Farol Branco AS532

ECE - TELEFLEX SYNERAVIA
COMPONENT MAINTENANCE MANUAL

4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646
ATA
33-49-19
Manufacturer
P/N
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646
Date of issue
APR 15/2012
DATE: APR 15/12 LETTER OF TRANSMITTAL

REVISION No. 9 33-49-19 Page 1
The document reference is online, please check the correspondence between the online documentation and the printed version.
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646
LETTER OF TRANSMITTAL
REVISION No. 9 DATED JUNE 30/2009
To: Holders of Searchlight Component Maintenance Manual with IPL, No. 33-49-19 dated
15 APRIL 12.
SUBJECT
The revised pages are indicated below with the subject of the revision. Discard Manual 33-
49-19 entirely. All pages were reissued with this revision.
PAGE LEFT BLANK INTENTIONALLY
DATE: APR 15/12 LETTER OF TRANSMITTAL

REVISION No. 9 33-49-19 Page 1
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WITH
ILLUSTRATED PARTS LIST
SEARCHLIGHTS
P/N 4168762
4202104
4217228
4226271
4307405
4360404
4361646
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Copyright ECE-TELEFLEX-SYNERAVIA
The data and information contained in this document are proprietary to ECE. This
document is given in confidence and may not be reproduced, stored in a retrieval system,
or transmitted to a third party, in any form or by any means, electronic, mechanical,
photocopying, or otherwise, without the prior written permission of ECE.
Any unauthorized copy, distribution or utilization is illegal according to Article L 122-4 and L
335-2 of the "Code de la Proprit Intellectuelle" and to international agreements related to
proprietary rights.
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RECORD OF REVISIONS
REV INSERTION REV INSERTION

DATE BY DATE BY
No. DATE No. DATE
1 OCT 83
2 DEC 31/86
3 FEB 29/92
4 AUG 31/94
5 DEC 15/97
6 NOV 30/98
7 APR 30/03
8 JUN 30/09
9 APR 15/12
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RECORD OF TEMPORARY REVISIONS
TEMPORARY REVISION INSERTED DELETED
PAGE ISSUE DATE

No. DATE BY DATE REVISION No. BY
No.
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ROTR - Page 2
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LIST OF EFFECTIVE PAGES
SUBJECT PAGE DATE SUBJECT PAGE DATE

Title Page APR 15/12 15 APR 15/12
16 APR 15/12
Record of 1 APR 15/12 17 APR 15/12
Revisions 2 Blank 18 APR 15/12
19 APR 15/12
Record of 1 APR 15/12 20 APR 15/12
Temporary 2 Blank 21 APR 15/12
Revisions 22 APR 15/12
23 APR 15/12
List of Effective 1 APR 15/12 24 APR 15/12
Pages 2 APR 15/12 25 APR 15/12
26 APR 15/12
Service Bulletins 1 APR 15/12
List 2 Blank Testing and Fault 101 APR 15/12
Isolation 102 APR 15/12
List of 1 APR 15/12 103 APR 15/12
Amendments 2 APR 15/12 104 APR 15/12
3 APR 15/12 105 APR 15/12
4 APR 15/12 106 APR 15/12
107 APR 15/12
Table of Contents 1 APR 15/12 108 APR 15/12
2 Blank
Disassembly 301 APR 15/12
List of Approved 1 APR 15/12 302 APR 15/12
Repair Facilities 2 Blank 303 APR 15/12
304 APR 15/12
List of Special 1 APR 15/12 305 APR 15/12
Materials 2 Blank 306 APR 15/12
307 APR 15/12
Introduction 1 APR 15/12 308 APR 15/12
2 Blank 309 APR 15/12
310 Blank
Description and 1 APR 15/12
Operation 2 APR 15/12 Cleaning 401 APR 15/12
3 APR 15/12 402 Blank
4 APR 15/12
5 APR 15/12 Check 501 APR 15/12
6 APR 15/12 502 APR 15/12
7 APR 15/12 503 APR 15/12
8 APR 15/12 504 Blank
9 APR 15/12
10 APR 15/12 Repair 601 APR 15/12
11 APR 15/12 602 Blank
12 APR 15/12
13 APR 15/12 Assembly and 701 APR 15/12
14 APR 15/12 Storage 702 APR 15/12
LEP - Page 1
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LIST OF EFFECTIVE PAGES
SUBJECT PAGE DATE SUBJECT PAGE DATE

703 APR 15/12 INTRO 1001 1 APR 15/12
704 APR 15/12 2 APR 15/12
705 APR 15/12 3 APR 15/12
706 APR 15/12 4 APR 15/12
707 APR 15/12
708 APR 15/12 VCI 1001 1 APR 15/12
709 APR 15/12 2 APR 15/12
710 APR 15/12
711 APR 15/12 NI/ALPHA 1001 1 APR 15/12
712 APR 15/12 2 Blank
713 APR 15/12
714 APR 15/12 NI/NUM 1001 1 APR 15/12
715 APR 15/12 2 APR 15/12
716 APR 15/12 3 APR 15/12
717 APR 15/12 4 APR 15/12
718 APR 15/12
719 APR 15/12 Detailed
720 APR 15/12 Parts List TP1001 APR 15/12
721 APR 15/12 1001-0 APR 15/12
722 APR 15/12 1001-00 Blank
723 APR 15/12 1001-0A APR 15/12
724 APR 15/12 1001-1 APR 15/12
725 APR 15/12 1001-2 APR 15/12
726 APR 15/12 1001-3 APR 15/12
727 APR 15/12 1001-4 APR 15/12
728 APR 15/12 1001-5 APR 15/12
729 APR 15/12 1002-0 APR 15/12
730 APR 15/12 1002-00 Blank
731 APR 15/12 1002-0A APR 15/12
732 APR 15/12 1002-1 APR 15/12
733 APR 15/12 1002-2 APR 15/12
734 Blank 1002-3 APR 15/12
1002-4 Blank
Fits and Clearances 801 APR 15/12
802 Blank
Special Tools 901 APR 15/12

Fixtures and 902 Blank
Equipment
Illustrated
Parts List (IPL)
TP 1001 1 APR 15/12

2 Blank
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SERVICE BULLETINS LIST
SERVICE BULLETIN REV No. DATE SUBJECT
4202104-33-001 Functional improvement of the searchlight
SBL - Page 1
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SBL - Page 2
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LIST OF AMENDMENTS
APPLICABLE TO
AMDT BRIEF DESCRIPTION
VERSION
BASIC EQUIPMENT
A Clearances reduced 4168762
Centering improved 4202104
Lighting improved
4226271
Eight caps added
Length changed
Tightening torque added
Light seal P/N 4183825 (1-30A) replaced by P/N 4318397 (1-30C) 4307405
4217228
Relay circuit board assembly P/N 4218968 (2-120B) discarded and
replaced by P/N 4384422 (2-120C). 4361646
Screw P/N 3059812 (2-130A) replaced by screw P/N 3131248
(2-130B).
Bumper P/N 3128826 (2-124A) added.
Spacer P/N 43851889 (2-122A) added.
Bumper P/N 4191612 (1-630A) discarded and replaced by the new
bumper P/N PE0000090Y00 (1-630B).
Locking plate P/N PE0000091Y00 (1-632A) added.
Screw P/N 3045478 (1-634A) added.
Nut P/N 3014407 (1-636A) added.
Screw P/N 3021942 (1-290A) replaced by the new screw P/N
3038231 (1-290B).
Cover plate P/N 4185854 (1-070A) modified.
Improvement of the optical retainer ring design. A screw replaces 4360404
the spring that maintains the retainer ring.
Retainer ring P/N 4206705 replaced by the P/N 4244598
LOA - Page 1
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APPLICABLE TO
VERSION
BASIC EQUIPMENT
B Design improved 4168762
Quality improved 4202104
Power supply contact improved
4226271
rotary contact item 1-150 modified
contact plate item 1-440 modified
Motor 4190654 (1-350A) replaced by motor 4245005 (1-350B).
Terminal board corrosion resistance improved. 4217228
nut 3016733 (2-230A) replaced by nut 3115226 (2-230B).
Relay circuit board assembly P/N 4191345 (2-120A) discarded and 4360404
replaced by P/N 4384422 (2-120C).
(2-130B).
bumper P/N PE0000090Y00 (1-630B).
Screw P/N 3045478 (1-634A) added.
Nut P/N 3014407 (1-636A) added.
3038231 (1-290B).
Cover plate P/N 4202141 (1-070B) modified.
Bumper P/N 4191612 (1-630A) discarded and replaced by the new 4307405
bumper P/N PE0000090Y00 (1-630B).
Screw P/N 3045478 (1-634A) added.
Nut P/N 3014407 (1-636A) added.
3038231 (1-290B).
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APPLICABLE TO
VERSION
BASIC EQUIPMENT
C Motor 4245005 (1-350B) replaced by motor 4297463 (1-350D). 4202104
Terminal board corrosion resistance improved. 4168762
nut 3016733 (2-230A) replaced by nut 3115226 (2-230B). 4226271
Relay circuit board assembly P/N 4191345 (2-120B) discarded and 4217228
replaced by P/N 4384422 (2-120C).
(2-130B).
bumper P/N PE0000090Y00 (1-630B).
Screw P/N 3045478 (1-634A) added.
Nut P/N 3014407 (1-636A) added.
3038231 (1-290B).
Relay circuit board assembly P/N 4218968 (2-120B) discarded and 4307405
replaced by P/N 4384422 (2-120C).
(2-130B).
D Terminal board corrosion resistance improved. 4202104
nut 3016733 (2A-230A) replaced by nut 3115226 (2A-230B).
nut 3018108 (2A-220A) replaced by nut 3068619 (2A-230B).
Moving light housing locking screw added.
Screw 3010565 (1A-112B).
Moving light housing 4202082 (1A-090B) replaced by 4347966
(1A-090C).
Light housing spindle 4190558 (1-170A) replaced by 4347973
(1-170C).
F Retainer ring P/N 4206705 (1-010B) replaced by retainer ring P/N 4202104
4244598 (1-010C).
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APPLICABLE TO
VERSION
BASIC EQUIPMENT
G Bumper P/N 4191612 (1-630A) discarded and replaced by the new 4202104
bumper P/N PE0000090Y00 (1-630B).
Screw P/N 3045478 (1-634A) added.
Nut P/N 3014407 (1-636A) added.
3038231 (1-290B).
Cover plate P/N 4202141 (1-070B) modified.
H Relay circuit board assembly P/N 4191345 (2-120A) discarded and 4202104
replaced by P/N 4384422 (2-120C).
(2-130B).
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TABLE OF CONTENTS
Page
DESCRIPTION AND OPERATION .......................................................................... 1
TESTING AND FAULT ISOLATION ........................................................................ 101
DISASSEMBLY ........................................................................................................ 301
CLEANING ............................................................................................................... 401
CHECK .................................................................................................................... 501
REPAIR.................................................................................................................... 601
ASSEMBLY AND STORAGE .................................................................................. 701
FITS AND CLEARANCES ....................................................................................... 801
SPECIAL TOOLS, FIXTURES AND EQUIPMENT .................................................. 901
ILLUSTRATED PARTS LIST ................................................................................... 1001
TOC - Page 1
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TOC - Page 2
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LIST OF APPROVED REPAIR FACILITIES
NAME ADDRESS
EUROPE: 26, rue des Solets

Zone S.I.L.I.C
E.C.E. TELEFLEX-SYNERAVIA BP 449
94152 RUNGIS CEDEX
FRANCE
Phone: +33 1 45 12 84 84
Fax: + 33 1 45 12 84 48
USA: W175 N5737 Technology Drive

Menomonee Falls
ZODIAC SERVICES AMERICAS WI 53051
USA
Phone: (262) 293 1000
Phone AOG: (262) 293 1111
Fax: (262) 293 1010
www.services.zodiac.com
ASIA: 36, Loyang Drive

SINGAPORE 508949
ZODIAC SERVICES ASIA Phone: (65) 6579 2230
Phone AOG: (65) 9770 5061
Fax: (65) 6579 2231
MIDDLE EAST AND AFRICA: Abu Dhabi International Airport

Cargo Village Area, P.O. Box 106675
IN-SERVICES MIDDLE EAST ABU DHABI
Phone: (971) 2575 7088
Phone AOG: (65) 5064 20034
Fax: (65) 2575 8482
LARF - Page 1
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LARF - Page 2
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LIST OF SPECIAL MATERIALS

NOTE Equivalent materials can be used instead of listed materials.
USE
DESIGNATION SUPPLIERS
PART NUMBER OR NAME AND ADDRESS TEST DISA CLEAN. CHECK REPAIR ASSY/ST.
SPECIFICATION
St des PETROLES SHELL X X

GREASE
307 Rue Estienne DORVES
AEROSHELL
92700 COLOMBES
33MS
MOLYCOTE TYPE DOW CORNING FRANCE SA X
BR2 Le Britannia
20, bd Eugne Deruelle
69003 LYON
BRENNTAG SA X
TRICHLORETHANE 90 av. du Progrs
69680 CHASSIEU
(France)
HENKEL TECHNOLOGIES FRANCE X

LOCTITE 242 DIVISION LOCTITE
8 BD MICHAEL FARADAY
77700 SERRIS

LOCTITE 243
DIVISION LOCTITE
77700 SERRIS

LOCTITE CYANO-
DIVISION LOCTITE
ACRYLATE IS496
or IS12
77700 SERRIS
ARALDITE 1012 Local X
WHITE SPIRIT Local X
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INTRODUCTION
1. GENERAL
This Component Maintenance Manual agrees with ATA Specification No. 100 (AIR
TRANSPORT ASSOCIATION OF AMERICA). This manual provides all the information
necessary for reconditioning the equipment.
This manual gives the work instructions for maintaining the equipment manufactured by
ECE - TELEFLEX SYNERAVIA 26 rue des Solets - 94152 RUNGIS - FRANCE.
The procedures specified must be done in maintenance shops with special tools and test
benches.
This manual does not include approved techniques, maintenance frequencies or details
which change for the different available shop equipment.
Values are generally given in SI Units (or multiples and sub-multiples of these units)
(meter, kilogram, second). In a few special cases, more commonly used units have been
used.
2. SHOP CHECK
The manufacturer did a check to make sure that the procedures given in the sections to
the manual are satisfactory. For this, he did the maintenance procedures such as
disassembly, assembly and testing.
3. REVISION
With each revision written for the manual, full instructions are supplied. These refer to the
related page numbers for insertion and deletion.
A vertical black line or the letter R in the margin show the revised, added or removed
material.
INTRO - Page 1
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INTRO - Page 2
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DESCRIPTION AND OPERATION

1. INTRODUCTION
This manual contains all the information which is necessary for the tests and overhaul of
the searchlights types 4168762, 4202104, 4217228, 4226271, 4307405, 4360404 and
4361646. Unless differently indicated, this information is the same for the seven types of
equipment.
Detailed instructions and procedures for overhaul are indicated when necessary. If not,
standard procedures must be used.
Spare parts which can be replaced are shown in the "Illustrated Parts List" of this manual.
2. PURPOSE
The searchlights 4168762, 4202104, 4226271, 4217228, 4307405 and 4360404 are used
to supply lighting for aircraft or helicopter night takeoffs and landings.
Searchlight 4361646 is used to supply lighting in search mode and for aircraft or helicopter
night landings.
3. SPECIFICATIONS
A. General specifications
(1) French standards

(a) Approval requirements AIR 8480
(b) Environmental requirements AIR 7304
(c) Electrical requirements AIR 2021 P
(d) Overvoltage and insulation requirements AIR 0520
(e) Acceptance requirements AIR 9480
(2) Foreign standards MIL-L81174

(3) Normal operating speed P/N 4168762: 140 kts
(at ground level) P/N 4202104: 100 kts
P/N 4226271: 140 kts
P/N 4217228: 140 kts
P/N 4307405: 140 kts
P/N 4360404: 100 kts
P/N 4361646: 140 kts
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Detail: searchlight 4360404
Searchlights P/N 4168762, Searchlights P/N 4202104

4226271, 4217228,
4307405 and 4361646
General view
Figure 1
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B. Light specifications
4168762 - 4217228 4202104 - 4360404 4226271

