack. Refer to Section 3001, Disassembly.
(2) Clean the handlight components except for the battery pack using a clean, lint-free cloth
moistened with a mild detergent solution if necessary. Dry the components thoroughly with a
clean, lint-free cloth or allow to air dry.
(3) Clean the battery pack using a dry, soft, clean, lint-free cloth. Do not moisten the cloth.
(4) If installed, clean the tamper shield using a clean, lint-free cloth moistened with a mild
detergent solution if necessary. Dry the tamper shield thoroughly with a clean, lint-free cloth
or allow to air dry.
(5) Clean the mounting bracket assembly using a clean, lint-free cloth moistened with a mild
detergent solution if necessary. Dry the components thoroughly with a clean, lint-free cloth or
allow to air dry.
(6) Reassemble the handlight. Refer to Section 7001, Assembly.
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INSPECTION/CHECK
1.
TASK1 General
NOTE: This section provides the check instructions for the Air Lite 1E LED flashlight system.
A. Checks
(1) Perform check of the Air Lite 1E LED flashlight system according to Table 5001, below.
Check of the Air Lite 1E LED Flashlight System
Table 5001. Check of the Air Lite 1E LED Flashlight System
Inspection/Action Requirements
Visually check the Air Lite 1E LED Remove and replace damaged or
flashlight system components for deteriorating components. Clean away
damage, deterioration, and any contamination, refer to CLEANING.
contamination.
If the LED flashes GREEN, the battery

pack is in operational condition.
Press the push-to-test button on the
mounting bracket and check the LED. If the LED flashes RED, schedule the
battery pack for replacement at the
earliest opportunity.
Perform the above checks, and then The handlight must turn ON immediately.
remove the handlight from the If it does not, refer to TESTING AND
mounting bracket. (Replace tamper FAULT ISOLATION for the cause and
shield if installed, Refer to corrective action.
ASSEMBLY)
Clean Air Lite 1E LED flashlight Clean away any contamination, refer to
system. CLEANING.
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REPAIR
1.
TASK1 General
NOTE: This section provides instructions for replacing components that are damaged or have failed in
the Air Lite 1E LED flashlight system. The repair procedures are limited to removal and
replacement of components.
2.
TASK2 Repair Procedures (See IPL Figures 1, 1A, 1B, and 1C)
A. Battery Pack Replacement
CAUTION: BATTERY PACKS THAT SHOW NO SIGNS OF DAMAGE OR CHEMICAL
EXPOSURE CAN BE HANDLED WITHOUT THE NEED OF PPE ITEMS.
BATTERY PACKS THAT ARE DAMAGED AND/OR HAVE SIGNS OF CHEMICAL
EXPOSURE SHOULD BE HANDLED WITH THE APPROPRIATE PPE ITEMS.
DIRECT EXPOSURE TO ANY PART OF THE BODY SHOULD BE AVOIDED. THE
EXPOSED BATTERY PACK PARTS SHOULD BE CAREFULLY PLACED IN A
CONTAINER THAT IS CAPABLE OF HOLDING AND SEALING THE CHEMICALS
TO AVOID ADDITIONAL EXPOSURE.
IF DIRECT CONTACT OF THE BATTERY CHEMICALS OCCURS IMMEDIATELY
FLUSH THE AREA WITH WATER OR OTHER ACCEPTABLE CLEANSING FLUID.
