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The document is a Component Maintenance Manual for the Honeywell Illuminated Switch, part number 4060084, and includes technical data subject to U.S. export regulations. It outlines the proprietary nature of the materials, licensing agreements for use, and the responsibilities of the user regarding confidentiality and compliance. The manual also includes a revision history and effective pages list, indicating its initial publication date as May 21, 2008.

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RELEASED FOR THE EXCLUSIVE USE BY: HONEYWELL EMPLOYEE AMERICAS

Honeywell International Inc.

21111 N. 19th Avenue
Phoenix, Arizona 85027-2708
U.S.A.
CAGE: 58960
Telephone: (800) 601-3099 (Toll Free U.S.A./Canada)
Telephone: (602) 365-3099 (International Direct)
Telephone: 00-800-601-30999 (EMEA Toll Free)
Telephone: 420-234-625-500 (EMEA Direct)
Web site: http://portal.honeywell.com/wps/portal/aero

Component Maintenance Manual

with Illustrated Parts List

Illuminated Switch
Part Number CAGE

4060084-3 58960
This document contains technical data and is subject to U.S. export regulations. These commodities, technology, or
software were exported from the United States in accordance with the export administration regulations. Diversion contrary
to U.S. law is prohibited.
ECCN: 7E994, NLR Eligible.

49-04-04
Page T-1
UP802726

Publication Number P15-2546-021, Revision 000 Initial 21 May 2008

© Honeywell International Inc. Do not copy without express permission of Honeywell.

RELEASED FOR THE EXCLUSIVE USE BY: HONEYWELL EMPLOYEE AMERICAS

COMPONENT MAINTENANCE MANUAL

4060084

Honeywell Confidential

THIS COPYRIGHTED WORK AND ALL INFORMATION ARE THE PROPERTY OF HONEYWELL
INTERNATIONAL INC., CONTAIN TRADE SECRETS AND MAY NOT, IN WHOLE OR IN PART, BE USED,
DUPLICATED, OR DISCLOSED FOR ANY PURPOSE WITHOUT PRIOR WRITTEN PERMISSION OF
HONEYWELL INTERNATIONAL INC. ALL RIGHTS RESERVED.

Honeywell Materials License Agreement

The documents and information contained herein ("the Materials") are the proprietary data of Honeywell
International Inc. and Honeywell Intellectual Properties Inc (collectively "Honeywell"). These Materials
are provided for the exclusive use of Honeywell Service Centers; Honeywell-authorized repair facilities;
operators of Honeywell aerospace products subject to an applicable product support agreement, their
wholly owned-subsidiaries or a formally designated third party service provider; and direct recipients of
Materials from Honeywell’s Aerospace Technical Publication Distribution. The terms and conditions of
this License Agreement govern your use of these Materials, except to the extent that any terms and
conditions of another applicable agreement with Honeywell regarding the operation, maintenance, or
repair of Honeywell aerospace products conflict with the terms and conditions of this License Agreement,
in which case the terms and conditions of the other agreement will govern. However, this License
Agreement will govern in the event of a conflict between its terms and conditions and those of a purchase
order or acknowledgement.
1. License Grant
If you are a party to an applicable product support agreement, a Honeywell Service Center agreement,
or an authorized repair facility agreement, Honeywell hereby grants you a limited, non-exclusive license
to use these Materials to operate, maintain, or repair Honeywell aerospace products only in accordance
with that agreement.
If you are a direct recipient of these Materials from Honeywell’s Aerospace Technical Publication
Distribution and are not a party to an agreement related to the operation, maintenance or repair of
Honeywell aerospace products, Honeywell hereby grants you a limited, non-exclusive license to use
these Materials to maintain or repair the subject Honeywell aerospace products only at the facility to
which these Materials have been shipped ("the Licensed Facility"). Transfer of the Materials to another
facility owned by you is permitted only if the original Licensed Facility retains no copies of the Materials
and you provide prior written notice to Honeywell.
2. Rights In Materials - Honeywell retains all rights in these Materials and in any copies thereof that are not
expressly granted to you, including all rights in patents, copyrights, trademarks, and trade secrets. No
license to use any Honeywell trademarks or patents is granted under this License Agreement.
3. Confidentiality - You acknowledge that these Materials contain information that is confidential and
proprietary to Honeywell. You agree to take all reasonable efforts to maintain the confidentiality of these
Materials.
4. Assignment And Transfer - This License Agreement may be assigned to a formally designated service
designee or transferred to a subsequent owner or operator of an aircraft containing the subject Honeywell
aerospace products. However, the recipient of any such assignment or transfer must assume all of
your obligations under this License Agreement. No assignment or transfer shall relieve any party of
any obligation that such party then has hereunder.
5. Copies of Materials - Unless you have the express written permission of Honeywell, you may not
make or permit making of copies of the Materials. Notwithstanding the foregoing, you may make copies
of only portions of the Material for your internal use. You agree to return the Materials and any copies
thereof to Honeywell upon the request of Honeywell.
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COMPONENT MAINTENANCE MANUAL