4307405 - 4361646
Type Sealed beam PAR46 - Sealed beam PAR64 - Sealed beam PAR46 -
halogen halogen halogen
Part number 3020865 (halogen light) 3057576 (halogen light) 3020865 (halogen light)
Number of filaments 1 1 1
Power 450 W 600 W 450 W
Supply voltage 28 V dc 28 V dc 28 V dc
Current 17 A 1 A 22 A 1 A 17 A 1 A
Axial light density 300 000 cd 765 000 candelas 300 000 candelas
Light distribution 15 horizontal 11 horizontal 15 horizontal
9 vertical 7 30' vertical 9 vertical
Average life 50 h 100 h 50 h
C. Electromechanical specifications (Figures 2 and 2A)
(1) Retraction
4168762 4307405 4202104 4360404 4226271 4361646
4217228
Extension angle (not 120 + 10 90 + 10 120 + 10 + 0 120 + 10 + 0 90 + 10 + 0 with
adjustable) + 0 + 0 intermediate position
40 5 (not
adjustable)
Extension time 10 s (at 140 kts) 10 s (at 100 kts) 10 s (at 140 kts) 8 s (at 140 kts)
End of travel 2 positions: 2 positions: 3 positions: 2 positions: 3 positions:
retracted, extended retracted, retracted, retracted, retracted,
extended extended extended intermediate and
and extended
light comes on:
intermediate Light comes on:
circuit closed
(adjustable intermediate position
from 60 to
from 70 to
120 of travel.
95)
Retraction end of Adjustable by a screw Factory adjusted Factory adjusted Factory adjusted
travel and nut in the
microswitch box
Extension end of Factory adjusted Factory adjusted Factory adjusted Factory adjusted
travel
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(2) Turning
4168762 - 4217228 4202104 - 4360404 4226271 4361646
4307405
Rotation 360 to left or right 360 to left or right 360 to left or right 90 5 right
60 5 left
Time about 15 s (at 140 kts) about 15 s (at 100 kts) about 15 s (at 140 kts) 4 s right
for 360 for 360 for 360 2.5 s left (at 140 kts)
Marked position Horizontal at each turn Horizontal at each turn Horizontal at each turn 3 switches
Light comes on: circuit Position zero for end of
closed from 90 to 180 travel retraction to right
travel to left or right. and left
(3) Motors
4168762 - 4217228 4202104 - 4360404 4226271
4307405
Type Permanent magnets Permanent magnets Permanent magnets
Supply 28 V dc 28 V dc 28 V dc
Current <2A <2A <2A
Torque 1.2 N.cm at 11000 rpm 1.2 N.cm at 11000 rpm 1.2 N.cm at 11000 rpm
(4) More information

4168762 - 4217228 4202104 4360404 4226271 4361646
4307405
Electrical 8 M4 terminals 8 M4 12 M4 8 M4 terminals 8 M4 terminals
connections terminals terminals
Operating - 35 C to + 55 C - 55 C to + 70 C - 35 C to + 55 C - 35 C to + 55 C
temperature range
Survival - 45 C to + 70 C - 45 C to + 70 C - 45 C to + 70 C
temperature range
Service life 2000 cycles (1 cycle = 2000 cycles (1 cycle = 2000 cycles (1 cycle = 2000 cycles (1 cycle
1 extension + 360 turn 1 extension + 360 turn 1 extension + 360 turn = 1 extension + left turn
(left + right) (left + right) (left + right) + 1 + right turn + 1
+ 1 retraction) + 1 retraction) retraction) retraction)
Weight 2.450 kg 10 g 3.200 kg 3.200 kg 2.480 kg 2 % 2.60 kg 2 % (5.63 lb.)
(5.402 lb.) 2% 2% (5.46 lb.)
(7.05 lb.) (7.05 lb.)
Attaching to Four screws Four screws Four screws Four screws
aircraft Dia 8-32 mm UNC Dia 8-32 mm UNC Dia 8-32 mm UNC Dia 8-32 mm UNC
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4. DESCRIPTION
A. General description (Figures 2 and 2A)
The searchlight is a single unit which has a fixed assembly whose support plate is
attached by four screws dia 8-32 mm UNC, on the aircraft structure.
B. Detailed description
(see IPL: figure 1 for searchlights P/N 4168762, 4226271, 4217228 and 4307405 and
figure 1A for searchlights P/N 4202104, 4360404 and 4361646).
(1) The main components of the moving light housing (1-90) are:
(a) the halogen light (1-20),
(b) the light seal (1-30),
(c) the clamp (1-10),
(d) the ground terminal for electrical connections, which is attached by the
screw (1-40).
(2) At the end of the housing (1-90) is a sleeve which two screws (1-100) and nuts
(1-110) attach to the directional spindle (1-170). On searchlights P/N 4202104
and 4360404 the attachment of the housing (1-90) is completed by a screw (1-
112).
(3) The "turn" casing (1-660) turns about the spindle (1-610) which is held by the
two bearings (1-580) and (1-620). The directional motor (1-350) is attached to
the casing by three screws (1-360) fitted with cable clamps (1-390) and (1-
395).
(4) The components of the reduction gear system, installed in the casing (1-660),
are:
(a) the screw at the end of the motor shaft,
(b) the gear and pinion spindle (1-270), held by the bearing (1-280), the shims
(1-260), and the bearing (1-250), which is held by the retaining ring (1-
240),
(c) the light housing spindle (1-170), held by the two bearings (1-210),
(d) the rotary contact (1-150), bonded inside an insulating bush (1-160) and
applied against the plate (1-140). The plate supplies the + 28 V dc to make
the light come on.
(5) The spindle (1-170) has a stop (1-200) and a spring (1-190) which operate the
lever of the microswitch (1-220). This shows the horizontal position of the light
at each turn (right or left) or position zero for retraction (P/N 4361646).
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(6) For the searchlight P/N 4226271 only: the gearwheel of the spindle (1-170) has
a cam (1-215) which operates the microswitch that makes the light (1-231)
come on. The microswitch (1-231) with its bracket (1-237) is attached in the
casing (1-660).
(7) For the searchlight P/N 4361646 only: the gearwheel of the spindle (1-170) has
a cam (1-215B) which operates the right turn (1-220B) and left turn (1-665)
microswitches. The microswitch (1-231) with bracket (1-233) and the
microswitch (1-665) with angle bracket (1-667) are attached in the casing (1-
660).
(8) A moving assembly, holding the searchlight and rotating about a spindle to be
retracted (positions: retracted - extended).
NOTE: The fixed assembly of the searchlights P/N 4202104 and 4360404 includes a
protective plate covering the case. This plate is used to attach the searchlight to the
aircraft.
(9) The case of the fixed assembly includes:
(a) the retracting system, which extends the searchlight through a maximum
angle of 120 (90 for 4307405 and 4361646),
(b) the end of travel box. For searchlights P/N 4168762, 4202104, 4217228
and 4307405, the end of travel box contains two microswitches controlling
the retracted and extended positions. For searchlights P/N 4226271,
4360404 and 4361646, this box contains three microswitches controlling
the retracted and extended positions and making the light come on,
(c) the electrical connections box including eight (twelve for searchlight P/N
4360404) 4 mm diameter external terminals and five remote-control relays:
retraction-extension, left/right turn, light on/off,
(d) for searchlights P/N 4217228 and 4307405 only: a relay noise-filter
including five diodes.
(10) The components of the moving assembly are:

(a) the searchlight, containing the halogen light which can be easily removed
by removing the clamp,
(b) the directional system which rotates about a spindle. The moving light
housing is attached to the output spindle of the directional system.
(11) Two self-adhesive labels are bonded to the relay box:

(a) one identifying the searchlight,
(b) the other indicating the modifications.
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(12) Searchlights P/N 4202104 and 4360404 also have a self-adhesive label
indicating the correct position of the light filament in the moving housing.
(13) A cover (1-120) attached by four screws (1-130) closes the casing which has a
cover plate (1-70) attached by two screws (1-80).
(14) The "retract" casing (1-640) contains the "retract" motor (1-410) which is
attached by three screws (1-420) and has a cable clamp (1-450).
(15) The components of the reduction gear system, installed in the casing (1-640)
are:
(a) the screw at the end of the motor shaft,
(b) the gear and pinion spindle (1-490), held by the bearing (1-500), the shims
(1-480), the shims (1-485) and the bushing (1-470) which is held by the
retaining ring (1-460),
(c) the gearwheel (1-560) whose spindle is held by the bearing (1-570), the
shims (1-550) and the bushing (1-540) which is held in position by the
retaining ring (1-530).
(16) The spindle of the gearwheel (1-560) is fitted with the pinion (1-520), held in
position by the pin (1-510). This pinion meshes with the gear sector (1-590).
The gear sector is attached to the casing (1-660) by two screws (1-600).
(17) The case (2-260) contains all the searchlight parts:
(a) the "retract" casing assembly (1-640), attached by the four screws (1-650),
(b) the microswitch box assembly (2-10), attached by the two screws (2-20),
washers (2-30) and (2-70) and nuts (2-40), and base (2-50).
(18) The microswitch box (2-10) includes:

(a) two microswitches (2-80), for the "RETRACTION" and "EXTENSION"
functions, each attached by two screws (2-90),
(b) for the searchlight P/N 4361646 only: the two microswitches (2-80), for the
"RETRACTION" and "EXTENSION" functions, each attached by two
screws (2-90) and two washers (2-91),
(c) for the searchlight P/N 4226271 only: a third microswitch (2-95A) attached
by two screws (2-97), to make the light come on,
(d) for the searchlight P/N 4360404 only: a third microswitch (2-95B) attached
by two screws (2-97) and two washers (2-98), to make the searchlight
extend to a preset intermediate position,
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(e) for the searchlight P/N 4361646 only: a third microswitch (2-95A) attached
by two screws (2-97), to make the light come on and for the intermediate
position.
(19) The boss of the box (2-10) is connected to the end of the spindle (1-610)
supporting the directional system.
(20) The case includes:
PRE SB 4202104-33-002
PRE SB 4361646-33-001
PRE SB 4217228-33-001
PRE SB 4307405-33-002
PRE SB 4360404-33-001
(a) a relay circuit board assembly (2-120A) or (2-120B) fitted with four relays
(2-140), from right to left:
"R1": turn to the left,

"R2": turn to the right,
"R3": extend,
"R4": retract.
(b) a circuit board (2-160) for interconnecting relays R1 to R4, and including
ten contacts, identified as follows:
"1": "retract" motor "6": "position 0" microswitch

"2": "retract" motor "7": ground
"3": "retracted" position microswitch "8": turn "to the left"
"4": + 28 V dc "9": "turn" motor
"5": "extended" position microswitch "10": "turn" motor
POST SB 4202104-33-002
POST SB 4361646-33-001
POST SB 4217228-33-001
POST SB 4307405-33-002
POST SB 4360404-33-001
(c) a relay circuit board assembly (2-120C) with the four relays:
"R1": turn to the left,

"R2": turn to the right,
"R3": extend,
"R4": retract,
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and thirteen contacts, identified as follow:

"1": "retract" motor "8": "turn" to the left
"2": "retract" motor "9": "turn" motor
"3": "retracted" position microswitch "10": "turn" motor
"4": + 28 V dc "11": position 0 microswitch
"5": "extended" position microswitch "12": end cycle signal
"6": "turn" to the right "13": turned position microswitch
"7": ground
(d) a relay (2-170) for turning the light on and off.
(21) Five screws (2-110) attach the cover (2-100) which has eight terminals (twelve
terminals for searchlight 4360404), identified as follows:
"1": ground "7": retraction
"2": turn on "8": indication
for searchlight P/N 4361646 only:
"2" turn on and intermediate extension
"3": + 28 V dc "9": + 28 V dc motor
Additional terminals
"4": right "10": intermediate extension on searchlight
"5": left "11": intermediate extension P/N 4360404
only
"6": extension "12": extension in the axis
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Overall dimensions of searchlights

P/N 4168762, 4226271, 4217228, 4307405 and 4361646
Figure 2
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Overall dimensions of searchlights

P/N 4202104 and 4360404
Figure 2A
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5. OPERATION (Figures 3, 3A, 3B, 4, 5, 6, 7, 8 and IPL Figures 1, 1A, 2 and 2A)
A. Retraction and extension movement
(1) The "turn" casing (1-660) with its searchlight (1-90) is hinged on the spindle (1-
610), which turns in the bearings (1-580) and (1-620). This spindle is also held
between the microswitch box (2-10) at one end and the "retract" casing (1-640)
at the other end.
(2) The pinion of the motor (1-410) turns the gear of the spindle (1-490). The
pinion of this spindle is engaged with the gear of spindle (1-560). The pinion of
this spindle turns the gear sector (1-590), which is connected to the turn
casing (1-660).
(3) The motor (1-410) can turn the reduction gear in both directions. The
searchlight can thus be set to the "retracted" or "extended" position.
(4) The motor supply is controlled by two relays: "extend" relay R3 the excitation
coil of which is controlled by the "extend" terminal. And "retract" relay R4 the
excitation coil of which is controlled by the "retract" terminal.
(5) The microswitch lever is stopped against a screw (1-290) which is locked in
position by the locknut (1-300). This causes the searchlight to stop in the
"retracted" position.
(6) The searchlight is stopped in the "extended" position through its design. The
unit stops against the bumper (1-630) and operates the "extended" microswitch
lever at the end of its travel. The extension of searchlights P/N 4307405 and
4361646 is limited to 90 by the lug (1-303A) or the lever (1-303B) touching the
lever of the microswitch (2-80).
(7) The searchlight P/N 4360404 has a cam (1-700) which is attached to the "turn"
casing (1-660). When this cam touches the blade of the microswitch (2-95B),
the searchlight is extended to an intermediate position which can be adjusted
from 70 to 95.
(8) The searchlight P/N 4361646 has a cam (1-343B) which is attached to the
"turn" casing (1-660). When this cam touches the microswitch (2-95A), the
searchlight is extended to an intermediate, at 40 (not adjustable).
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B. Left or right turn movement
(1) The pinion of the motor (1-350) turns the gear of the spindle (1-270). The
pinion of this spindle is engaged with the gear of spindle (1-170) held by
bearings (1-210). The end of this spindle is attached to the moving light
housing (1-90) which is turned.
(2) The motor (1-350) can turn the reduction gear in both directions. The
searchlight can thus be turned to the left or the right.
(3) The motor supply is controlled by two relays: "turn to the left" R1 and "turn to
the right" R2, the excitation coil of which is controlled directly for each of these
two movements.
(4) The relay operates the "retracted" microswitch. After this operation is
completed, this microswitch operates the "turn to the right" relay.
(5) At the end of the travel, the spring stop of the spindle (1-170) operates the
"turn" microswitch blade.
C. Light operation
(1) Searchlights P/N 4168762, 4202104, 4217228 and 4307405

(a) A "light" relay (2-170), whose field coil is controlled directly, turns the light
off and on. The positive 28 V dc is supplied to the light housing (1-90)
through the spindle (1-170) by means of a rotary contact (1-150). This
rotary contact is insulated by the bushing (1-160) and is supplied by the
plate (1-140).
(2) Searchlight P/N 4226271

(a) The + 28 V dc is supplied to the light housing (1-90) in the same way as for
searchlights P/N 4168762, 4202104, 4217228 and 4307405. The "light"
relay (2-170) is supplied by the two microswitches (1-231) and (2-80).
(b) During the extension, the cam (1-343) leaves the contact of the
microswitch (2-95): the circuit is open (light off) from the retracted position
to the 60 position, and closed (light on) during the remaining travel.
(c) During the turn, the cam (1-215) operates the contact of the microswitch
(1-231) when the spindle (1-170) turns: the circuit is closed (light on) over
180 (90 on both sides of the horizontal position) and open (light off)
during the remaining travel.
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(3) Searchlight P/N 4361646

(a) The + 28 V dc is supplied to the light housing (1-90) in the same way as for
searchlights P/N 4168762, 4202104, 4217228 and 4307405.
(b) During extension, the cam (1-343B) leaves the contact of the microswitch
(2-95): the circuit is open (light off) from the retracted position and 60, and
closed (light on) during the remaining travel.
(c) During the turn, the cam (1-215) operates the contacts of the
microswitches (1-231) when the spindle (1-170) turns: the circuit is closed
(light on) over 150 (90 to the right and 60 to the left) and open (light off)
during the remaining travel.
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+ 28 V dc 1-140
1-280 1-150
1-160
1-350 1-270
1-220 1-250
1-660 1-170
1-560
1-410
1-620 1-590
2-10 1-580
1-210 1-610
1-470
1-490
1-560
1-500
1-540
1-570
1-90
Transmission system, searchlights

P/N 4168762, P/N 4202104, P/N 4217228 and P/N 4307405
Figure 3
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+ 28Vdc 1-140
1-280 1-150
1-215 1-160
1-350 1-270
1-220 1-250
1-660 1-170
1-560
1-343 1-410
1-620 1-590
2-10 1-580
1-210 1-610
1-470
1-490
1-560
1-500
1-540
1-570
1-90
Transmission system, searchlight P/N 4226271 and P/N 4361646

Figure 3A
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+ 28Vdc 1-140
1-280 1-150
1-160
1-350 1-270
1-220 1-250
1-660 1-170
1-560
1-700 1-410
1-620 1-590
2-10 1-580
1-210 1-610
1-470
1-490
1-560
1-500
1-540
1-570
1-90
Transmission system, searchlight P/N 4360404

Figure 3B
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PRE SB 4202104-33-002
7
"Retraction" C "Extension" C
switch switch "Turn" switch
NC NO NC NO NO NC 6
5
R4 R3 R2 R1
4
"Retraction" "Extension" "Right" "Left"
3
C1 T1 C1 T1 C1 T1 T1
C1
R1 R1 R1 R1 2
1
C2 T2 C2 T2 C2 T2 C2 T2
R2 R2 R2
R2
M M
"Retraction" "Turn"
Light
Light relay
Electrical
rotary contact
(Searchlight retracted)
C1 C2 C1 C2 C1 C2 C1 C2
B B B B B B B B
R1 T2 R1 T2 R1 T2 R1 T2
Relay Relay Relay Relay

R1 R2 R3 R4
B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
Circuit diagram, searchlights P/N 4168762