SEEK IMMEDIATE MEDICAL ATTENTION IF NECESSARY.
(1) In the event the battery pack requires replacement, remove and replace battery pack per
instructions located in Section 3001, Disassembly and 7001, Assembly.
NOTE: All spent or used battery packs should be stored in a cool dry area until they can
be properly disposed of.
B. Lanyard Kit Replacement
(1) If the lanyard or bottom cap is cracked or broken, remove and replace lanyard cap and O-
ring per instructions located in Section 3001, Disassembly and 7001, Assembly.
NOTE: The lanyard kit contains the Assembly, Bottom Cap with Lanyard, and an O-ring for
bottom cap.
C. LED Flashlight Handlight Assembly
(1) The only replaceable component on the Handlight is the Lanyard Kit (see 2.B. above). If any
other component in the handlight fails, replace the entire Handlight Assembly.
D. Mounting Bracket Assembly
(1) There are no repairable/replaceable items on the Mounting Bracket Assembly. If any
component on the Mounting Bracket Assembly fails, replace the Mounting Bracket Assembly.
E. Bracket Clamp Replacement Kit
(1) If the bracket clamp is cracked or broken, remove the handlight from the bracket.
(2) Remove the 4 fasteners on the backside of the bracket holding the bracket clamp(s).
Remove the bracket clamp(s). See Figure 6001
(3) Install the new bracket clamp(s) into the bracket and install the 4 fasteners. Torque to 2.2 in-
lbs.
(4) Install handlight back into bracket.
1
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Rev. 8 Dec 14/17
Bracket Clamp Replacement Fig. Sheet 1
Bracket Clamp
4x Fasteners
Figure 6001 Bracket Clamp Replacement
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Rev. 8 Dec 14/17
ASSEMBLY
1.
TASK1 General
NOTE: The mounting bracket is installed by the airframe manufacturer. Since the material/
structure that the mounting bracket is attached to varies by aircraft, Astronics DME
recommends a torque value of 10 in-lbs based on using #8 flat head mounting screws
with 100 degree countersink to install the mounting bracket on a metal plate using #8-32
PEM nuts.
NOTE: The mounting bracket has two mounting holes to mount it to flat surfaces such as walls,
panels, or bulkheads. The P2-07-0019-001 mounting holes are 4.98 mm (0.196 in.) dia.
with a counter sink of 9.65 mm (0.380 in.) x100L. The PN P2-07-0019-002, -003, -004, -
005, -102,-103, -104, and -105 mounting holes are 5.18 mm (0.204 in.) dia. with a counter
sink of 9.65 mm (0.380 in.) x100L.
(1) Assemble the handlight assembly and install it into the mounting bracket according to the
instructions provided below.
2.
TASK2 Assembling the Handlight (Battery Pack Installation) (See IPL Figures 1, 1A, 1B, and 1C)
NOTE: Assemble the handlight assembly and install it into the mounting bracket according to the
instructions provided below.
Handlight Assembly Consumables
Table 7001. Handlight Assembly Consumables
REFERENCE DESCRIPTION
Battery Pack PN: P2-07-0021-002
O-Ring A1-25-0097-001
Bottom Cap (w/ Lanyard) *Only to be ordered if replacement is necessary