4060084

6. Term - This License Agreement is effective until terminated as set forth herein. This License Agreement
will terminate immediately, without notice from Honeywell, if you fail to comply with any provision of this
License Agreement or will terminate simultaneously with the termination or expiration of your applicable
product support agreement, authorized repair facility agreement, or your formal designation as a third party
service provider. Upon termination of this License Agreement, you will return these Materials to Honeywell
without retaining any copies and will have one of your authorized officers certify that all Materials have
been returned with no copies retained.
7. Remedies - Honeywell reserves the right to pursue all available remedies and damages resulting from
a breach of this License Agreement.
8. Limitation of Liability - Honeywell does not make any representation regarding the use or sufficiency of
the Materials. THERE ARE NO OTHER WARRANTIES, WHETHER WRITTEN OR ORAL, EXPRESS,
IMPLIED OR STATUTORY, INCLUDING, BUT NOT LIMITED TO, (i) WARRANTIES ARISING FROM
COURSE OF PERFORMANCE, DEALING, USAGE, OR TRADE, WHICH ARE HEREBY EXPRESSLY
DISCLAIMED, OR (ii) WARRANTIES AGAINST INFRINGEMENT OF INTELLECTUAL PROPERTY
RIGHTS OF THIRD PARTIES, EVEN IF HONEYWELL HAS BEEN ADVISED OF ANY SUCH
INFRINGEMENT. IN NO EVENT WILL HONEYWELL BE LIABLE FOR ANY INCIDENTAL DAMAGES,
CONSEQUENTIAL DAMAGES, SPECIAL DAMAGES, INDIRECT DAMAGES, LOSS OF PROFITS, LOSS
OF REVENUES, OR LOSS OF USE, EVEN IF INFORMED OF THE POSSIBILITY OF SUCH DAMAGES.
TO THE EXTENT PERMITTED BY APPLICABLE LAW, THESE LIMITATIONS AND EXCLUSIONS WILL
APPLY REGARDLESS OF WHETHER LIABILITY ARISES FROM BREACH OF CONTRACT, WARRANTY,
TORT (INCLUDING BUT NOT LIMITED TO NEGLIGENCE), BY OPERATION OF LAW, OR OTHERWISE.
9. Controlling Law - This License shall be governed and construed in accordance with the laws of the
State of New York without regard to the conflicts of laws provisions thereof. This license sets forth the
entire agreement between you and Honeywell and may only be modified by a writing duly executed by
the duly authorized representatives of the parties.

Honeywell is a registered trademark of Honeywell International Inc.

All other marks are owned by their respective companies.
THIS IS THE CMM FOSI - DATE: CMM FOSI - 20080523, VERSION 0019 (GBB)
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4060084

Blank Page
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COMPONENT MAINTENANCE MANUAL

4060084

TRANSMITTAL INFORMATION

COMPONENT MAINTENANCE MANUAL, PUB. NO. P15-2546-021 (ATA NO. 49-04-04), ILLUMINATED
SWITCH
Honeywell Publication No. P15-2546-021 has 0 revision(s) as shown in the Table TI-1Table of Revisions.

Table TI-1. Table of Revisions

Revision Number Revision Date

000 21 May 2008

Revision History
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COMPONENT MAINTENANCE MANUAL

4060084

RECORD OF REVISIONS

For each revision, write the revision number, revision date, date put in the manual, and your initials in the
applicable column.
NOTE: Refer to the Revision History in the TRANSMITTAL INFORMATION section for revision data.
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SERVICE BULLETIN LIST

Service Bulletin / Date Put in

Revision Number Title Modification Manual
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4060084