Figure 4
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POST SB 4202104-33-002
Circuit diagram, searchlight P/N 4202104

Figure 4A
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7
"Retraction" C "Extension" C C
switch switch "Turn" switch
NC NO NC NO NO NC 6
5
R4 R3 R2 R1
4
3
C1 T1 C1 T1 C1 T1 T1
C1
R1 R1 R1 R1 2
1
C2 T2 C2 T2 C2 T2 C2 T2
R2 R2 R2
R2
M M
"Retraction" "Turn"
"Retraction"
Light
Light relay
Electrical
"Turn"
rotary contact
C1 C2 C1 C2 C1 C2 C1 C2
B B B B B B B B
R1 T2 R1 T2 R1 T2 R1 T2

R1 R2 R3 R4
B10 B9 B8 B7 B6 B5 B4 B3 B2 B1

Figure 5
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PRE SB 4217228-33-001
PRE SB 4307405-33-002
7
"R etraction" C "Extension" C C
switch sw itch "Turn" switch
NC NO NC NO NO NC 6
5
R4 R3 R2 R1
4
"R etraction" "Extension" "R ight" "Left"
3
C1 T1 C1 T1 C1 T1 T1
C1
R1 R1 R1 R1 2
1
C2 T2 C2 T2 C2 T2 C2 T2
R2 R2 R2 R2
M M
"R etraction" "Turn"

Light
Light relay
Electrical
rotary contact
C1 C2 C1 C2 C1 C2 C1 C2
B B B B B B B B
R1 T2 R1 T2 R1 T2 R1 T2

R1 R2 R3 R4
B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
Circuit diagram, searchlights P/N 4217228 and P/N 4307405

Figure 6
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POST SB 4217228-33-001
POST SB 4307405-33-002
Circuit diagram, searchlights P/N 4217228 and P/N 4307405

Figure 6A
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PRE SB 4360404-33-001
12
11
10
"Extension"
"Retraction" switch
switch C
C C
"Turn" switch
NC NO NC NO NC NO NO NC 9 + 28 V
Interm ediate switch
Adjustable
= 70 et 95)
8
R4 R3 R2 R1
7
C1 T1 C1 T1 C1 T1 T1 6
C1
R1 R1 R1 R1 5
C2 T2 C2 T2 C2 T2 C2 T2 4
R2 R2 R2
R2 3
2
M M
"R etraction" "Turn" 1
Light Light
relay
Electrical
rotary contact
C1 C2 C1 C2 C1 C2 C1 C2
B B B B B B B B
R1 T2 R1 T2 R1 T2 R1 T2

R1 R2 R3 R4
B10 B9 B8 B7 B6 B5 B4 B3 B2 B1

Figure 7
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POST SB 4360404-33-001

Figure 7A
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PRE SB 4361646-33-001
End of travel signal
8
"Retraction"
switch
7
C "Extension" C "Intermediate
"Turn" switch extension"
sw itch
NC NO NC NO NO NC 6
"Retraction"
5 "Left" "Right"
R4 R3 R2 R1
4 "Extension"
3 + 28 V
C1 T1 C1 T1 C1 T1 T1
C1
R1 R1 R1 R1 2
1
C2 T2 C2 T2 C2 T2 C2 T2
R2 R2 R2 R2
Stop
M M "Lighting" "Retraction"
"Retraction" "Turn"
+ 28 V
Light "Right"
Light
relay
Electrical "Left"
rotary contact
C1 C2 C1 C2 C1 C2 C1 C2
B B B B B B B B
R1 T2 R1 T2 R1 T2 R1 T2

R1 R2 R3 R4
B10 B9 B8 B7 B6 B5 B4 B3 B2 B1

Figure 8
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POST SB 4361646-33-001

Figure 8A
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TESTING AND FAULT ISOLATION

1. ACCEPTANCE TESTS
A. Test equipment P/N 4168762 P/N 4202104, P/N 4226271, P/N 4217228, P/N
4307405, P/N 4360404 and P/N 4361646
(1) Power supply: 0 to 30 V dc.

(2) Voltmeter: 0 to 30 V dc, accuracy %.
(3) Ammeter: 10 A.
(4) Shunt: 50 A.
(5) Ohmmeter.
(6) Stopwatch.
B. Test equipment for P/N 4361646
(1) Power supply: 0-100 V dc, 0-20 A.

(2) Voltmeter: 0 to 150 V dc.
(3) Ammeter: 0 to 50 A.
(4) Stopwatch and/or oscilloscope.
(5) Scales.
(6) Bench/searchlight interface plate ref: 690-427613.
(7) Test bench ref: 690-427613-02.
(8) 2 500 g weight.
C. Tests on load
(1) Operation tests

(a) Connect the power supply positive pole to terminal 3 (terminal 9 for the
searchlight P/N 4360404) identified + 28 V and to terminal 6 identified
EXTENDED. Connect the negative pole to terminal 1 "GROUND" of the
searchlight.
(b) For P/N 4361646 connect the terminal 2 to the terminal +28V.
1 The moving light housing must extend.

2 Measure the extension time.
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(c) Connect the power supply positive pole to terminal 7 identified

RETRACTED.
1 The positive pole stays connected to terminal 3 (terminal 9 for the

searchlight P/N 4360404) identified + 28 V. The negative pole stays
connected to terminal 1 identified GROUND.
2 The moving light housing must retract.
3 Measure the retraction time.
4 The EXTENSION or RETRACTION operation times must be less than
10 seconds (8 seconds for searchlight P/N 4361646) for a maximum
travel of 120 maxi (90 for searchlight P/N 4307405 and 4361646)
(test on the ground or on the aircraft).
(d) Searchlight P/N 4361646: connect the power supply positive pole to
terminal 2 identified TURN ON AND INTERMEDIATE EXTENSION.
1 The positive pole stays connected to terminal 3 identified + 28 V, and

the negative pole stays connected to terminal 1 identified GROUND.
2 The light housing must extend by 40 5.

3 Measure the extension time which must be less than or equal to 5
seconds.
(e) Repeat the EXTENSION and RETRACTION tests of the moving light
housing at 18 V dc (19 V dc for searchlight P/N 4361646).
(2) Turning tests at 28 V dc

(a) Searchlights P/N 4168762, P/N 4202104, P/N 4226271, P/N 4217228,
P/N 4307405 and P/N 4360404
1 Extend the searchlight, as specified in (1) (a).

2 Connect the power supply positive pole to terminal 5 identified LEFT.
The positive pole stays connected to terminal 3 identified + 28 V and
the negative pole stays connected to terminal 1 identified GROUND.
3 The searchlight must turn to the left.
4 Measure the turning time as specified in B (2).
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(b) Searchlight P/N 4361646
1 Extend the searchlight, as specified in (1) (a).

2 Connect the power supply positive pole to terminal 5 identified LEFT.
The positive pole stays connected to terminal 3 + 28 V and the
negative pole stays connected to terminal 1 identified GROUND.
3 The searchlight must turn to the left by an angle of 60 5.

4 Measure the turning time which must be less than or equal to 3.5
seconds.
(3) Lighting tests
(a) Connect the power supply positive pole to the terminal identified 2 ON and
the negative pole to terminal 1 GROUND of searchlight. The relay must
stay energized.
(b) When terminal 3 identified + 28 V is connected to the power supply

positive pole: the light must come on (with the relay staying energized).
The time taken to turn through one turn must be less than 15 seconds (test
on the ground or on the aircraft).
(c) Disconnect the positive pole from terminal 5 identified LEFT and connect it
to terminal 4 identified RIGHT.
The positive pole stays connected to terminal 3 identified + 28 V and the

negative pole stays connected to terminal 1 identified GROUND.
(d) Searchlights P/N 4168762, P/N 4202104, P/N 4226271, P/N 4217228,
P/N 4307405 and P/N 4360404
1 The searchlight must turn to the right. Measure the turning time for
360.
2 The time taken to turn through one turn must be less than 15 seconds
(test on the ground or on the aircraft).
(e) Searchlight P/N 4361646
1 The searchlight must turn to the right by an angle of 90 5.

2 Measure the turning time which must be less than or equal to 5
seconds.
(f) Repeat the LEFT and RIGHT turning tests at 18 V dc (19 V dc for
searchlight P/N 4361646).
(g) Connect the positive pole to terminal 7 identified RETRACTED +28V.
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1 After this operation is completed, the housing must turn to the right to
the end of its travel.
2 At the end of its travel, the searchlight must be in the horizontal plane.
(4) Current test
During the searchlight operation tests, connect an ammeter in series with the
power supply.
The current measured must be less than 2 A.
During the searchlight turning tests, connect an ammeter in series with the
power supply.
The current measured must be less than 2 A.
(a) Searchlight P/N 4361646.
During the lighting tests, connect an ammeter and a shunt in series with:
terminal 3 identified + 28 V and the power supply positive pole: the
measured current must be about 17 A 1 in intermediate position and
19 A 1 when not in intermediate position.
(5) Indication tests
(a) Connect an indicator light to terminal 8.
(b) Connect the power supply positive pole to terminal 3 identified + 28 V and
the negative pole to terminal 1 identified GROUND.
(c) Make sure that the indicator light comes on when the searchlight is in the
"retracted" position.
(6) Tests after storage

(a) Do the tests specified in paragraph 1.
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2. FAULT ISOLATION
FAULT PROBABLE CAUSE CORRECTIVE ACTION
Light burned out Replace the light

Relay defective Replace the relay
Lighting failure
Light supply rotary contact damaged Replace the rotary contact
Relay coil supply wire cut Replace the wire
Screws of light supply wires loose Tighten the screws
Supply terminals of the relay or the coil Tighten the corresponding terminals
loose
Intermittent lighting
Ground screws loose Tighten the screws
For P/N 4226271 only: lighting Replace the microswitches
microswitches damaged
Unusual noise from one of Motor caught or pinion defective Replace the motor assembly
the two motors
Microswitch supply contact defective Replace the microswitch
"Extended" relay R3 defective PRE SB 4202104-33-002
PRE SB 4217228-33-001
PRE SB 4361646-33-001
PRE SB 4307405-33-002
PRE SB 4360404-33-001
Replace the relay R3
POST SB 4202104-33-002
POST SB 4217228-33-001
The searchlight does not
extend and the ammeter POST SB 4361646-33-001
measures no current POST SB 4307405-33-002
POST SB 4360404-33-001
Replace the relay circuit board
assembly
END SB 4202104-33-002
END SB 4217228-33-001
END SB 4361646-33-001
END SB 4307405-33-002
END SB 4360404-33-001
Motor supply wires cut Splice and solder the wires
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Microswitch supply contact defective Replace the microswitch

"Retracted" relay R4 defective PRE SB 4202104-33-002
PRE SB 4217228-33-001
PRE SB 4361646-33-001
PRE SB 4307405-33-002
PRE SB 4360404-33-001
POST SB 4202104-33-002
POST SB 4217228-33-001
The searchlight does not
retract and the ammeter POST SB 4361646-33-001
measures no current POST SB 4307405-33-002
POST SB 4360404-33-001
assembly
END SB 4202104-33-002
END SB 4217228-33-001
END SB 4361646-33-001
END SB 4307405-33-002
END SB 4360404-33-001
Reduction spindles locked Clean and lightly lubricate with grease
The searchlight does not AEROSHELL 33MS
extend or retract and a
Turn spindles caught Clean and lightly lubricate with grease
current greater than 2.5 A
AEROSHELL 33MS
is measured
Motor short-circuit Replace the motor
Friction points between gears and Clean and lightly lubricate with grease
pinions of reduction spindles AEROSHELL 33MS
The searchlight is slow to Gear sector fouled or damaged Clean and lightly lubricate with grease
extend or retract AEROSHELL 33MS
Motor switching defective Motor cannot be disassembled.
Replace the motor
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"Left" relay R1 defective PRE SB 4202104-33-002

PRE SB 4217228-33-001
PRE SB 4361646-33-001
PRE SB 4307405-33-002
PRE SB 4360404-33-001
POST SB 4202104-33-002
POST SB 4217228-33-001
The searchlight does not POST SB 4361646-33-001
turn to the left and the POST SB 4307405-33-002
ammeter does not measure
POST SB 4360404-33-001
current
assembly
END SB 4202104-33-002
END SB 4217228-33-001
END SB 4361646-33-001
END SB 4307405-33-002
END SB 4360404-33-001
"Right" relay R2 defective PRE SB 4202104-33-002
PRE SB 4217228-33-001
PRE SB 4361646-33-001
PRE SB 4307405-33-002
PRE SB 4360404-33-001
POST SB 4202104-33-002
POST SB 4217228-33-001
The searchlight does not POST SB 4361646-33-001
turn to the right and the POST SB 4307405-33-002
ammeter does not measure
POST SB 4360404-33-001
current
assembly
END SB 4202104-33-002
END SB 4217228-33-001
END SB 4361646-33-001
END SB 4307405-33-002
END SB 4360404-33-001
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Reduction spindle caught Clean and lightly lubricate with grease

The searchlight does not AEROSHELL 33MS
turn right or left and a
Turn spindle caught Clean and lightly lubricate with grease
current greater than 2.5 A
AEROSHELL 33MS
is measured
Motor short-circuit Replace the motor
Friction points between gears and Clean and lightly lubricate with grease
pinions of reduction spindle AEROSHELL 33MS
The searchlight is slow to Turn spindle caught Clean and lightly lubricate with grease
extend or retract AEROSHELL 33MS
Motor switching defective Motor cannot be disassembled.
Replace the motor
Dampness Measure the insulation of the motors,
Insulation defect Ageing relays and microswitches. Replace the
defective part
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DISASSEMBLY
1. GENERAL
The disassembly of the light is necessary to exchange a part, to carry out repairs, or to
overhaul the light.
NOTE : The components are identified by their "Figure - Item" number in the Illustrated Parts
List.
NOTE : Do not do more disassembly than necessary. For the identification of damage or
functional failure refer to sections CHECK and TESTING AND TROUBLE
SHOOTING.
2. PROCEDURE
A. Light (1-20) - See figures 1 and 2, chapter 1001
(1) Remove the retaining ring (1-10) to remove the light (1-20).
(2) Disconnect the two supply wires from the light.
(3) Remove the light and its seal (1-30); put in a cardboard box.
(4) Remove the screw (1-40) and the washers (1-50) and (1-60).
(5) Remove the ground wire.
B. Light housing (1-90)
(1) Remove the two screws (1-80).

(2) Remove the cover plate (1-70).
(3) Remove the two nuts (1-110) and the two screws (1-100).
(4) For the searchlights P/N 4202104 and P/N 4360404, remove the locking
screw (1-112).
(5) Remove the light housing (1-90).
(6) For the searchlights P/N 4202104 and P/N 4360404, release the seal (1-115).
C. Case (2-260)
(1) Remove the five screws (2-110).

(2) Remove the cover (2-100).
(3) Remove the terminals as follows:
(a) For the searchlights P/N 4202104 and P/N 4360404, remove the protection
cap (2-235).
(b) Remove the nut (2-230) and the two washers (2-210).
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(c) Remove the nut (2-220) and the washer (2-200).
(d) Remove the screw (2-190).
(4) For the searchlight P/N 4360404 only, remove terminals 9 to 12 as follows:
(a) Remove the protection cap (2-380).
(b) Remove the nut (2-370) and the two washers (2-350).
(c) Remove the nut (2-360) and the washer (2-340).
(d) Remove the screw (2-330).
(e) Unsolder the wires of the circuit board.
(5) For the searchlight P/N 4360404 only, remove the angle bracket as follows:
(a) Remove the nuts (2-320) and the washers (2-310).
(b) Remove the screw (2-300).
(c) Remove the bracket (2-290).
(6) For all the searchlights:

(a) Remove the four screws (2-180).
(b) Remove the relay (2-170).
PRE SB 4202104-33-002
PRE SB 4217228-33-001
PRE SB 4361646-33-001
PRE SB 4307405-33-002
PRE SB 4360404-33-001
(7) Remove the circuit board assembly, as follows:
(a) Remove the four screws (2-130).
(b) Remove the circuit board assembly (2-120).
(c) Unsolder the relay (2-140), if necessary.
(d) Unsolder the four resistors (2-165), if necessary.
(e) For the searchlights P/N 4217228 and P/N 4307405, unsolder the diode
(2-167), if necessary.
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POST SB 4202104-33-002
POST SB 4217228-33-001
POST SB 4361646-33-001
POST SB 4307405-33-002
POST SB 4360404-33-001
(8) Remove the circuit board assembly, as follows:
(a) Remove the four screws (2-130B).
(b) Remove the four spacers (2-122A) from the four bumpers (2-124A).
(c) Remove the four bumpers (2-124A) from the relay circuit board assembly
(2-120C).
(d) Remove the relay circuit board assembly (2-120C).
END SB 4202104-33-002
END SB 4217228-33-001
END SB 4361646-33-001
END SB 4307405-33-002
END SB 4360404-33-001
(e) Remove the grommet (2-239) and remove the wiring; cut the sheath (2-
237), if necessary.
(f) Cut the cable clamps (2-60).
(g) Remove the nuts (2-40), the washers (2-70).
(h) Remove the bases (2-50), the washers (2-70).
(i) Remove the last two nuts (2-40) and the two washers (2-30).
(j) Remove the two screws (2-20),
(k) Remove the microswitch box (2-10).
(l) Remove the four screws (1-650) attaching the "retract" casing (1-640).
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(9) For the searchlights P/N 4202104 and P/N 4360404, remove the four screws
(2-250) to remove the plate (2-240).
(a) Remove the case (2-260).
(b) Unsolder the supply wires of the microswitches (2-80).
(c) For the searchlights P/N 4226271, P/N 4360404 and P/N 4361646,
unsolder the supply wires of the microswitches (2-95).
(d) Remove the screws (2-90).
(e) Remove the microswitches (2-80) and the washers (2-91) from the box (2-
10).
(f) Remove the levers of the microswitches (2-93), except for the searchlight
P/N 4217228.
(10) For the searchlights P/N 4226271 and P/N 4361646, remove the two screws
(2-97), the microswitch (2-95A) from the box (2-10B).
(11) For the searchlight P/N 4360404 only, remove the two screws (2-97), the
microswitch (2-95B), the two washers (2-98) from the box (2-10C) and remove
the microswitch blade (2-99).
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GROUND
LIGHTING
+ 28 V
RIGHT
LEFT
+ 28 V
EXTENSION MOTOR
RETRACTION INTERMEDIATE
EXTENSION
END OF EXTENSION IN
TRAVEL SIGNAL AXIS
Searchlights P/N 4168762, Searchlight P/N 4360404

4202104, 4226271,
4217228, 4307405,
4361646.
Connection terminals
Figure 301
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D. "TURN" casing (1-660)
(1) Remove the "retract" casing (1-640).