A3-06-2090-001 (Gray)
A3-06-2090-003 (Beige)
Tamper Shield *Only to be ordered if replacement is necessary

A1-26-0086-001 (for P2-07-0015-001)
A1-26-0086-002 (for P2-07-0015-002 and -004)
(1) Install the battery pack into the handlight tube, making sure the battery pack is correctly
oriented (battery contacts facing the handlight head) and seated against the handlight head
assembly.
(2) Place a new O-ring on the handlight tube. Install the bottom cap assembly, turning it onto the
handlight tube finger tight until it is fully seated.
(3) Verify that the handlight is ON when the battery pack is inserted in the handlight tube.
(4) Verify that the handlight turns OFF when the handlight is inserted in the mounting bracket.
(5) Verify that the mounting bracket LED illuminates GREEN when the push-to-test button is
pressed.
TASK3
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REMOVAL
1.
TASK1 General
CAUTION: REMOVAL OF THE MOUNTING BRACKET IS AIRCRAFT SPECIFIC. REFER TO THE

AIRCRAFT’S MAINTENANCE MANUAL FOR THIS PROCEDURE.
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INSTALLATION
1.
TASK1 Handlight to Bracket
A. Handlight Installation - P2-07-0015-001
[1] Position the handlight, see Figure 13001, using the handlight position icon on the mounting
bracket as a guide.
[2] Orient the handlight so the lanyard hook is outward and the contacts are facing the bracket.
Install the handlight into the mounting bracket, making sure the contacts engage the pogo
stick rivets on the mounting bracket.
[3] To check a proper installation, press the push-to-test button and verify the test LED
illuminates green. If it does not, rotate the handlight in the bracket to correctly mate the
contacts with the pogo pins. Again, this is ensured by pressing the push-to-test button and
verifying the test LED illuminates green.
NOTE: The anti-rotation tabs aid in ensuring the contacts are aligned properly to the pogo
pins.
Handlight Installation (P2-07-0015-001) Fig. Sheet 1
Contacts
Anti-Rotation
Tabs
Handlight Position Icon
Charge Indicator
Pogo Pin Rivets
Push to Test Button
Figure 13001 Handlight Installation (P2-07-0015-001)
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Rev. 8 Dec 14/17
B. Handlight Installation - P2-07-0015-002 thru P2-07-0015-005

NOTE: The alignment tab aids in ensuring the contacts are aligned properly to the pogo pins.
Models 002 and -004 have an orientation placard on the mounting bracket as a guide.
[1] Orient the handlight so the alignment tab and contacts are facing the bracket. Position the
handlight as shown in Figure 13002.
[2] Install the handlight into the mounting bracket, making sure the alignment tab on the
handlight goes into the recessed slot and the contacts engage the pogo stick rivets on the
mounting bracket.
[3] Double-check this by pressing the push-to-test button and verifying the test LED illuminates
green. If it does not, rotate the handlight in the bracket to correctly mate the contacts with the
pogo pins. Again, this is ensured by pressing the push-to-test button and verifying the test
LED illuminates green.
Fig. Sheet 2
Contacts
Alignment Tab
Pogo Pins
Recessed Slot
Orientation Placard
(002/004 ONLY)
Charge Indicator
Push to Test Button
Figure 13002 Handlight Installation (P2-07-0015-002 thru P2-07-0015-05)

C. Tamper Shield Installation (Optional)
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Rev. 8 Dec 14/17
NOTE: Make sure the surface to which the tamper shield will be applied is free of contamination
and old adhesive before applying the new tamper shield.
(1) Verify that the handlight is correctly positioned in the mounting bracket, with the lanyard
seated over the lanyard stowage hook on the handlight tube.
(2) Peel the backing from the adhesive side of the tamper shield;
(a) P2-07-0015-001 : Position the tamper shield so the clearance hole is over the lanyard
storage hook.
(b) P2-07-0015-002 and -004 : Position the tamper shield as shown in IPL Figure 1A.
(3) Working from the center of the tamper shield to the ends, press the tamper shield firmly
against the mounting bracket. This will avoid wrinkles in the shield material and assure a tight
fit against the handlight tube.
2.
TASK2 Bracket to Aircraft
CAUTION: INSTALLATION OF THE MOUNTING BRACKET IS AIRCRAFT SPECIFIC. REFER TO

THE AIRCRAFT’S MAINTENANCE MANUAL FOR THIS PROCEDURE.
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STORAGE
1.
TASK1 General
NOTE: All spent or used battery packs should be stored in a cool dry area until they can be
properly disposed of.
(1) Store the LED flashlight system and components in a dry, well-ventilated, temperature
controlled environment away from direct sunlight. Normal storage temperature range should
be 25L ± 3L C (77L ± 5L F). Storage of the handlight or the battery at lower temperatures
retards battery degradation due to aging.
If the aircraft is to be idled in an elevated temperature environment [up to a maximum of 71LC