(2) Remove the four screws (1-130).
(3) Remove the cover (1-120).
(4) Remove the plate assembly (1-140).
(5) Remove the light housing assembly spindle (1-170):
(a) Release the rotary contact (1-150) and the insulating bush (1-160).
(b) Remove the pin (1-180), and then the spring (1-190) and the stop (1-200).
(6) For the searchlights P/N 4226271 and 4361646:

(a) Remove the two screws (1-217) and the cam (1-215).
(7) For the searchlight 4361646, only:

(a) Remove the four washers (1-219).

(9) Remove the microswitch (1-220).
(10) For the searchlight 4361646 only:
(a) Remove the two screws (1-663).
(b) Remove the microswitch (1-665) and the flexible lever (1-661).
(11) For the searchlights P/N 4226271 and 4361646:

(a) Remove the two screws (1-235) and the microswitch (1-231).
(b) Remove the lever (1-233).
(c) Remove the two screws (1-239) and the microswitch housing (1-237).
(12) Remove the retaining ring (1-240), the bearing (1-250) and the shims (1-260).
(13) Remove the gear and pinion spindle (1-270) with the bearing (1-280) and the
shim (1-260).
(14) For the searchlights P/N 4168762, P/N 4202104, P/N 4226271, P/N 4217228,
P/N 4307405:
(a) Remove the screw (1-310), the nut (1-320), the washers (1-330) and (1-
340) to release the wiring.
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(15) For the searchlight P/N 4361646 only, remove the screw (1-310), the washers
(1-330) and (1-340) to release the wiring.
(16) For the searchlight P/N 4360404 only:
(a) Remove the screw (1-680) and the washer (1-690) to release the wiring.
(b) Remove the screw (1-710) and the washer (1-720) then remove the cam
(1-700).
(c) Remove the screw (1-750), the nut (1-770) and the washer (1-760).
(d) Remove the bracket (1-730) and the stop (1-740).
(e) Remove the screw (1-780).
PRE SB 4361646-33-001
(a) Remove the adjusting screw (1-290A) and the nut (1-300A).
POST SB 4361646-33-001
(18) For the searchlight P/N 4361646:
(a) Remove the adjusting screw (1-290B) and the nut (1-300) from the turn
casing (1-660).
(b) Discard the adjusting screw (1-290B).

(a) Remove the nut (1-349) and the washer (1-347).
(b) Remove the screw (1-345B).
(c) Remove the lever (1-303B) and the cam (1-343B).

(a) Remove the nut (1-349) and the washer (1-347).
(b) Remove the screw (1-345).
(c) Remove the cam (1-343A).
(21) Remove the three screws (1-360) to remove the motor assembly (1-350).
(22) Remove the clamp (1-390) and the cable clamp (1-395).
(23) Heat the part, then hit lightly to remove the bearings (1-210).
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(24) Remove the bearings (1-280), (1-580) and (1-620) using an extractor.
(26) Remove the gear sector (1-590).
(27) For the searchlight P/N 4307405, remove the nut (1-305) and the lug (1-303).
PRE SB 4202104-33-001
PRE SB 4217228-33-001
PRE SB 4307405-33-001
(28) Remove the adjusting screw (1-290) and the nut (1-300), then remove the
casing (1-660) (except for searchlight P/N 4360404 and P/N 4361646).
POST SB 4202104-33-001
POST SB 4217228-33-001
POST SB 4307405-33-001
(29) For the searchlights P/N 4202104, P/N 4217228, P/N 4307405 :
(a) Remove the adjusting screw (1-290B) and the nut (1-300) from the turn
casing (1-660).
(b) Discard the adjusting screw (1-290B).
E. "RETRACT" CASING (1-640)
PRE SB 4202104-33-001
PRE SB 4217228-33-001
PRE SB 4307405-33-001
PRE SB 4360404-33-001
PRE SB 4361646-33-001
(1) Remove the bumper (1-630).
POST SB 4202104-33-001
POST SB 4217228-33-001
POST SB 4307405-33-001
POST SB 4360404-33-001
POST SB 4361646-33-001
(2) For the searchlights P/N 4202104, P/N 4217228, P/N 4307405, P/N 4360404
and P/N 436164, remove the bumper (1-630B) as follows:
(a) Remove the screw (1-634) and the nut (1-636).
(b) Remove the locking plate (1-632) with the bumper (1-630B) from the turn
casing (1-640).
(c) Discard the bumper (1-630B).
(3) Remove the retaining ring (1-460), the bushing (1-470) and the shims (1-480).
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(4) Remove the gear and pinion spindle (1-490) and the shims (1-485).
(5) Remove the pin (1-510), then remove the pinion (1-520).
(6) Remove the retaining ring (1-530), the bushing (1-540) and the shims (1-550).
(7) Remove the gear (1-560).
(8) Loosen the plug (1-400).
(9) Remove the three screws (1-420).
(10) Remove the motor (1-410).
(11) Remove the motor cable clamp (1-450).
(12) Remove the bearings (1-500) and (1-570) using a press.
(13) Remove the spindle (1-610) using a press.
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CLEANING
1. GENERAL
Ingredients can be found in the LIST OF PRODUCTS section.

2. NECESSARY EQUIPMENT
NOTE : The cleaning agents used are given in the LIST OF PRODUCTS section.
WARNING : DO NOT BREATHE THE FUMES : SOLVENTS ARE DANGEROUS.
USE PROTECTION FOR EYES AND SKIN.
CLEAN THE PARTS IN A ROOM WICH HAS A GOOD AIRFLOW.
DO NOT CLEAN THE PARTS NEAR AN OPEN FLAME.
A. Necessary material
- Cleaning container.
- Fine brush.
- Soft brush.
- Emery-cloth No. 03.
- Lint-free cloth.
- Low-pressure (0,6 bar) and dehydrated compressed-air supply.
3. PROCEDURE
A. Motors
After removing the motors, carefully clean their spindle and screws, using a clean cloth
moistened with alcohol. Dry using dry compressed air.
B. Light relay
Clean the relay contacts with very fine abrasive cloth.

C. Mechanical parts
Clean all the mechanical parts with trichlorethane and dry them with dry compressed
air.
D. Electrical parts
Clean the microswitch blades using a clean cloth lightly moistened with alcohol.
Dry using compressed air.
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CHECK
1. GENERAL
A. Environmental conditions
The checks must be done under the following conditions:

temperature 10 to 50 C,
relative humidity less than 85%,
ambient pressure between 84 and 107 kPa.
B. Equipments
Scales.
Ohmmeter.
2. WEIGHT CHECK
Total weight: 2.45 kg 2% (5.40 lb.) for the searchlights P/N 4168762, 4217228 and
4307405
3.20 kg 2% (7.05 lb.) for the searchlight P/N 4202104.
3. INSPECTION AND CHECK
A. Visual inspection of mechanical parts
(1) Examine the anticorrosion paint for condition:

(a) Ambient paint of the moving light housing and the two motors.
(b) Treatment of the light housing clamp and the gear sector: dichromated
cadmium plating.
(c) Examine the external connection terminals for condition (deformation,

oxidization, etc.).
(d) Examine the teeth of the gear sector and pinion: if the teeth are damaged,
replace the gear sector and the pinion.
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(e) Examine the teeth:
1 of the gear of the light housing spindle (1-170),

2 of the gear and pinion of the spindle (1-270),
3 of the gear and pinion of the spindle (1-490),
4 of the gear of the spindle (1-560).
If the teeth are damaged, replace the defective part.
(f) Examine the moving light housing for condition.
(g) Examine the casings for condition.
(h) Examine the light clamp for condition.
(i) Examine the terminal cover for condition, and washers and nuts for
presence on connections.
B. Electrical check
(1) Motors
NOTE: The searchlights must be tested on a bench, under load with an operating
speed simulation of 100 kts or 140kts.
(a) Do the following checks for each of the two motors.
1 Measure the electrical insulation when cold. The insulation resistance

must be 20 M or greater under 50 V.
2 Make sure that the motor starts, when supplied with 18 V dc.
(2) Light relay
(a) Measure the insulation. The insulation resistance must be 20 M or

greater under 50 V.
(b) Make sure that the relay is energized, when supplied with 18 V dc.
(c) Make sure there are no strong sparks between the relays contacts, when
the contacts are supplied with 28 V with a current of 20 A.
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(3) Microswitches
(a) Measure the electrical insulation. The insulation resistance must be 20 M

or greater under 50 V.
(b) With the contacts supplied with 26 V with a current of 2.5 A, make sure
that the current is cut off suddenly. If the current is cut off slowly, replace
the defective microswitch.
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REPAIR
1. MOTORS
Replace the motor if its insulation resistance is less than 20 M under 50 V.

2. LIGHT RELAY AND SWITCHING RELAY
Replace the relay if, after cleaning the contacts, there is a strong sparking during the
electrical tests.
3. MECHANICAL PARTS
Protection treatment of light housings: black aluminum coating.

Protection treatment of the light clamp: dichromated cadmium plating.
Lock washers and lock nuts must be systematically replaced if removed.
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ASSEMBLY AND STORAGE

1. GENERAL
Lubricate gears and pinions with AEROSHELL 33MS.

Lock screws without a lockwasher with Loctite 242 (unless otherwise indicated).
Solder wiring with tin solder.
NOTE: To reconnect the electrical connections inside the searchlight, see figures 702, 703,
704 and 705 (refer to part number).
PRODUCT DEFINITION
AEROSHELL MIL-G-21164D
grease 33MS
Loctite locking compound 222
Loctite thread locking compound 242
Loctite thread locking compound 243
Loctite cyanoacrylate locking compound IS496
Tin solder SnPb 60/40
PRIMER 1200 AND RTV 734 Glue, local supply
BR2 type MOS 2 Molykote SPEC MIL G3278
2. PROCEDURE (Refer to Figures 1, 1A and 2, Chapter 1001.)
A. "Retract" casing (1-640)
(1) Install the spindle (1-610) until it is aligned in the "turn" casing (1-660) using a
press.
(2) Install the bearings (1-570) and (1-500) using a press.
(3) Install the gear (1-560) in the "retract" casing (1-640).
(4) Install the shims (1-550) and the bushing (1-540) on the spindle (1-560).
(5) Attach the assembly with the retaining ring (1-530).
(6) Add or remove shims (1-550) to adjust the end clearance to 0.05 mm or less.
(7) Install the pinion (1-520) on the gear (1-560).
(8) Lock with the pin (1-510).
(9) Install the motor (1-410) on the retract casing (1-640).
(10) Attach the motor (1-410) with the three screws (1-420).
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(11) Tighten the plug (1-400).

(12) Install the shims (1-485) on the gear and pinion spindle (1-490).
(13) Install the gear and pinion spindle (1-490) in the "retract" casing (1-640).
(14) Install the shims (1-480), the bushing (1-470) on the gear and pinion spindle (1-
490).
(16) For searchlights P/N 4168762, P/N 4202104, P/N 4226271, P/N 4217228,
P/N 4307405 and P/N 4360404, add or remove shims (1-485) to remove the
end clearance without locking or friction points.
(17) For searchlight P/N 4361646, add or remove shims (1-480) or (1-485) to adjust
the end clearance to 0.05 mm or less.
PRE SB 4202104-33-001
PRE SB 4217228-33-001
PRE SB 4307405-33-001
PRE SB 4360404-33-001
PRE SB 4361646-33-001
(18) Install the bumper (1-630). Bond the bumper with Loctite cyanoacrylate IS496.
POST SB 4202104-33-001
POST SB 4217228-33-001
POST SB 4307405-33-001
POST SB 4360404-33-001
POST SB 4361646-33-001
(19) Apply a layer of Loctite cyanoacrylate IS496 on the vertical surface of the new
bumper (1-630B).
(20) Install the new bumper (1-630B) and the locking plate (1-632A) on the "retract"
casing (1-640) with the screw (1-634) and the nut (1-636).
END SB 4202104-33-001
END SB 4217228-33-001
END SB 4307405-33-001
END SB 4360404-33-001
END SB 4361646-33-001
B. "Turn" casing (1-660)
(1) Install the gear sector (1-590) on the "turn" casing (1-660).
(2) Attach the assembly with the two screws (1-600) without tightening them.
(3) Install the bearing (1-580) in the gear sector and the turn casing (1-660) using
a press.
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(a) Remove the two screws (1-600) and apply Loctite 243 thread locking
compound.
(b) Install the two screws (1-600).
(5) Tighten the two screws (1-600) and lock them with a center punch mark.
(6) Install the bearings (1-620), (1-210) and (1-280) in the "turn" casing (1-660)
using a press.
(7) Install the shims (1-260) on the gear and pinion spindle (1-270).
(8) Install the gear and pinion spindle (1-270) in the "turn" casing (1-660).
(9) Install the shims (1-260) and the bearing (1-250).
(11) Add or remove shims (1-260) on both sides to adjust the end play to 0.05 or
less.
(12) For the searchlights P/N 4226271 and P/N 4361646:
(a) Attach the microswitch (1-231) with its lever (1-233) on the microswitch
housing (1-237) using the two screws (1-235),
(b) Install the microswitch housing (1-237) in the "turn" casing (1-660) and
attach it using the screws (1-239).
(13) Install the microswitch (1-220), then attach it using the screws (1-230).
(14) For the searchlight P/N 4361646, install the microswitch (1-665) and attach it
using the screws (1-663).
(15) Install the motor assembly (1-350) on the casing and attach it using the screws
(1-360).
(16) Install the stop (1-200) in the light housing spindle (1-170).
(17) Install the spring (1-190).
(18) Put the pin (1-180) fully into the stop (1-200) (except for P/N 4361646).
(19) For the searchlight P/N 4361646 only, put the pin (1-180) in the stop (1-200)
and let it protrude by 0.2 to 0.3 mm.
(20) For the searchlight P/N 4226271 only, install the cam (1-215) on the gear of the
spindle (1-170) and attach it using the two screws (1-217).
(21) For the searchlight P/N 4361646 only, fit the four washers (1-219) between the
gear of the spindle (1-170) and the cam (1-215):
(a) Install the cam (1-215),.
Page 703
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4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646
(b) Attach it using the two screws (1-217).
(22) Bond the contact (1-150) on the insulator (1-160) and then bond the insulator
on the pinion of the spindle (1-170) using Araldite.
(23) Install the spindle (1-170) in the casing.
(24) For the searchlights P/N 4202104 and P/N 4360404, measure the 3 mm Js13
dimensions between the mating face of the cover on the casing (1-660) and the
rotary contact (1-150), using a dial gauge (see figure 701).
(25) Install the plate (1-140) on the cover (1-120).
(26) Attach the cover (1-120) on the casing using the screws (1-130).
PRE SB 4202104-33-001
PRE SB 4217228-33-001
PRE SB 4307405-33-001
(27) Install the adjusting screw (1-290). Attach with the nut (1-300) (except
searchlights P/N 4360404 and P/N 4361646).
POST SB 4202104-33-001
POST SB 4217228-33-001
POST SB 4307405-33-001
(28) For the searchlights P/N 4202104, P/N 4217228 and P/N 4307405:
(a) Apply a layer of Loctite 222 on the screw (1-290B), the nut (1-300) and the
mating surface of the turn casing (1-660).
(b) Install the screw (1-290B) and the nut (1-300) on the turn casing (1-660).
(c) Make sure that the screw (1-290B), the nut (1-300) and the turn casing
are correctly bonded.
END SB 4202104-33-001
END SB 4217228-33-001
END SB 4307405-33-001
(29) For the searchlight P/N 4307405, install the lug (1-303) on the screw (1-290)
and attach with the nut (1-305).
(30) For the searchlight P/N 4360404, only:
(a) Attach the bracket (1-730) and the stop assembly (1-740) using the screw
(1-750), the washer (1-760) and the nut (1-770).
(b) Install the screw (1-780) on the stop assembly (1-740).
(c) Attach the cam (1-700) on the bracket (1-730) using the screw (1-710) and
the washer (1-720).
Page 704
33-49-19 APR 15/12
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646
(31) For the searchlight P/N 4361646:

(a) Install the lever (1-303B) and the cam (1-343B).
(b) Install the screw (1-345B).
(c) Install the washer (1-347) and the nut (1-349).
PRE SB 4361646-33-001
(d) Install the adjusting screw (1-290A) and the nut (1-300A).
POST SB 4361646-33-001
(e) Apply a layer of Loctite 222 on the screw (1-290B), the nut (1-300) and the
mating surface of the turn casing (1-660).
(f) Install the screw (1-290B) and the nut (1-300) on the turn casing (1-660).
(g) Make sure that the screw (1-290B), the nut (1-300) and the turn casing
are correctly bonded.
END SB 4361646-33-001
(32) For searchlights P/N 4168762, P/N 4202104 and P/N 4217228), connect the
motors to ground using the screw (1-310), the washers (1-330) and (1-340) and
the nut (1-320).
(33) For searchlight P/N 4360404, attach the ground lug using the screw (1-680)
and the washer (1-690).
(34) Assemble the "retract" casing (1-640) and the "turn" casing (1-660).
C. Microswitches (2-80) and (2-95)
(1) Install the levers (2-93) on the microswitches (2-80B).