(160L F)] for more than seven days, remove the battery pack from the handlight and place it
in temperature controlled storage. If the temperature is above 71L C (160L F), remove battery
pack immediately and place it in temperature controlled storage.
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25-60-13 Page 15002
1.
TASK1 Function
A. General
(1) The Illustrated Part List (IPL) contains the illustrations and the parts lists for the assembly
given in the Leading Particulars (Ref. Description and Operation). The parts lists give the
items which can be disassembled, repaired or replaced, and assembled.
2.
TASK2 To Use this Section
A. General
(1) Not all the details in 2.B. thru 2.G. are always used in the Illustrated Parts List (IPL).
B. Fig/Item Column
(1) The figure number is given at the top left of the column. It shows how the parts list is related
to an illustration.
(2) The end item number 1A is applicable to that end item (assembly) which is shown in the
illustration. Variants are given immediately after the end item (1B, 1C,... as applicable).
(3) A dash (-) before an item number shows that the item is not shown on the illustration.
(4) The item number sequence follows, as far as possible, the sequence in which the end item is
disassembled. The sequence is broken to let more items be put in to the sequence, when
necessary.
(5) Alpha suffixes are given, A thru Z (without I and O), when it is necessary to add more items to
show:
(a) Special-to-type items.
(b) Service bulletin modifications.
(c) Configuration differences.
(d) Parts that were made better (not service bulletin modifications).
(6) Alpha suffixes to the item numbers are not shown on the illustration (when the shape and
location of the alpha item are the same as the basic item).
C. Part Number Column
NOTE: The part number column contains the part number which can be:
AN ARMY-NAVY STANDARD
MIL MILITARY SPECIFICATION
MS MILITARY STANDARD
NAS NATIONAL AEROSPACE STANDARD
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Rev. 8 Dec 14/17
D. Airline Part Number Column
(1) This empty column (with space for 11 characters) is given for the use of the equipment
operator.
E. Nomenclature Column
(1) The parts are shown in an indenture system sequence. This shows how one part is related to
the other parts, as shown below:
1234567 (Indenture number)
Assembly or Installation Assembly (RF) number (End Item)
Parts which attach the assembly or installation of the RF assembly
***
.Detail parts for assembly
.Subassembly (secondary to end item)
.Attaching parts for subassembly
***
..Detail parts for subassembly
..Sub-subassembly (secondary to subassembly)
..Attaching parts for sub-subassembly
***
...Detail parts for sub-subassembly
NOTE: The words 'or Installation Assembly (RF) number' refer to:
– Those times where an identity which cannot be obtained is given to a group

(installation) of parts
– That group (or installation) of parts does not make a known assembly.
(2) When the entry in the part number column is not an Astronics DME part number, this data will
follow the noun (and words which change that noun).
(a) A five character code that identifies the vendor code of the supplier or the standard
parts authority, or the manufacturers name.
(b) The DSR number.
(3) The suppliers part number and vendor code is given in the nomenclature column. This is
when:
(a) A DSR number is given in the part number column because the suppliers part number
is too long (more than 15 characters).
(b) The suppliers part number is not available.
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Rev. 8 Dec 14/17
(4) When a DSR number is given in the part number column (because a suppliers part number is
not available), the data in the nomenclature column gives:
(a) The materials from which the part is made
(b) Its dimensions.
(c) The suppliers vendor code.
(5) Parts which you must be careful with are identified. For example electronic components
which are sensitive to electrostatic discharge are identified with the abbreviation (ESDS) in
brackets.
(6) Parts Replacement Data
(a) The parts that are interchangeable are identified in the NOMENCLATURE column of
the parts list. The abbreviations used to show if those parts are interchangeable are
given in the table below:
NOTE: Currently no parts are identified as interchangeable for the Air LiteW 1E LED
Flashlight System, except as defined by the effectivity codes defined in
paragraph F below.
Term Parts list Definition

Abbreviation
Optional OPT The part is optional to and is interchangeable

with other parts in the same item number group
(or other item number if specified).
Superseded by SUPSD BY The part is replaced by and is not

interchangeable with the item number given.
Supersedes SUPSDS The part replaces and is not interchangeable

with the item number given.
Replaced by REPLD BY The part is replaced by and is interchangeable

with the item number given.
Replaces REPLS The part replaces and is interchangeable with

the item number given.
(7) Included through Service Bulletin Procedure:
(a) (PRE SB XXXX) in the Nomenclature column identifies the initial configuration.
(b) (POST SB XXXX) identifies the assemblies and the parts after the service bulletin
modification is completed.
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F. Effectivity Column
(1) If variations exist between similar assemblies or sub-assemblies, 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 sub-assemblies.
G. Units per Assembly Column
(1) The quantity given is the quantity of that part necessary to build:
(a) Its subsequent higher sub-subassembly.
(b) Subassembly.
(c) Assembly or installation level as applicable.
(2) When the quantity is shown as NP, the item is non-procurable and is used for reference only.
All NP items in the electrical IPLs are located in the DESCRIPTION AND OPERATION
section of this manual.
(3) AR (As Required) is the quantity that is necessary for that assembly. It is used for bulk items,
and selection-from-a-range parts that are not shown on the illustration.
(4) RF (Reference) shows the part is given for identification only.
Vendor Code List

A. The vendor code numbers given in the table are those given in:
The national NATO code for manufacturers H4-1 and H4-2, or:
The USA, Department of Defense, Commercial and Government Entity (CAGE) Cataloging Handbook
H4/H8.
As referenced above, the code number prefixed by ”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:
Vendor Code Vendor Names and Addresses
V55827 Astronics DME

6830 NW 16th Terrace
Ft Lauderdale, Florida 33309-1518
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OPTIONAL PARTS LIST
AIRLINE 1234567
PART NUMBER PN NOMENCLATURE USED ON MIN BUY
NOTE: The following items are spares/spare kits. These are the only items that are available
for replacement. The items in IPL Figures 1, 1A, 1B, and 1C are for reference when
performing maintenance.
K2-01-0001-001 LANYARD KIT P2-07-0015-001, -002, AND 1

(GRAY) -003
— ASSY, BOTTOM
CAP W/ LANYARD
— O-RING FOR
BOTTOM CAP
K2-01-0001-003 LANYARD KIT P2-07-0015-004 AND -005 1

(BEIGE)
— ASSY, BOTTOM
CAP W/ LANYARD
— O-RING FOR
BOTTOM CAP
K1-02-0010-002 BRACKET CLAMP/S P2-07-0019-002 AND -003 1

(GRAY)
K1-02-0010-003 BRACKET CLAMP/S P2-07-0019-004 AND -005 1

(BEIGE)
A1-26-0086-001 TAMPER SHEILDS P2-07-0015-001 100
A1-26-0086-002 TAMPER SHEILDS P2-07-0015-002 AND -004 100
P2-07-0021-002 BATTERY PACK P2-07-0015-001, -002, -003, 1

-004, AND -005
P2-07-0019-001 BRACKET P2-07-0015-001 1
P2-07-0019-102 BRACKET P2-07-0015-002 1
P2-07-0019-103 BRACKET P2-07-0015-003 1
P2-07-0019-104 BRACKET P2-07-0015-004 1
P2-07-0019-105 BRACKET P2-07-0015-005 1
P2-07-0020-001 HANDLIGHT P2-07-0015-001 1
P2-07-0020-002 HANDLIGHT P2-07-0015-002 AND -003 1
P2-07-0020-003 HANDLIGHT P2-07-0015-004 AND -005 1
Y3-01-0147 CMM - COMPONENT P2-07-0015-001, -002, -003, 1

MAINTENANCE MANUAL -004, AND -005
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Rev. 8 Dec 14/17
AIRLINE 1234567
PART NUMBER PN NOMENCLATURE USED ON MIN BUY
A1-25-0097-002 O-RING P2-07-0015-001, -002, -003, 1

PACKAGE OF QTY 1 -004 AND -005
A1-25-0097-003 O-RING P2-07-0015-001, -002, -003, 1

PACKAGE OF QTY 50 -004 AND -005
25-60-13 20171
214
Page 10006
Rev. 8 Dec 14/17
Fig. 1 Sheet 1
Air Lite® 1E LED Flashlight System P2-07-0015-001

Figure 1
25-60-13 20171
214
Page 10007
Rev. 8 Dec 14/17
AIRLINE EFF UNITS

FIG.-ITEM PART NUMBER STOCK NOMENCLATURE CODE PER
NUMBER 1234567 ASSY
1 -1 P2-07-0015-001 LED FLASHLIGHT, ASSEMBLY(V55827), RF