(2) Install the microswitches (2-80B) on the box (2-10) with the washers (2-91) in
between, and attach them using the screws (2-90).
(3) For the searchlights P/N 4226271 and P/N 4361646: install the microswitch (2-
95A) on the box (2-10B) and attach it with the screws (2-97).
(4) Solder the wires to the contacts of the microswitches as shown in the wiring
diagrams.
Page 705
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D. Circuit board (2-160)
(1) Install the grommet (2-239) in the casing (2-260).

(2) Install a sheath (2-237) on the wiring of the casing (2-260).
(3) Install the wiring in the casing through the grommet (2-239) until the sheath is
engaged by about 5 mm into the casing, to avoid damaging the wires.
PRE SB 4202104-33-002
PRE SB 4217228-33-001
PRE SB 4361646-33-001
PRE SB 4307405-33-002
PRE SB 4360404-33-001
(4) Solder the relays (2-140) and the resistors (2-165) on the circuit board (2-160).
For the searchlights P/N 4217228 and P/N 4307405 only: solder the diodes (2-
167) on the circuit board.
END PRE SB 4202104-33-002
END PRE SB 4217228-33-001
END PRE SB 4361646-33-001
END PRE SB 4307405-33-002
END PRE SB 4360404-33-001
(5) For the searchlight P/N 4360404: attach the bracket (2-290) to the cover (2-
100) using the two screws (2-300), washers (2-310) and nuts (2-320).
(6) Install the relay (2-170) on the cover using the screws (2-180).
PRE SB 4202104-33-002
PRE SB 4217228-33-001
PRE SB 4361646-33-001
PRE SB 4307405-33-002
PRE SB 4360404-33-001
(7) Attach the circuit board (2-120) with the relays to the cover using the screws (2-
130).
POST SB 4202104-33-002
POST SB 4217228-33-001
POST SB 4361646-33-001
POST SB 4307405-33-002
POST SB 4360404-33-001
(8) Attach the new relay circuit board assembly (2-120C) on the relay box cover (2-
100) as follow:
(a) Install the four bumpers (2-124A) on the relay circuit board assembly (2-
120C).
(b) Install the four spacers (2-122A) in the four bumpers (2-124A).
Page 706
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(c) Install the relay circuit board assembly (2-120C) on the cover (2-100) and
attach it with the four screws (2-130B).
END SB 4202104-33-002
END SB 4217228-33-001
END SB 4361646-33-001
END SB 4307405-33-002
END SB 4360404-33-001
(9) Make the electrical connections, as shown in figures 702, 703, 704 and 705.
(10) Attach the terminals on the cover by successively installing the screws (2-190),
the washer (2-200), the nuts (2-220), the two washers (2-210) and the nut (2-
230).
(11) For searchlight P/N 4360404 only, attach the terminals to the bracket (2-290)
by successively installing the screws (2-330), the washer (2-340), the nuts (2-
360), the two washers (2-350) and the nut (2-370).
(12) For searchlights P/N 4202104 and P/N 4360404, install the protection cap (2-
235) and (2-380) on each terminal.
(13) Install the four cable clamps (2-60).
(14) Install the cover (2-100) on the casing (2-260).
(15) Attach the assembly with the five screws (2-110).
(16) Install the microswitch box (2-10) on the spindle (1-610).
(17) For searchlights P/N 4202104 and P/N 4360404 only, attach the plate (2-240)
on the box (2-260) with the four screws (2-250).
(18) Assemble the case (2-260) on the "turn" casing (1-660) with the four screws (1-
650).
(19) Assemble the case (2-260) with the microswitch box (2-10) with the two screws
(2-20).
(20) On each of these screws, install the washer (2-30) and the nut (2-40).
(21) Install the washer (2-70) and the base (2-50).
(22) Install the second washer (2-70) and attach with the nut (2-40).
E. Light housing (1-90)
(1) For searchlights P/N 4202104 and P/N 4360404:

(a) Bond the seal (1-115) in the light housing (1-90) using primer 1200 and
RTV 734 glue.
(2) For all searchlights:
Page 707
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(a) Install the light housing (1-90) on the "turn" casing (1-660) and tighten the
two screws (1-100) with the nuts (1-110).
(b) Tighten the screws (1-100) to a torque of 2.5 N.m.
(3) For the searchlights P/N 4202104 and P/N 4360404 only:
(a) Install the locking screws (1-112) on the light housing (1-90).
(4) For all searchlights:

(a) Attach the ground lug using the screw (1-40) and the washers (1-50) and
(1-60).
(b) Make the electrical connections of the light (1-20) and then install it in the
housing, with its seal (1-30). Attach the assembly using the clamp (1-10).
(c) Attach the plate (1-70) using 2 screws (1-80).
Page 708
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3. TESTING
Refer to chapter 101.

CAUTION:Extend the moving light bracket by about 20 if the searchlight must be stored.
3 Js13
Adjusting the rotary contact,

searchlights P/N 4202104 and P/N 4360404
Figure 701
Page 709
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4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646
4. WIRING TABLE
Cross references table for wiring tables.
DESCRIPTION P/N DESCRIPTION P/N

Black cable N/A Lug 25002 3681952
Cable AWG 14 - 9 3012089 Lug 25504 3070097
Cable AWG 22 - 0 3016875 Lug 25509 3068418
Cable AWG 22 - 1 3040007 Lug 25511 3068396
Cable AWG 22 - 2 3016868 Lug 50840 3040103
Cable AWG 22 - 3 3027249 Red cable N/A
Cable AWG 22 - 4 3027256 Red cable N/A
Cable AWG 22 - 6 3016852 White cable N/A
Cable AWG 22 - 8 3027233
Cable AWG 22 - 9 3016845
A. Searchlights P/N 4168762, P/N 4202104, P/N 4217228 and P/N 4307405 (see fig.
702)
PRE SB 4202104-33-002
PRE SB 4217228-33-001
PRE SB 4307405-33-002
ITEM DESCRIPTION QTY LENGTH FROM TO

FIG. 702 IN mm (in.)
1 Cable AWG 14 - 9 1 510 (20.079) Light relay Rotary contact

2 Cable AWG 22 - 0 1 495 (19.488) Light relay Casing ground
Lug 25002 1 Item 2 Casing ground
Light relay
3 Cable AWG 14 - 9 1 125 (4.921) Terminal 3 "+ 28 V" Light relay
Lug 25511 1 Item 3 Terminal 3 "+ 28 V"
Light relay
4 Cable AWG 22 - 2 1 185 (7.283) Terminal 2 "Light" Light relay
Lug 25504 1 Item 4 Terminal 2 "Light"
Light relay
5 Cable AWG 14 - 9 1 470 (18.504) Terminal 1 "Ground" Casing ground
Lug 25511 1 Item 5 Terminal 1 "Ground"
Casing ground
Casing ground
6 Cable AWG 22 - 3 1 65 (2.559) Terminal 4 "Right" Relay R2
Lug 25504 1 Item 6 Relay R2 Terminal 4 "Right"
Page 710
33-49-19 APR 15/12
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646

7 Cable AWG 22 - 2 1 70 (2.756) Terminal 3 "+ 28 V" Relay R3

Lug 25504 1 Item 7 Relay R3 Terminal 3 "+ 28 V"
8 Cable AWG 22 - 9 1 85 (3.346) Terminal 5 "Left" Relay R1
Lug 25504 1 Item 8 Relay R1 Terminal 5 "Left"
9 Cable AWG 22 - 0 1 75 (2.953) Terminal 1 "Ground" Relay R2
Lug 25504 1 Item 9 Relay R2 Terminal 1 "Ground"
10 Cable AWG 22 - 2 1 215 (8.464) Terminal 7 "Retraction" switch
"Retraction"
Lug 25504 1 Item 10 Terminal 7 "Retraction"
"Retraction" switch
11 Cable AWG 22 - 6 1 230 (9.055) Terminal 6 "Extension" switch
"Extension"
Lug 25504 1 Item 11 Terminal 6 "Extension"
"Extension" switch
12 Cable AWG 22 - 4 1 160 (6.299) "Retraction" switch Relay R4
13 Cable AWG 22 - 8 1 180 (7.087) "Extension" switch Relay R3
14 Cable AWG 22 - 9 1 460 (18.110) "Position 0" switch Relay R2
15 Cable AWG 22 - 3 1 410 (16.142) "Retraction" switch "Position 0" switch
16 Cable AWG 14 - 9 1 175 (6.889) Halogen light Light housing ground
Lug 50840 2 Item 16 Halogen light
Light housing ground
Lug 25509 1 Item 16 Light housing ground
17 Red cable 1 320 (12.598) Relay R1 "Turn" motor
18 Black cable 1 320 (12.598) "Turn" motor Terminal 10 circuit
board
19 Black cable 1 265 (10.433) "Retraction" motor Terminal 1 circuit
board
20 Red cable 1 265 (10.433) Relay R4 "Retraction" motor
21 Cable AWG 22 - 1 495 (19.488) Terminal 8 "End of "Position 0" switch
1 travel signal"
21a Lug 25504 1 Item 21 Item 8
"Position 0" switch "End of travel signal"
22 White cable 1 310 (12.205) Rotary contact Halogen light
22a Lug 50840 1 Item 22 Halogen light
Rotary contact
Page 711
33-49-19 APR 15/12
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646
POST SB 4202104-33-002
POST SB 4217228-33-001
POST SB 4307405-33-002

FIG. IN mm (in.)
702A

Light relay
Light relay
Light relay
5 Cable AWG 14 - 9 1 470 (18.504) Terminal 1 "Ground" Casing ground
Casing ground
Casing ground
6 Cable AWG 22 - 3 1 65 (2.559) Terminal 4 "Right" Relay PT6
Lug 25504 1 Item 6 Relay PT6 Terminal 4 "Right"

7 Cable AWG 22 - 2 1 70 (2.756) Terminal 3 "+ 28 V" Relay PT4
Lug 25504 1 Item 7 Relay PT4 Terminal 3 "+ 28 V"
8 Cable AWG 22 - 9 1 85 (3.346) Terminal 5 "Left" Relay PT8
Lug 25504 1 Item 8 Relay PT8 Terminal 5 "Left"
9 Cable AWG 22 - 0 1 75 (2.953) Terminal 1 "Ground" Relay PT7
Lug 25504 1 Item 9 Relay PT7 Terminal 1 "Ground"
"Retraction"
"Retraction" switch
11 Cable AWG 22 - 6 1 230 (9.055) Terminal 6 "Extension" switch
"Extension"
"Extension" switch
12 Cable AWG 22 - 4 1 160 (6.299) "Retraction" switch Relay PT3
13 Cable AWG 22 - 8 1 180 (7.087) "Extension" switch Relay PT5
Page 712
33-49-19 APR 15/12
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646

FIG. IN mm (in.)
702A
14 Cable AWG 22 - 9 1 460 (18.110) "Position 0" switch Relay PT6

17 Red cable 1 320 (12.598) Relay PT2 "Turn" motor
board
19 Black cable 1 265 (10.433) "Retraction" motor Relay PT1
20 Red cable 1 265 (10.433) Relay PT9 "Retraction" motor
21 Cable AWG 22 - 1 1 495 (19.488) Relay PT13 "Position 0" switch
21a Lug 25504 1 Item 21 Item 8
"Position 0" switch "End of travel signal"
22a Lug 50840 1 Item 22 Halogen light
Rotary contact
23 Brown cable 1 200 (7.8740) Relay PT12 "Terminal 8 "End of
travel signal
24 Red cable 200 (7.8740) Relay PT11 Terminal 7 "Retraction"
END SB 4202104-33-002
END SB 4217228-33-001
END SB 4307405-33-002
Page 713
33-49-19 APR 15/12
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646
PRE SB 4202104-33-002
PRE SB 4217228-33-001
PRE SB 4307405-33-002
Wiring diagram, searchlights

P/N 4168762, P/N 4202104, P/N 4217228 and P/N 4307405
Figure 702
Page 714
33-49-19 APR 15/12
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646
POST SB 4202104-33-002
POST SB 4217228-33-001
POST SB 4307405-33-002
Wiring diagram, searchlights

P/N 4202104, P/N 4217228 and P/N 4307405
Figure 702A
Page 715
33-49-19 APR 15/12
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646
B. Searchlight P/N 4226271 (see fig. 703)


Light relay
Light relay
4 Cable AWG 22 - 4 1 500 (19.685) "Extension" "turn" Light relay
switch
5 Cable AWG 22 - 9 1 300 (11.811) "Retraction" switch Light relay
6 Cable AWG 22 - 3 1 300 (11.811) Terminal "Light" "Retraction" switch
7 Cable AWG 14 - 1 1 500 (19.685) Terminal 2 "Light" "Extension" switch
8 Cable AWG 14 - 9 1 470 (18.504) Terminal 1 Ground Casing ground
Lug 25511 1 Item 8 Terminal 1
"Ground"
9 Cable AWG 22 - 0 1 75 (2.953) Terminal 1 Relay R2
"Ground"
Lug 25504 1 Item 10 Terminal 4 "Right"
11 Cable AWG 22 - 2 1 70 (2.756) Terminal 3 "+ 28V" Relay R3
Lug 25504 1 Item 11 Terminal 3 "+ 28V"
Lug 25504 1 Item 12 Terminal 5 "Left"

"Retraction"
"Retraction"
Page 716
33-49-19 APR 15/12
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646

14 Cable AWG 22 - 6 1 230 (9.055) Terminal 6 Relay R2

"Extension" "Extension"
"Extension"
15 Cable AWG 22 - 9 1 460 (18.110) "Position 0" switch Relay R2
16 Cable AWG 22 - 5 1 180 (7.087) "Extension" switch Relay R2
17 Cable AWG 22 - 4 1 160 (6.299) "Retraction" switch Relay R4
19 Cable AWG 14 - 9 1 175 (6.889) Halogen light Light housing
ground
Lug 25509 1 Item 19 Light housing
ground
board
21 Red cable 1 265 (10.433) "Retraction" motor Relay R4
22 Red cable 1 320 (12.598) "Turn" motor Relay R1
board
24 Cable AWG 22 - 1 1 495 (19.488) Terminal 8 "End of "Position 0" switch
travel signal"
Rotary contact
"Ground"
Page 717
33-49-19 APR 15/12
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646
1 2 3 4 5 6 7
"Extracsion"
"R etraction" switch
switch
1 4 2 1 4 2
"R etraction" motor
Light relay
M
22 23
8 "End of
Casing ground
Elec trical travel signal"
rotary contact 8
"Retraction"
24 7
Circuit board - Relays "Extension"
25 6
"R e t ra c tio n " "Ex t en s io n " "R igh t" "L ef t"
"Left"
5
Halogen light R4 R3 R2 R1
"Right"
"Turn" mot ro 4
"+ 28 V"
1 2 3 4 5 6 7 8 9 10 3
20 21 "Light"
M 2
"Ground"
1
"Position 0" "Extension" "Retraction"

switch sw itch switch
18 17 16 15 14 13 12 11 10 9
1 24 4 2 1 1 24
19 C N C N O NO N C C C N C NO
Light housing
ground
Wiring diagram,
searchlight P/N 4226271
Figure 703
Page 718
33-49-19 APR 15/12
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646
PRE SB 4360404-33-001
C. Searchlight P/N 4360404 (see fig. 704)