MAIN
1
ATTACHING PARTS
10 A1-26-0086-001 TAMPER SHIELD, (OPTIONAL) 1
*** 1
20 P2-07-0020-001 HANDLIGHT ASSEMBLY, LED 1

FLASHLIGHT
FOR DETAILS SEE:
IPL FIGURE 1A
30 P2-07-0019-001 BRACKET ASSEMBLY, MOUNTING 1
- ITEM NOT ILLUSTRATED
25-60-13 20171
214
Page 10008
Rev. 8 Dec 14/17
Fig. 1A Sheet 1
10 (-002 AND -004 ONLY)
20
40 (-002 AND -004

ONLY)
30
Air Lite® 1E LED Flashlight Systems P2-07-0015-002 through -005

Figure 1A
25-60-13 20171
214
Page 10009
Rev. 8 Dec 14/17
AIRLINE EFF UNITS

NUMBER 1234567 ASSY
1A -1 P2-07-0015-002 LED FLASHLIGHT (V55827), ASSEMBLY, A RF

MAIN: GRAY
-1A P2-07-0015-003 LED FLASHLIGHT (V55827), ASSEMBLY, B RF

MAIN: GRAY
-1B P2-07-0015-004 LED FLASHLIGHT (V55827), ASSEMBLY, C RF

MAIN: BEIGE
-1C P2-07-0015-005 LED FLASHLIGHT (V55827), ASSEMBLY, D RF

MAIN: BEIGE
1
ATTACHING PARTS
10 A1-26-0086-002 TAMPER SHIELD, (OPTIONAL) A, 1
*** C
1
20 P2-07-0020-002 HANDLIGHT ASSEMBLY,, LED A, 1

FLASHLIGHT B
GRAY
FOR DETAILS SEE:
IPL FIGURE 1C
1
20 P2-07-0020-003 HANDLIGHT ASSEMBLY, LED C, 1

FLASHLIGHT D
BEIGE
FOR DETAILS SEE:
IPL FIGURE 1C
30 P2-07-0019-002 BRACKET ASSEMBLY, MOUNTING, A 1

GRAY
RPLD BY P2-07-0019-102
30 P2-07-0019-003 BRACKET ASSEMBLY, MOUNTING, B 1

GRAY
RPLD BY P2-07-0019-103
30 P2-07-0019-004 BRACKET ASSEMBLY, MOUNTING, C 1

BEIGE
RPLD BY P2-07-0019-104
30 P2-07-0019-005 BRACKET ASSEMBLY, MOUNTING, D 1

BEIGE
RPLD BY P2-07-0019-105
30 P2-07-0019-102 BRACKET ASSEMBLY, MOUNTING, A 1

GRAY
25-60-13 20171
214
Page 10010
Rev. 8 Dec 14/17
AIRLINE EFF UNITS

NUMBER 1234567 ASSY
1A 30 P2-07-0019-103 BRACKET ASSEMBLY, MOUNTING, B 1

GRAY
30 P2-07-0019-104 BRACKET ASSEMBLY, MOUNTING, C 1

BEIGE
30 P2-07-0019-105 BRACKET ASSEMBLY, MOUNTING, D 1

BEIGE
40 A1-20-0619-001 LABEL, ORIENTATION, FLASHLIGHT A, 1

C
25-60-13 20171
214
Page 10011
Rev. 8 Dec 14/17
Fig. 1B Sheet 1
20
30
10
HANDLIGHT ASSEMBLY P2-07-002-001

Figure 1B
25-60-13 20171
214
Page 10012
Rev. 8 Dec 14/17
AIRLINE EFF UNITS

NUMBER 1234567 ASSY
1B -1 P2-07-0020-001 LED FLASHLIGHT, HANDLIGHT RF

ASSEMBLY
(V55827)
10 A3-06-2090-001 BOTTOM CAP ASSEMBLY 1

(WITH LANYARD)
20 A1-25-0097-001 O-RING 1
30 P2-07-0021-002 BATTERY PACK 1
25-60-13 20171
214
Page 10013
Rev. 8 Dec 14/17
HANDLIGHT ASSEMBLY P2-07-0020-002 AND P2-07-0020-003 Fig. 1C Sheet 1
20
30
10
HANDLIGHT ASSEMBLY P2-07-0020-002 AND P2-07-0020-003