1 Cable AWG 14 - 9 1 530 Light relay Rotary contact

(20.867)
2 Cable AWG 22 - 0 1 495 Light relay Casing ground
(19.488)
Light relay
Light relay
Light relay
5 Cable AWG 22 - 9 1 400 "Intermediate" switch Terminal 11
(15.748) "Intermediate
extension"
Lug 25504 1 Item 5 "Intermediate" Terminal 11
switch "Intermediate
extension"
6 Cable AWG 22 - 3 1 400 Terminal 2 "Light" Terminal 10
(15.748) "Intermediate
extension"
Lug 25504 1 Item 6 "Intermediate" Terminal 10
switch "Intermediate
extension"
7 Cable AWG 22 - 8 1 500 Terminal 12 "Position 0" switch
(19.685) "Extension in the axis"
Lug 25504 1 Item 7 "Position 0" Terminal 12 "Extension
switch in the axis"
8 Cable AWG 14 - 9 1 470 Casing ground Terminal 1 "Ground"
(18.504)
Lug 25509 1 Item 8 Terminal 1 Casing ground
"Ground"
Lug 25511 1 Item 8 Casing ground Terminal 1 "Ground"
Lug 25504 1 Item 9 Terminal 4 "Right"
Relay R2
Page 719
33-49-19 APR 15/12
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646

Lug 25504 1 Item 10 Relay R1 Terminal 5 "Left"
11 Cable AWG 22 - 6 1 230 (9.055) "Extension" switch Terminal 6 "Extension"

"Extension" switch
"Retraction"
"Retraction" switch
14 Cable AWG 22 - 2 1 70 (2.756) Terminal 9 "+ 28 V Relay R3
motor"
Lug 25504 1 Item 14 Relay R3 Terminal 9 "+ 28 V
motor"
15 Cable AWG 22 - 9 1 460 Relay R2 "Position 0" switch
(18.110)
16 Cable AWG 22 - 5 1 180 (7.087) Relay R3 "Extension" switch
17 Cable AWG 22 - 4 1 160 (6.299) Relay R4 "Retraction" switch
18 Cable AWG 22 - 3 1 410 "Retraction" switch "Position 0" switch
(16.142)
Lug 50840 1 Item 19 Light housing Halogen light
ground
Lug 25509 1 Item 19 Halogen light Light housing ground
20 White cable 1 310 Rotary contact Halogen light
(12.205)
Lug 50840 1 Item 20 Rotary Halogen light
contact
21 Cable AWG 22 - 1 1 495 Terminal 8 "End of "Position 0" switch
(19.488) travel signal"
Lug 25504 1 Item 21 "Position 0" Terminal 8 "End of
switch travel signal"
22 Black cable 1 320 "Turn" Motor Terminal 10 circuit
(12.598) board
23 Red cable 1 320 "Turn" Motor Relay R1
Page 720
33-49-19 APR 15/12
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646

(12.598)
24 Black cable 1 265 "Retract" Motor Terminal 1 circuit
(10.433) board
25 Red cable 1 265 "Retract" Motor Relay R4
(10.433)
Page 721
33-49-19 APR 15/12
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POST SB 4360404-33-001
D. Searchlight P/N 4360404 (see fig. 704A)

FIG. 704A IN mm (in.)

5 Cable AWG 22 - 9 1 400 (15.748) "Intermediate" switch Terminal 11
"Intermediate
extension"
6 Cable AWG 22 - 3 1 400 (15.748) Terminal 2 "Light" Terminal 10
"Intermediate
extension"
7 Cable AWG 22 - 8 1 300 (11.811) Terminal 12 Contact "16" of circuit
"Extension in the axis" board
8 Cable AWG 14 - 9 1 470 (18.504) Casing ground Terminal 1 "Ground"
9 Cable AWG 22 - 3 1 65 (2.559) Terminal 4 "Right" Contact "6" of circuit
board
10 Cable AWG 22 - 9 1 85 (3.346) Terminal 5 "Left" Contact "9" of circuit
board
11 Cable AWG 22 - 6 1 230 (9.055) "Extension" switch Terminal 6
"Extension"
"Retraction"
13 Cable AWG 22 - 0 1 115 (4.528) Terminal 1 "Ground" Contact "4" of circuit
board
14 Cable AWG 22 - 2 1 200 (7.874) Terminal 9 "+ 28 V Contact "5" of circuit
motor" board
15 Cable AWG 22 - 9 1 430 (16.930) Contact "16" of circuit "Position 0" switch
board
16 Cable AWG 22 - 5 1 200 (7.874) Contact "3" of circuit "Extension" switch
board
17 Cable AWG 22 - 4 1 140 (5.512) Contact "10" of circuit "Retraction" switch
board
board
Page 722
33-49-19 APR 15/12
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646


board
22 Black cable 1 320 (12.598) "Turn" Motor Contact "8" of circuit
board
23 Red cable 1 320 (12.598) "Turn" Motor Contact "7" of circuit
board
24 Red cable 1 265 (10.433) "Retract" Motor Contact "1" of circuit
board
25 Black cable 1 265 (10.433) "Retract" Motor Contact "2" of circuit
board
26 Yellow cable 1 200 (7.874) Terminal 8 "End of Contact "15" of
travel signal" circuit board
27 Red cable 1 200 (7.874) Terminal 7 "Retraction Contact "14" of
circuit board
28 White cable 1 430 (16.930) Contact "11" of circuit "Position 0" switch
board
END SB 4360404-33-001
Page 723
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4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646
PRE SB 4360404-33-001
1 2 3 4 5 6 7
"Extension in axis"
12
"Turn" motor Interm ediate switch
11
"Intermediate extension"
Light relay
M 4 21 10
22 NO N C C "+ 28 V motor"
9
23 "End of travel signal"
Casing ground
Electrical 8
rotary contact "Retraction"
20 7
Circuit board - Relays "Extension"
21 6
"Left"
5
Halogen light R4 R3 R2 R1
"Right"
"Retraction" motor 4
1 2 3 4 5 6 7 8 9 10
"+ 28 V"
25 24 3
M
"Light"
2
"Ground"
1
"Position 0" "Extension" "R etraction"

sw itch switch switch
18 17 16 15 14 13 12 11 10 9 8
1 24 4 2 1 1 24
19 C N C NO NO N C C C N C NO
Light housing
ground
Wiring diagram,
Figure 704
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POST SB 4360404-33-001
Wiring diagram, searchlight

P/N 4360404
Figure 704A
Page 725
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PRE SB 4361646-33-001
E. Searchlight P/N 4361646 (see fig. 705)


Light relay
Light relay
Light relay
5 Cable AWG 22 - 9 1 300 (11.811) "Intermediate" switch Light relay
6 Cable AWG 22 - 3 1 300 (11.811) "Intermediate" switch Terminal 6
"Extension"
Lug 25504 1 Item 6 "Intermediate" Terminal 6 "
switch Extension"
7 Cable AWG 22 - 4 1 500 (19.685) Terminal 5 "Left" "Left turn" switch
Lug 25504 1 Item 7 "Left turn" Terminal 5 "Left"
switch
8 Cable AWG 22 - 1 1 500 (19.685) "Left turn" switch Relay R1
9 Cable AWG 22 - 6 1 500 (19.685) "Right turn" switch Terminal 4 "Right"
Lug 25504 1 Item 9 "Right turn" Terminal 4 "Right"
switch
10 Cable AWG 22 - 9 1 500 (19.685) "Right turn" switch Relay R2
11 Cable AWG 14 - 9 1 470 (18.504) Casing ground Terminal 1 "Ground"
Lug 25511 1 Item 11 Terminal 1 " Ground"

Casing ground
"Ground"
12 Cable AWG 22 - 6 1 400 (15.748) "Intermediate" switch "Extension" switch
13 Cable AWG 22 - 2 1 70 (2.756) Terminal 3 "+ 28 V" Relay R3

Lug 25504 1 Item 13 Relay R3 Terminal 3 "+ 28 V"
Page 726
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"Retraction"
Lug 25504 1 Item 14 "Retraction" Terminal 9 "+ 28 V
switch motor"
16 Cable AWG 22 - 9 1 460 (18.110) Relay R2 "Position 0" switch
17 Cable AWG 22 - 5 1 200 (7.874) Relay R3 "Extension" switch
18 Cable AWG 22 - 4 1 180 (7.087) Relay R4 "Retraction" switch
20 Cable AWG 14 - 9 1 175 (6.889) Halogen light Ground light housing
Lug 50840 1 Item 20 Ground light Halogen light
housing
Lug 25509 1 Item 20 Halogen light Ground light housing
21 Cable AWG 22 - 1 1 495 (19.488) Terminal 8 "End of "Position 0" switch
travel signal"
Lug 25504 1 Item 21 "Position 0" Terminal 8 "End of
switch travel signal"
board
Lug 50840 1 Item 24 Rotary Halogen light
contact
board
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POST SB 4361646-33-001
F. Searchlight P/N 4361646 (see fig. 705A)

1 White cable Filotex 1 530 (20.87) Light relay Electrical rotary
2100 S= 1.91 contact
Cable AWG 14 - 9
2 Black cable Filotex 1 510 (20.079) Light relay Casing ground
1900A - S=0,38
Cable AWG 22 - 0
Lug 25002 1 Item2 Light relay Casing ground
3 White cable Filotex 1 125 (4.92) Terminal 3 +28 Light relay
2100 S=1.91
Cable AWG 14 - 9
Lug 25511 1 Item 3 Lignt relay Terminal 3 +28
4 White cable Filotex 1 300 (11.81) Terminal 2 Light relay
2100 S = 1.91 Light
AWG 22 - 9
Lug 25504 1 Item 4 Light relay Terminal 2 Light
5 White cable Filotex 1 300 (11.81) Intermediate Switch Light relay
2100 S = 1.91
6 Orange cable 1 300 (11.81) Terminal 6 Intermediate switch
Filotex 1900A S = Extension
0.38
Lug 25504 1 Item 6 Intermediate Terminal 6
switch Extension
7 Yellow cable 1 500 (19.685) Terminal 5 Left turn switch
Filotex 1900A Left
Left turn switch Left
8 Brown cable Filotex 1 500 (19.685) Left turn Circuit Board Relay
1900A S = 0.38 Switch PT8
9 Blue cable 1 500 (19.685) Right turn Terminal 4
Filotex 1900A S = switch Right
0.38
AWG 22 - 9
Lug 25504 1 Item 9 Terminal 4 Right turn
Right switch
10 White cable 1 500 (19.685) Right turn Circuit Board Relay
Filotex 1900A S = Switch PT6
0.38
Cable AWG 22 - 9
11 White cable 1 470 (18.504) Casing ground Terminal 1
Filotex 2100 S = Ground
1.91
Cable AWG 14 - 9
Ground
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Casing ground Ground
12 Blue cable 1 400 (15.748 ) Intermediate switch Extension switch
Filotex 1900A S =
0.38
Cable AWG 22 - 6
13 Red cable 1 70 (2.756) Terminal 3 Circuit Board
Filotex 1900A S = +28V Relay
0.38 PT4
Cable AWG 22 - 2
Lug 25504 1 ITEM 13 Circuit Terminal 3
Board +28V
Relay
PT4
14 Red cable 1 215 (8.865 ) Terminal 7 Retraction switch
Filotex 1900A S = Retraction
0.38
Cable AWG 22 - 2
Lug 25504 1 Item 14 Retraction Terminal 7
switch Retraction
15 Black cable 1 75 ( 2.953 ) Terminal 1 Circuit board Relays
Filotex 1900A S = Ground PT7
0.38
Cable AWG 22 - 9
Lug 25504 1 Item 6 Circuit board Terminal 1
Relays Ground
PT7
16 White cable Filotex 1 460 (18.11) Circuit Board Relays Position 0
1900A S = 0.38 PT 6 Switch
Cable AWG 22 - 9
17 Green cable Filotex 1 200 (7.874) Circuit Board Relays Extension switch
1900A S = 0.38 PT5
Cable AWG 22 - 5
18 Yellow cable 1 180 (7.087) Circuit Board Relays Retraction Switch
Filotex 1900A S = PT3
0.38
Cable AWG 22 - 4
19 Orange cable 1 410 (16.142) Retraction Switch Position 0
Filotex 1900A S = Switch
0.38
Cable AWG 22 - 3
20 White cable 1 175 (6.889) Halogen light Light housing ground
Filotex 2100
Cable AWG 14 - 9
Halogen light
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21 Brown cable 1 495 (19.488) Circuit Board Relays Position 0
Filotex 1900A S = PT13 Switch
0.38
Cable AWG 22 - 1
22 Black cable 1 265 (10.433) Circuit Board Relays Retraction motor
0.38
Cable AWG 22-00
23 Red cable 1 265 (10.433) Circuit Board Relays Retraction motor
0.38
Cable AWG 22-4
24 White cable 1 310 (12.205) Rotary Contact Halogen light
Filotex 2100
Cable AWG 14-9
Lug 50840 1 Item 24 Halogen light Rotary Contact
25 Red cable 1 320 (12.598) Circuit Board Turn motor
Filotex 1900A S = Relays
0.38 PT9
Cable AWG 22-4
26 Black cable Filotex 1 320 (12.598) Circuit Board Turn motor
1900A S = 0.38 Relays
Cable AWG 22-00 PT10
27 Red cable Filotex 1 200 (7.874) Circuit Board Terminal 7
1900A S = 0.38 Relays Retraction
Cable AWG 22-4 PT11
Lug 25504 1 Item 27 Terminal 7 Circuit Board
Retraction Relays
PT11
28 Brown cable 1 200 (7.874) Circuit Board Terminal 8
Filotex 1900A S = Relays End of travel signal
0.38 PT12
Cable AWG 22-1
Lug 25504 1 Item 28 Terminal 8 Circuit Board
End of travel signal Relays
PT12
Page 730
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PRE SB 4361646-33-001
Wiring diagram,
Figure 705
Page 731
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POST SB 4361646-33-001
Wiring diagram, searchlight

P/N 4361646
Figure 705A
Page 732
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5. STORAGE AND REMOVAL FROM STORAGE
A. STORAGE
(1) Make sure that the moving light housing is extended by about 20.
(2) Put the unit in greaseproof paper (greaseproof side to the part).
(3) Seal the envelope (the greaseproof paper is self-bonding).
(4) Put this envelope in a vinyl chloride cover or a heat-sealing cloth, with a
desiccant bag.
(5) Hermetically seal the bag with high-frequency welding.
(6) Place this bag is a correctly-dimensioned cardboard box.
(7) Prevent free movement with greaseproof paper or pieces of dry undulated
cardboard.
(8) Close the cardboard box and strengthen the closing flaps with adhesive tape.
(9) Identify the equipment with a stick-on label.
(10) Apply a layer of transparent waterproof varnish to the label and bond
transparent adhesive tape on the label.
(11) Keep the cardboard box in a temperate room.
B. Removal from storage
Remove the light from storage and examine its condition before a new extension of
storage time.
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FITS AND CLEARANCES
NOT APPLICABLE
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SPECIAL TOOLS, FIXTURES AND EQUIPMENT
NOTE : Equivalent alternatives can be used for the items shown.
USE
PART NUMBER CODE DESCRIPTION
690-427613 Bench/searchlight interface plate X X
690-427613-02 Test bench X X
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Page 902
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ILLUSTRATED PARTS LIST

(IPL)
TP 1001 Page 1
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TP 1001 Page 2
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INTRODUCTION
1. GENERAL
The Illustrated Parts List (IPL) agrees with the ATA 100 specification. The IPL identifies all the
components of the unit.
The Illustrated Parts List contains these following sections:
Introduction,
Vendors Code Index,
Alphanumerical index,
List of Circuit Symbols (if applicable),
Detailed Parts List.
2. HOW TO USE THE DETAILED PARTS LIST
The detailed parts list includes the nomenclature and the illustrations of the unit components.
The detailed parts list columns are laid in this manner:
1st column: Fig. Item - Figure and Item number.
2nd column: Part number - Manufacturer's part number.
3rd column: Nomenclature.
4th column: Usage code - Effectivity.
5th column: Units per Assy - Quantity in the next higher assembly.
A. Figure and item numbers
The figure number which contains the items listed, is shown on the first line at the top of
each page.
Each assembly, sub-assembly or item listed in the parts list has an item number. A letter
after the item number identifies the variant. The basic variant has the letter A.
A dash (-) located before item numbers identifies the assemblies, sub-assemblies and
parts which are listed, but not illustrated.
A letter located before the item number refers to the illustration of the variant called out
from the related basic figure.
INTRO 1001 Page 1

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B. Manufacturer's part number
Each of the assemblies, sub-assemblies and detail parts, illustrated or not, is related to a
manufacturer's part number.
When the manufacturer's actual part number has more than 15 characters, an equivalent
assigned part number is given in the "Part number" column with such note:
ORDER OVERLGTH... MADE BY V...
The two part numbers are in the Alphanumeric index in their logical order; the actual
overlength part number is referred to the assigned part number with the note "SEE..."
(SEE).
C. Nomenclature
The nomenclature has indents to show the relationship between the parts listed.
1 2 3 4 5 6 7
Assembly
. Detail parts for assembly
. Sub-assembly
. Attaching parts and/or storage parts for sub-assembly
* * *
. . Detail parts for sub-assembly
. . Sub-sub-assembly
. . Attaching parts and/or storage parts for sub-sub-assembly
* * *
. . . Detail parts for sub-sub-assembly
etc.
A vendor code is given to each item or article not made by the prime manufacturer of the
assembly.
This vendor code or the abbreviation "NP" (not procurable) is located at the right-hand side
limit of the 1st line of the nomenclature.
D. Effectivity (Usage code)
An alphanumeric usage code shows the applicability of sub-assemblies and detail parts to
the next higher assembly(ies) or sub-assembly(ies).
When the applicability is for all items, the usage code column is left blank.
The usage code relates to the figure/item number of the next higher assembly(ies) or sub-
assembly(ies). e.g., effectivity 1A, 1B, 1C is written 1ABC.
INTRO 1001 Page 2