(P2-07-0020-002 USED ON P2-07-0015-002 AND P2-07-0015-003)
(P2-07-0020-003 USED ON P2-07-0015-004 AND P2-07-0015-005)
Figure 1C
25-60-13 20171
214
Page 10014
Rev. 8 Dec 14/17
AIRLINE EFF UNITS

NUMBER 1234567 ASSY
1C -1 P2-07-0020-002 LED FLASHLIGHT HANDLIGHT A, RF

ASSEMBLY, (V55827), GRAY B
-1 P2-07-0020-003 LED FLASHLIGHT HANDLIGHT C, RF

ASSEMBLY, (V55827), BEIGE D
ATTACHING PARTS
10 A3-06-2090-001 BOTTOM CAP ASSEMBLY (WITH A, 1
LANYARD), GRAY B
10 A3-06-2090-003 BOTTOM CAP ASSEMBLY (WITH C, 1

LANYARD), BEIGE D
20 A1-25-0097-001 O-RING A, B, 1
C, D
30 P2-07-0021-002 BATTERY PACK A, B, 1

C, D
25-60-13 20171
214
Page 10015
Rev. 8 Dec 14/17
INTENTIONALLY BLANK
25-60-13 Page 10016

Air Lite 1E Led Flashlight System: Component Maintenance Manual With Illustrated Parts List

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Astronics DME

6830 NW 16th Terrace,

COMPONENT MAINTENANCE MANUAL WITH

AIR LITE® 1E LED FLASHLIGHT SYSTEM

PART No.: P2-07-0015-001 [mfr?]

Revision Issue Date By Revision Issue Date By

25-60-13 Page RR-2

RECORD OF TEMPORARY REVISIONS

Temporary Issue Date Date Inserted / Date Removed / Date

25-60-13 Page RTR-2

SERVICE BULLETIN LIST

Service Bulletin / Issue Date Date Title

XX-XXXX N/A SB Title N/A R

25-60-13 Page SBL-2

LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

TITLE PAGE T-1 Dec 14/17 5002 Blank

TABLE OF CONTENTS TOC-1 Dec 14/17 STORAGE 15001 Dec 14/17

DISASSEMBLY 3001 Dec 14/17

CLEANING 4001 Dec 14/17

INSPECTION/CHECK 5001 Dec 14/17

25-60-13 Page LEP-2

2. List of Abbreviations Used INTRO-1

3. Manual Sections INTRO-2

DESCRIPTION AND OPERATION

TESTING AND FAULT FINDING

TABLE OF CONTENTS (CONTINUED)

ILLUSTRATED PARTS LIST

2. To Use this Section 10001

1 Air Lite® 1E LED Flashlight System P2-07-0015-001 10007

1. List of Abbreviations and Acronyms INTRO 1

LIST OF TABLES (CONTINUED)

4001. Cleaning Consumables 4001

25-60-13 Page TOC-4

Dates of Shop Verification by Actual Performance:

• Testing and Fault Isolation Verified Jan 15/09-

• Disassembly Verified Jan 15/09

• Assembly Verified Jan 15/09

• Engineering Technical Review Completed Jan 15/09

Table 1. List of Abbreviations and Acronyms

ATA Air Transport Association

ABS Acrylontrile Butadiene Styrene

ESD Electrostatic Discharge

IEC International Electro-Technical

LED Light Emitting Diode

MTOSS Maintenance Task Oriented Support

(1) TITLE PAGE

(2) RECORD OF REVISIONS

(3) RECORD OF TEMPORARY REVISIONS

If it is necessary to provide changed or additional information before a permanent revision

(4) SERVICE BULLETIN LIST

•The service bulletin number

(5) SERVICE INFORMATION LETTERS

•The service information letter number

(6) LIST OF EFFECTIVE PAGES

(7) TABLE OF CONTENTS

(8) LIST OF FIGURES

(1) DESCRIPTION AND OPERATION

(2) TESTING AND FAULT ISOLATION

This section provides testing and fault isolation procedures.

This section provides instructions and inspection intervals.

This section provides assembly instructions.

This section provides removal information.