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E. Units per assembly
The Units per Assy column shows the number of units necessary for the next higher
assembly.
If not, then the letters RF (reference) or AR (as required) replace this information.
3. TERMS AND ABBREVIATIONS USED
AMDT: Amendment
AR: As Required
ATTACHING PARTS
DELETED
DET: DETail
LH and RH: Left and Right
MADE BY
MADE FROM
MATCHED PART
MODIFIED FROM
NHA: Next Higher Assembly
NI/ALPHA: Numerical Index (ALPHA part)
NI/NUM: Numerical Index (NUMerical part)
NP: Not Procurable
OPT TO: OPTional parts
ORDER OVERLGTH MPN / Actual part number longer than 15 characters.
OVERSIZE: Oversize repair parts.
POST AMDT: Configuration after application of amendment.
POST SB: Configuration after application of Service Bulletin.
R: Modified.
RF: For Reference.
SEE
SEL FROM: (SELect FROM parts)
STORAGE PARTS
SUPSD BY: Superseded by
SUPSDS: Supersedes
UNDERSIZE: Undersize repair parts
INTRO 1001 Page 3

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4. REVISION
When an item number is revised, added or deleted, the letter "R" appears in the right hand
margin (the date of issue is modified).
The letter "R" appears in the right hand margin opposite the page number when all item
numbers are modified.
INTRO 1001 Page 4

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VENDOR NAME - ADDRESS

CODE
08808 GENERAL ELECTRIC CO

LAMP GLASS AND COMPONENTS DEPT
4901 CAMPBELL RD
WILLOUGHBY OH 44094-3366
USA
56501 THOMAS AND BETTS CORPORATION

8155 T&B Blvd
38125-8888 MENPHIS USA
80205 NATIONAL AEROSPACE STANDARDS COMMITTEE

AEROSPACE INDUSTRIES ASSOCIATION OF AMERICA INC
1250 EYE NW USA
F0110 ASSOCIATION FRANCAISE DE NORMALISATION

11, av. Francis de Pressense
93571 SAINT DENIS LA PLAINE CEDEX
F0111 BNAE - Bureau de Normalisation de l'Aronautique et de l'Espace

TECHNOPOLIS 54
199, rue Jean-Jacques Rousseau
92130 ISSY LES MOULINEAUX
F0126 GIFAS (Groupement des Industries Franaises Aronautiques et Spatiales)

4, rue Galile
75116 PARIS CEDEX 16
F0224 ALCOA FIXATIONS SIMMOND SAS

9, rue des Cressonnires
72110 SAINT COSME EN VAIRAIS
F0280 ECE-TELEFLEX-SYNERAVIA
26, rue des Solets
Zone SILIC
BP 449
94152 RUNGIS CEDEX
F0289 BERNIER
2-4, rue du Languedoc
91220 BRETIGNY SUR ORGE
VCI 1001 Page 1

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VENDOR NAME - ADDRESS

CODE
F0344 L.G.C.
2, rue de la Ternier
BP 50039
49241 AVRILLE CEDEX
F0349 ACUMENT LA FERTE FRENEL SAS

LD FORET DU CHATEAU
61550 LA FERTE FRENEL
F0737 FEDERAL MOGUL OPERATIONS SAS
Place Paul Bert
BP 39
45141 SAINT JEAN DE LA RUELLE CEDEX
F1701 ACUMENT BONEUIL SUR MARNE
10, Quai du Rancy
BP 75
94381 BONNEUIL SUR MARNE CEDEX
F1907 HONEYWELL SA
Parc Technologique
Route d'Orme
BP 87
91193 ST AUBIN
F3316 LEDUC SA
274, Rue du Marchal Juin
BP 526
77005 MELUN CEDEX
F6728 TYCO ELECTRONICS MPI FRANCE
29, Cours Jules Csar
95300 PONTOISE
FAL02 ABB FRANCE
9, avenue Edouard Belin
92566 RUEIL MALMAISON CEDEX
FAX02 CROUZET AUTOMATISMES
2, Rue du Docteur Abel
BP 59
26902 VALENCE CEDEX 9
VCI 1001 Page 2

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AIRLINE PART NUMBER TTL

PART NUMBER FIGURE ITEM
REQ
ASQ1AG030015UL 1 290B 1
BHM1AG030010TL 1 A 650B 4
BHQ1AG050010UL 1 600A 2
C12/17X12BP25 1 210A 2
CTR1-17-6B2 1 180A 1
CTR1-2X8B1 1 180B 1
DEQ1AG030010UL 1 345B 1
DZM1UB040018U 2 190C 8
DZM1UB040018U 2 A 330A 4
DZM1UB040020U 2 190A 8
SUPSD BY 190B
DZQ1AG030008UL 1 345A 1
E3RP2364 2 124A 4
G05-3X16 1 510A 1
GAQ1UY040T 2 220B 8
GAQ1UY040T 2 A 360A 4
GEQ4559X 1 A 020B 1
GEQ4681 1 020A 1
H5463R 2 080B 2
H5463R 2 095A 1
H5463R 1 220B 1
HLS11L22C 2 080A 2
HLS11L24C 2 080C 2
CANCELLED
HPS-11 1 220A 1
JZAJ030TL 1 060A 1
JZAJ030TL 1 347A 1
JZAJ030TL 1 A 720A 1
L20H 2 093A 2
LHM1AG030010L 1 040A 1
LHM1AG030010UL 1 310A 1
LHM1AG040016UL 1 100A 2
MILR57-57B 2 170A 1
NAS 517-2-00 2 A 250A 4
PC16-2RT24VCCAG-PD 2 140A 4
PE0000090Y00 1 630B 1
PE0000091Y00 1 632A 1
SY20306 1 020C
CANCELLED
T3-18-25-5 1 190A 1
T3-2X2-8X6-3 1 A 190B 1
TC814 2 050A 2
TY232M 2 060A 2
TY232M 1 395A 1
TY232M 1 450A 1
TY25M 1 390A 1
XAUJ040T 2 200A 8
XAUJ040T 2 A 340A 4
NI/ALPHA 1001 Page 1

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NI/ALPHA 1001 Page 2

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REQ
1N4006 2 167A 4
1SE1T 2 A 095B 1
21030100 2 030A 2
22208AG030018L 1 A 780A 1
22208UB040018 2 190B 8
22291AG020006L 1 217A 2
22291AG020006L 1 239A 2
22291AG030008L 1 080A 2
22291AG030008L 1 130A 4
22291AG030008L 1 650A 4
22291AG030010L 1 A 750A 1
22291AG030014L 2 020A 2
22291AG030016L 2 A 020B 2
22293AG020008L 1 235A 2
22293AG020008L 1 663A 2
22293AG020010L 2 090A 2
22293AG020010L 2 097A 2
22293AG020010L 1 230A 2
22293AG020010L 1 669A 2
22293AG025006L 1 360A 3
22293AG025006L 1 420A 3
22293AG030006L 1 040C 1
22293AG030006L 2 180A 4
22293AG030006L 1 A 112A 1
22293AG030006L 1 A 680A 1
22293AG030006L 1 A 710A 1
22293AG030008L 1 A 040B 1
22293AG030012L 1 634A 1
22293AG030012L 2 A 300A 2
22293AG030014L 1 290A 1
22431AG030L 2 040A 4
22431AG030L 1 300A 1
22431AG030L 1 320A 1
22431AG030L 1 349A 1
22431AG040L 2 220A 8
3PA108 1 305A 1
3PA108 1 636A 1
3PA108 2 A 320A 2
3PA108 1 A 770A 1
3010103 2 237A AR
3014392 2 070A 4
3015619 2 091A 2
3015619 2 098A 2
3015619 1 219A 4
3016519 1 330A 1
3025063 2 239A 1
3053235 1 661A 1
3059812 2 130A 4
NI/NUM 1001 Page 1

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REFERENCE COMPAGNIE QTE

REFERENCE FABRICANT FIGURE REPERE
AERIENNE TTL
3059835 2 210A 16
3059835 2 A 350A 8
3059888 1 370A
CANCELLED
3060674 1 400A 1
3064516 1 050A 1
3064516 1 340A 1
3064516 2 A 310A 2
3064516 1 A 690A 1
3064516 1 A 760A 1
3066671 2 165A 2
3068336 2 110B 5
3074869 2 A 235A 8
3074869 2 A 380A 4
3086268 2 150A NP
3131248 2 130B 4
4PA104 2 230B 8
4PA104 2 A 370A 4
4PA108NYLSTOP 1 110A 2
4PA108NYLSTOP 2 230A 8
4058126 2 280A 1
4076942 1 A 670B 1
4168762 1 001A RF
4168762 2 001A RF
4174589 1 480A 3
4174589 1 550A AR
4174625 1 260A AR
4174625 1 485A AR
4183825 1 030A 1
4185788 1 660A 1
4185801 1 120A 1
4185817 1 640A 1
4185831 2 160A NP
4185854 1 070A 1
4187147 1 010A 1
4190535 1 090A 1
4190542 2 100A 1
4190558 1 170A 1
4190565 1 270A 1
4190572 1 380A
CANCELLED
4190588 1 250A 1
4190595 1 160A 1
4190601 1 200A 1
4190631 1 150A 1
4190647 1 140A 1
4190654 1 350A
CANCELLED
NI/NUM 1001 Page 2

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REQ
4190654 1 410A 1
SUPSD BY 410B
4191345 2 120A 1
4191352 1 590A 1
4191368 2 010A 1
4191569 1 520A 1
4191576 1 470A 1
4191576 1 540A 1
4191583 1 560A 1
4191599 1 490A 1
4191605 1 610A 1
4191612 1 630A 1
4192006 2 270A 1
4202082 1 A 090B 1
4202104 1 001B RF
4202104 2 001B RF
4202141 1 A 070B 1
4202372 2 A 240A 1
4202477 2 260A 1
4203152 2 A 270B 1
4203168 1 A 030B 1
4206705 1 A 010B 1
4217228 1 001D RF
4217228 2 001D RF
4218968 2 120B 1
4218975 2 270D 1
4226271 1 001C RF
4226271 2 001C RF
4226472 1 237A 1
4226488 1 215A 1
4226495 1 170B 1
4226501 1 343A 1
4226524 1 A 660B 1
4226666 1 233A 1
4226725 2 270C 1
4228546 1 A 115A 1
4229663 2 100B 1
4230775 2 010B 1
4244598 1 A 010C 1
4245005 1 350B 1
4245005 1 410B 1
4264647 1 A 700A 1
4297463 1 350D 1
4297463 1 410D 1
4297486 2 A 099A 1
4307405 1 001E RF
4307405 2 001E RF
4308186 1 303A 1
NI/NUM 1001 Page 3

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REFERENCE COMPAGNIE QTE

REFERENCE FABRICANT FIGURE REPERE
AERIENNE TTL
4308565 2 270E 1
4318397 1 030C 1
4347966 1 A 090C 1
4347973 1 170C 1
4360404 1 001F RF
4360404 2 001F RF
4360829 2 A 290A 1
4360836 2 270F 1
4360866 1 A 660C 1
4361036 2 260B 1
4361646 1 001G RF
4361646 2 001G RF
4366209 2 A 010C 1
4366253 1 A 730A 1
4366276 1 A 740A 1
4382208 1 667A 1
4382215 1 215B 1
4382222 1 303B 1
4382282 1 660D 1
4382535 1 343B 1
4382661 2 270G 1
4383628 1 237B 1
4384422 2 120C 1
4385189 2 122A 4
6-10-16BP25 1 580A 1
6-10-6BP25 1 280A 1
6-10-6BP25 1 500A 1
6-10-6BP25 1 620A 1
8-12-8BP25 1 570A 1
80-0240 1 240A 1
80-0260 1 460A 1
80-0260 1 530A 1
83141 1 231A 1
83141 1 665A 1
NI/NUM 1001 Page 4

33-49-19 APR 15/12
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646
DETAILED PARTS LIST
TP Page 1001
33-49-19 APR 15/12
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646
Searchlights
P/N 4226271, P/N 4307405 and P/N 4361646
Page 1001-0
Figure 1
33-49-19 APR 15/12
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646
Searchlights
P/N 4168762, P/N 4217228, P/N 4202104 and P/N 4360404 Page 1001-0A
Figure 1A 33-49-19 APR 15/12
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646
UNIT PER
FIGURE PART
USAGE
ASSY
NOMENCLATURE
CODE
ITEM NUMBER
1234567
1
-001A 4168762 SEARCHLIGHT A RF
-001B 4202104 SEARCHLIGHT B RF
-001C 4226271 SEARCHLIGHT C RF
-001D 4217228 SEARCHLIGHT D RF
-001E 4307405 SEARCHLIGHT E RF
-001F 4360404 SEARCHLIGHT F RF
-001G 4361646 SEARCHLIGHT G RF
010A 4187147 . LIGHT RETAINING RING ACDEG 1
A 010B 4206705 . LIGHT RETAINING RING B 1
PRE AMDT F
SUPSD BY ITEM 010C
A 010C 4244598 . LIGHT RETAINING RING BF 1
POST AMDT F
SUPSDS ITEM 010B
020A GEQ4681 . HALOGEN LIGHT 450 W (3020865) (08808) ACDEG 1
A 020B GEQ4559X . HALOGEN LIGHT 600 W (3057576) (08808) BF 1
020C SY20306 . DELETED
030A 4183825 . LIGHT SEAL AC 1
A 030B 4203168 . LIGHT SEAL BF 1
030C 4318397 . LIGHT SEAL DEG 1
040A LHM1AG030010L . SCREW C (3022999) (F0110) ACDE 1
A 040B 22293AG030008L . SCREW (3015158) (F0111) BF 1
040C 22293AG030006L . SCREW (3010565) (F0111) G 1
050A 3064516 . WASHER 1
060A JZAJ030TL . WASHER (3016518) (F0110) 1
070A 4185854 . COVER PLATE ACDEG 1
A 070B 4202141 . COVER PLATE BF 1
ATTACHING PART
080A 22291AG030008L . SCREW (3028214) (F0111) 2
***
090A 4190535 . MOVING LIGHT HOUSING ACDEG 1
A 090B 4202082 . MOVING LIGHT HOUSING B 1
SUPSD BY ITEM 090C
A 090C 4347966 . MOVING LIGHT HOUSING BF 1
SUPSDS ITEM 090B
ATTACHING PART
100A LHM1AG040016UL . SCREW (3064471) (F0110) 2
110A 4PA108NYLSTOP . NUT (3016733) (F0224) 2
A 112A 22293AG030006L . SCREW (3010565) (F0111) BF 1
***
A 115A 4228546 . SEAL BF 1
120A 4185801 . CASING COVER 1
ATTACHING PART
130A 22291AG030008L . SCREW (3028214) (F0111) 4
***
140A 4190647 . PLATE ASSEMBLY 1
150A 4190631 . ROTARY CONTACT ASSEMBLY 1
160A 4190595 . INSULATING BUSH 1
- ITEM NOT ILLUSTRATED Page 1001-1

33-49-19 APR 15/12
ECE TELEFLEX SYNERAVIA
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646
UNIT PER
ASSY
USAGE
FIGURE PART
CODE
ITEM NUMBER NOMENCLATURE
1234567
1
170A 4190558 . LIGHT HOUSING SPINDLE ADE 1
170B 4226495 . LIGHT HOUSING SPINDLE CG 1
170C 4347973 . LIGHT HOUSING SPINDLE BF 1
180A CTR1-17-6B2 . PIN (3064539) (F0344) 1
SUPSD BY ITEM 180B
180B CTR1-2X8B1 . PIN (3068313) (F0344) 1
SUPSDS ITEM 180A
190A T3-18-25-5 . SPRING (3064523) (F3316) 1
SUPSD BY ITEM 190B
190B T3-2X2-8X6-3 . SPRING (3068329) (F3316) 1
SUPSDS ITEM 190A
200A 4190601 . STOP 1
210A C12/17X12BP25 . BEARING (F0737) 2
(3064546)
215A 4226488 . CAM C 1
215B 4382215 . CAM G 1
ATTACHING PARTS
217A 22291AG020006L . SCREW (3044757) (F0111) CG 2
219A 3015619 . WASHER CG 4
***
-220A HPS-11 . MICROSWITCH (3065036) (FAL02) 1
SUPSD BY ITEM 220B
220B H5463R . MICROSWITCH (3078204) (FAL02) 1
SUPSDS ITEM 220A
ATTACHING PARTS
230A 22293AG020010L . SCREW (3064457) (F0111) 2
***
231A 83141 . MICROSWITCH (FAX02) CG 1
(3053123)
233A 4226666 . MICROSWITCH LEVER CG 1
ATTACHING PARTS
235A 22293AG020008L . SCREW (3013709) (F0111) CG 2
***
237A 4226472 . MICROSWITCH BRACKET C 1
237B 4383628 . MICROSWITCH BRACKET G 1
ATTACHING PART
239A 22291AG020006L . SCREW (3044757) (F0111) CG 2
***
240A 80-0240 . RETAINING RING (3026624) (F0349) 1
250A 4190588 . BEARING 1
260A 4174625 . SHIM, TH 0.05 AR
270A 4190565 . GEAR AND PINION SPINDLE 1
280A 6-10-6BP25 . BEARING (F0737) 1
(3016726)
290A 22293AG030014L . SCREW (3021942) (F0111) ABCDG 1
PRE SB 4202104-33-001
PRE SB 4217228-33-001
PRE SB 4361646-33-001
PRE SB 4360404-33-001
SUPSD BY ITEM 290B

33-49-19 APR 15/12
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646
UNIT PER
USAGE
ASSY
FIGURE PART
CODE
1234567
1
290B ASQ1AG030015UL . SCREW (3038231) (F0110) BDEG 1
POST SB 4202104-33-001
POST SB 4217228-33-001
POST SB 4361646-33-001
POST SB 4360404-33-001
SUPSDS ITEM 290A
300A 22431AG030L . NUT (3021503) (F0111) 1
303A 4308186 . LUG E 1
303B 4382222 . LEVER G 1
305A 3PA108 . NUT (3014407) (F0224) E 1
310A LHM1AG030010UL . SCREW (3022999) (F0110) ABCDE 1
320A 22431AG030L . NUT (3021503) (F0111) ABDE 1
330A JZAJ030TL . WASHER (3016518) ABCDE 1
340A 3064516 . WASHER ABCDE 1
343A 4226501 . CAM C 1
343B 4382535 . CAM G 1
ATTACHING PARTS
345A DZQ1AG030008UL . SCREW (3023904) (F0110) C 1
345B DEQ1AG030010UL . SCREW (3046719) (F0110) G 1
347A JZAJ030TL . WASHER(3016518) (F0110) CG 1
349A 22431AG030L . NUT H (3021503) (F0111) CG 1
***
-350A 4190654 . MOTOR ASSEMBLY
SUPSD BY ITEM 350B
350B 4245005 . MOTOR ASSEMBLY ACDEG 1
SUPSDS ITEM 350A
350D 4297463 . MOTOR ASSEMBLY BF 1
ATTACHING PARTS
360A 22293AG025006L . SCREW (3043426) (F0111) 3
***
-370A 3059888 . . DELETED
-380A 4190572 . . DELETED
390A TY25M . CABLE CLAMP (3067325) (F6728) 1
400A 3060674 . CAP 1
-410A 4190654 . MOTOR ASSEMBLY
SUPSD BY ITEM 410B
410B 4245005 . MOTOR ASSEMBLY ACDEG 1
SUPSDS ITEM 410A
410D 4297463 . MOTOR ASSEMBLY BF 1
ATTACHING PARTS
420A 22293AG025006L . SCREW (3043426) (F0111) 3
***
470A 4191576 . BUSH 1
480A 4174589 . SHIM, TH 0.05 3
485A 4174625 . SHIM, TH 0.05 AR
490A 4191599 . GEAR AND PINION SPINDLE 1

33-49-19 APR 15/12
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646
UNIT PER
ASSY
USAGE
FIGURE PART
CODE
1234567
1
500A 6-10-6BP25 . BEARING (F0737) 1
(3016726)
510A G05-3X16 . PIN (3038574) (F0344) 1
520A 4191569 . PINION 1
540A 4191576 . BUSH 1
550A 4174589 . SHIM, TH 0.05 AR
560A 4191583 . GEAR 1
570A 8-12-8BP25 . BEARING (F0737) 1
(3013924)
580A 6-10-16BP25 . BEARING (F0737) 1
(3064553)
590A 4191352 . GEAR SECTOR 1
ATTACHING PARTS
600A BHQ1AG050010UL . SCREW (3029479) (F0110) 2
***
610A 4191605 . SPINDLE 1
620A 6-10-6BP25 . BEARING (F0737) 1
(3016726)
630A 4191612 . BUMPER 1
PRE SB 4202104-33-001
PRE SB 4207405-33-001
PRE SB 4217228-33-001
PRE SB 4361646-33-001
PRE SB 4360404-33-001
SUPSD BY ITEM 630B
630B PE0000090Y00 . BUMPER BDEFG 1
POST SB 4202104-33-001
POST SB 4207405-33-001
POST SB 4217228-33-001
POST SB 4361646-33-001
POST SB 4360404-33-001
SUPSDS ITEM 630A
632A PE0000091Y00 . PLATE, LOCKING BDEFG 1
POST SB 4202104-33-001
POST SB 4207405-33-001
POST SB 4217228-33-001
POST SB 4361646-33-001
POST SB 4360404-33-001
ATTACHING PARTS
634A 22293AG030012L . SCREW (3045478) (F0111) BDEFG 1
POST SB 4202104-33-001
POST SB 4207405-33-001
POST SB 4217228-33-001
POST SB 4361646-33-001
POST SB 4360404-33-001

33-49-19 APR 15/12
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646
UNIT PER
USAGE
ASSY
FIGURE PART
CODE
1234567
1
636A 3PA108 . NUT (3014407) (F0224) BDEFG 1
POST SB 4202104-33-001
POST SB 4207405-33-001
POST SB 4217228-33-001
POST SB 4361646-33-001
POST SB 4360404-33-001
***
640A 4185817 . RETRACT CASING
ATTACHING PARTS
650A 22291AG030008L . SCREW (3028214) (F0111) ACDEG 4
A 650B BHM1AG030010TL . SCREW (3054915) (F0110) BF 4
***
660A 4185788 . TURN CASING ABDE 1
A 660B 4226524 . TURN CASING C 1
A 660C 4360866 . TURN CASING F 1
660D 4382282 . TURN CASING G 1
-661A 3053235 . FLEXIBLE LEVER G 1
ATTACHING PARTS
663A 22293AG020008L . SCREW (3013709) (F0111) G 2
***
665A 83141 . MICROSWITCH (3053123) (F0282) G 1
667A 4382208 . BRACKET G 1
ATTACHING PARTS
-669A 22293AG020010L . SCREW (3064457) (F0111) G 2
***
A 670B 4076942 . LIGHT POSITION LABEL BF 1
A 680A 22293AG030006L . SCREW (3010565) (F0111) F 1
A 690A 3064516 . WASHER F 1
A 700A 4264647 . CAM F 1
ATTACHING PARTS
A 710A 22293AG030006L . SCREW (3010565) (F0111) F 1
A 720A JZAJ030TL . WASHER (3016518) (F0110) F 1
***
A 730A 4366253 . BRACKET F 1
A 740A 4366276 . STOP ASSEMBLY F 1
ATTACHING PARTS
A 750A 22291AG030010L . SCREW (3021942) (F0111) F 1
A 760A 3064516 . WASHER F 1
A 770A 3PA108 . NUT (3014407) (F0224) F 1
***
A 780A 22208AG030018L . SCREW (3050426) (F0111) F 1

33-49-19 APR 15/12
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646
Searchlights
P/N 4168762, P/N 4226271, P/N 4217228, P/N 4307405 and P/N 4361646
Figure 2
Page 1002-0
33-49-19 APR 15/12
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646
Searchlights
P/N 4202104 and P/N 4360404
Figure 2A
Page 1002-0A
33-49-19 APR 15/12
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646
UNIT PER
USAGE
ASSY
CODE
FIGURE PART
1234567
2
-001A 4168762 SEARCHLIGHT A RF
-001B 4202104 SEARCHLIGHT B RF
-001C 4226271 SEARCHLIGHT C RF
-001D 4217228 SEARCHLIGHT D RF
-001E 4307405 SEARCHLIGHT E RF
-001F 4360404 SEARCHLIGHT F RF
-001G 4361646 SEARCHLIGHT G RF
010A 4191368 . MICROSWITCH BOX ABDE 1
010B 4230775 . MICROSWITCH BOX CG 1
A 010C 4366209 . MICROSWITCH BOX F 1
ATTACHING PARTS
020A 22291AG030014L . SCREW (3030934) (F0111) ACDEG 2
A 020B 22291AG030016L . SCREW (3064487) (F0111) BF 2
030A 21030100 . WASHER (3064509) (F0349) 2
040A 22431AG030L . NUT (3021503) (F0111) 4
050A TC814 . BASE (3066598) (56501) 2
-060A TY232M . CABLE CLAMP (3057829) 2
070A 3014392 . WASHER 4
***
-080A HLS11L22C . MICROSWITCH (3059783) (FAL02) 2
SUPSD BY ITEM 080B
080B H5463R . MICROSWITCH (3078204) (FAL02) 2
SUPSDS ITEM 080A
-080C HLS11L24C . DELETED
ATTACHING PARTS
090A 22293AG020010L . SCREW (3064457) (F0111) 2
091A 3015619 . WASHER 2
***
093A L20H . LEVER (3078211) (FAL02) 2
095A H5463R . MICROSWITCH (3078204) (FAL02) CG 1
A 095B 1SE1T . MICROSWITCH (3090466) (F1907) F 1
ATTACHING PART
097A 22293AG020010L . SCREW (3064457) (F0111) CFG 2
098A 3015619 . WASHER FG 2
***
A 099A 4297486 . MICROSWITCH BLADE F 1
100A 4190542 . RELAY BOX COVER ABCDEG 1
100B 4229663 . RELAY BOX COVER F 1
ATTACHING PARTS
110B 3068336 . SCREW (F1701) 5
***
-120A 4191345 . RELAY CIRCUIT BOARD ASSEMBLY ABCFG 1
PRE SB 4202104-33-002
PRE SB 4361646-33-001
PRE SB 4360404-33-001
SUPSD BY ITEM 120C
-120B 4218968 . RELAY CIRCUIT BOARD ASSEMBLY DE 1
PRE SB 4217228-33-001
PRE SB 4307405-33-002
SUPSD BY ITEM 120C

33-49-19 APR 15/12
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646
UNIT PER
ASSY
USAGE
CODE
FIGURE PART
1234567
2
120C 4384422 . BOARD ASSEMBLY, RELAY CIRCUIT BDEFG 1
POST SB 4202104-33-002
POST SB 4217228-33-001
POST SB 4361646-33-001
POST SB 4307405-33-002
POST SB 4360404-33-001
SUPSDS ITEM 120A
SUPSDS ITEM 120B
122A 4385189 . SPACER 120C 4
POST SB 4202104-33-002
POST SB 4217228-33-001
POST SB 4361646-33-001
POST SB 4307405-33-002
POST SB 4360404-33-001
124A E3RP2364 . BUMPER (3128826) (F0220) 120C 4
POST SB 4202104-33-002
POST SB 4217228-33-001
POST SB 4361646-33-001
POST SB 4307405-33-002
POST SB 4360404-33-001
ATTACHING PARTS
130A 3059812 . SCREW (F1701) 120AB 4
PRE SB 4202104-33-002
PRE SB 4217228-33-001
PRE SB 4361646-33-001
PRE SB 4307405-33-002
PRE SB 4360404-33-001
SUPSD BY ITEM 130B
130B 3131248 . SCREW (N2 2.2X10 ) (F0280) 120C 4
POST SB 4202104-33-002
POST SB 4217228-33-001
POST SB 4361646-33-001
POST SB 4307405-33-002
POST SB 4360404-33-001
SUPSDS ITEM 130A
***
140A PC16-2RT24VCCAG-PD . . RELAY (3059917) (F0289) 4
150A 3086268 . . CIRCUIT BOARD CONTACT NP
160A 4185831 . . CIRCUIT BOARD NP
165A 3066671 . . RESISTOR 2
167A 1N4006 . . DIODE (3062309) (F0126) DE 4
170A MILR57-57B . RELAY MTD 60A (3059799) (F0289) 1
ATTACHING PART
180A 22293AG030006L . SCREW (3010565) (F0111) 4
***
-190A DZM1UB040020U . SCREW (3064569) (F0110)
SUPSD BY ITEM 190B
190B 22208UB040018 . SCREW (3059858) (F0111) 8
SUPSDS ITEM 190A
SUPSD BY ITEM 190C
190C DZM1UB040018U . SCREW (3081058) (F0110) 8
SUPSDS ITEM 190B
- ITEM NOT ILLUSTRATED

Page 1002-2
33-49-19 APR 15/12
4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646
UNIT PER
USAGE
ASSY
CODE
FIGURE PART
1234567
2
200A XAUJ040T . WASHER (3011249) (F0110) 8
210A 3059835 . WASHER 16
220A 22431AG040L . NUT (3018108) (F0111) E 8
220B GAQ1UY040T . NUT (3068619) (F0110) ABCDFG 8
230A 4PA108NYLSTOP . NUT (3016733) (F0224) E 8
SUPSD BY ITEM 230B
230B 4PA104 . NUT (3115226) (F0224) ABCDF 8
A 235A 3074869 . PROTECTION CAP BF 8
237A 3010103 . SHEATH PL10 AR
239A 3025063 . GROMMET 1
A 240A 4202372 . PLATE BF 1
ATTACHING PARTS
A 250A NAS 517-2-00 . SCREW (3064992) (80205) BF 4
***
260A 4202477 . CASE ABCDEG 1
260B 4361036 . CASE F 1
270A 4192006 . IDENTIFICATION PLATE A 1
A 270B 4203152 . IDENTIFICATION PLATE B 1
270C 4226725 . IDENTIFICATION PLATE C 1
270D 4218975 . IDENTIFICATION PLATE D 1
270E 4308565 . IDENTIFICATION PLATE E 1
270F 4360836 . IDENTIFICATION PLATE F 1
270G 4382661 . ENGRAVED IDENTIFICATION PLATE G 1
280A 4058126 . MODIFICATION PLATE 1
A 290A 4360829 . BRACKET F 1
ATTACHING PARTS
A 300A 22293AG030012L . SCREW (3045478) (F0111) F 2
A 310A 3064516 . WASHER F 2
A 320A 3PA108 . NUT (3014407) (F0224) F 2
***
A 330A DZM1UB040018U . SCREW (3081058) (F0110) F 4
A 340A XAUJ040T . WASHER (3011249) (F0110) F 4
A 350A 3059835 . WASHER F 8
A 360A GAQ1UY040T . NUT (3068619) (F0110) F 4
A 370A 4PA104 . NUT (3115226) (F0224) F 4
A 380A 3074869 . PROTECTION CAP F 4

33-49-19 APR 15/12

Farol Branco AS532

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ECE - TELEFLEX SYNERAVIA

COMPONENT MAINTENANCE MANUAL

ECE - TELEFLEX SYNERAVIA

4168762 - 4202104 - 4217228 - 4226271 - 4307405 - 4360404 - 4361646

DATE: APR 15/12 LETTER OF TRANSMITTAL

PAGE LEFT BLANK INTENTIONALLY

DATE: APR 15/12 LETTER OF TRANSMITTAL

COMPONENT MAINTENANCE MANUAL

REV INSERTION REV INSERTION

PAGE LEFT BLANK INTENTIONALLY

RECORD OF TEMPORARY REVISIONS

TEMPORARY REVISION INSERTED DELETED

PAGE ISSUE DATE

PAGE LEFT BLANK INTENTIONALLY

LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

Special Tools 901 APR 15/12

TP 1001 1 APR 15/12

SERVICE BULLETINS LIST

SERVICE BULLETIN REV No. DATE SUBJECT

4202104-33-001 Functional improvement of the searchlight

4202104-33-002 Functional improvement of the searchlight

4217228-33-001 Functional improvement of the searchlight

4307405-33-001 Functional improvement of the searchlight

4307405-33-002 Functional improvement of the searchlight

4360404-33-001 Functional improvement of the searchlight

4361646-33-001 Functional improvement of the searchlight

PAGE LEFT BLANK INTENTIONALLY

DESCRIPTION AND OPERATION .......................................................................... 1

TESTING AND FAULT ISOLATION ........................................................................ 101

DISASSEMBLY ........................................................................................................ 301

CLEANING ............................................................................................................... 401

CHECK .................................................................................................................... 501

ASSEMBLY AND STORAGE .................................................................................. 701

FITS AND CLEARANCES ....................................................................................... 801

SPECIAL TOOLS, FIXTURES AND EQUIPMENT .................................................. 901

ILLUSTRATED PARTS LIST ................................................................................... 1001

PAGE LEFT BLANK INTENTIONALLY

LIST OF APPROVED REPAIR FACILITIES

EUROPE: 26, rue des Solets

USA: W175 N5737 Technology Drive

ASIA: 36, Loyang Drive

MIDDLE EAST AND AFRICA: Abu Dhabi International Airport

PAGE LEFT BLANK INTENTIONALLY

LIST OF SPECIAL MATERIALS

St des PETROLES SHELL X X

HENKEL TECHNOLOGIES FRANCE X

HENKEL TECHNOLOGIES FRANCE X

HENKEL TECHNOLOGIES FRANCE X

ARALDITE 1012 Local X

WHITE SPIRIT Local X

PAGE LEFT BLANK INTENTIONALLY

PAGE LEFT BLANK INTENTIONALLY

DESCRIPTION AND OPERATION

(1) French standards

(b) Environmental requirements AIR 7304

(c) Electrical requirements AIR 2021 P

(d) Overvoltage and insulation requirements AIR 0520

(e) Acceptance requirements AIR 9480

(2) Foreign standards MIL-L81174

Detail: searchlight 4360404

Searchlights P/N 4168762, Searchlights P/N 4202104