LIST OF EFFECTIVE PAGES

Subheading and Page Date Subheading and Page Date

Title Description and Operation

T-1 21 May 2008 1 21 May 2008
T-2 21 May 2008 2 21 May 2008
T-3 21 May 2008 3 21 May 2008
T-4 21 May 2008 4 21 May 2008
Transmittal Information 5 21 May 2008
6 21 May 2008
TI-1 21 May 2008
F 7/8 21 May 2008
TI-2 21 May 2008
9 21 May 2008
Record of Revisions 10 21 May 2008
RR-1 21 May 2008 Testing and Fault Isolation
RR-2 21 May 2008
1001 21 May 2008
Record of Temporary Revisions 1002 21 May 2008
RTR-1 21 May 2008 1003 21 May 2008
RTR-2 21 May 2008 1004 21 May 2008
Service Bulletin List 1005 21 May 2008
1006 21 May 2008
SBL-1 21 May 2008
SBL-2 21 May 2008 Schematic and Wiring Diagrams
List of Effective Pages 2001 21 May 2008
2002 21 May 2008
LEP-1 21 May 2008
F 2003/2004 21 May 2008
LEP-2 21 May 2008
2005 21 May 2008
Table of Contents 2006 21 May 2008
TC-1 21 May 2008 Disassembly
TC-2 21 May 2008
3001 21 May 2008
TC-3 21 May 2008
3002 21 May 2008
TC-4 21 May 2008
3003 21 May 2008
TC-5 21 May 2008
3004 21 May 2008
TC-6 21 May 2008
TC-7 21 May 2008 Cleaning
TC-8 21 May 2008 4001 21 May 2008
Introduction 4002 21 May 2008
4003 21 May 2008
INTRO-1 21 May 2008
4004 21 May 2008
INTRO-2 21 May 2008
INTRO-3 21 May 2008 Inspection/Check
INTRO-4 21 May 2008 5001 21 May 2008
5002 21 May 2008

* indicates pages changed or added data

F indicates a right foldout
LF indicates a left foldout
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LIST OF EFFECTIVE PAGES (cont)

Subheading and Page Date Subheading and Page Date

5003 21 May 2008 14002 21 May 2008

5004 21 May 2008 Storage (Including Transportation)
Repair 15001 21 May 2008
6001 21 May 2008 15002 21 May 2008
6002 21 May 2008 Rework (Service Bulletin Accomplishment
6003 21 May 2008 Procedures)
6004 21 May 2008
16001 21 May 2008
Assembly 16002 21 May 2008
7001 21 May 2008 Illustrated Parts List
7002 21 May 2008
10001 21 May 2008
7003 21 May 2008
10002 21 May 2008
7004 21 May 2008
10003 21 May 2008
7005 21 May 2008
10004 21 May 2008
7006 21 May 2008
10005 21 May 2008
Fits and Clearances 10006 21 May 2008
8001 21 May 2008 10007 21 May 2008
8002 21 May 2008 10008 21 May 2008
Special Tools, Fixtures, Equipment, and 10009 21 May 2008
Consumables 10010 21 May 2008
10011 21 May 2008
9001 21 May 2008
10012 21 May 2008
9002 21 May 2008
10013 21 May 2008
Special Procedures 10014 21 May 2008
11001 21 May 2008 LF 10015/10016 21 May 2008
11002 21 May 2008 10017 21 May 2008
Removal 10018 21 May 2008
10019 21 May 2008
12001 21 May 2008
10020 21 May 2008
12002 21 May 2008
10021 21 May 2008
Installation 10022 21 May 2008
13001 21 May 2008 10023 21 May 2008
13002 21 May 2008 10024 21 May 2008
Servicing 10025 21 May 2008
10026 21 May 2008
14001 21 May 2008

* indicates pages changed or added data

F indicates a right foldout
LF indicates a left foldout
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COMPONENT MAINTENANCE MANUAL

4060084

TABLE OF CONTENTS

LIST OF SECTIONS

Title Page

INTRODUCTION
1. How to Use This Manual (TASK 49-04-04-99F-801-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO-1
A. General (Subtask 49-04-04-99F-001-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO-1
B. Symbols (Subtask 49-04-04-99F-002-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO-1
C. Weights and Measurements (Subtask 49-04-04-99F-003-A01) . . . . . . . . . . . . . . . . . . INTRO-1
2. Customer Support (TASK 49-04-04-99F-802-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO-1
A. Honeywell Aerospace Online Technical Publications Web
Site (Subtask 49-04-04-99F-004-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO-1
B. Complete Customer Care Center (Subtask 49-04-04-99F-005-A01) . . . . . . . . . . . . . INTRO-1
3. Data Verification (TASK 49-04-04-99F-803-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO-2
A. General (Subtask 49-04-04-99F-006-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO-2
4. References (TASK 49-04-04-99F-804-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO-2
A. Honeywell Publications (Subtask 49-04-04-99F-007-A01) . . . . . . . . . . . . . . . . . . . . . . . . INTRO-2
B. Other Publications (Subtask 49-04-04-99F-008-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO-2
5. Acronyms and Abbreviations (TASK 49-04-04-99F-805-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO-3
A. General (Subtask 49-04-04-99F-009-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO-3
DESCRIPTION AND OPERATION
1. Description (TASK 49-04-04-870-801-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. General (Subtask 49-04-04-870-001-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Job Setup Data (Subtask 49-04-04-99C-001-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Chassis (Subtask 49-04-04-870-002-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. Subassemblies (Subtask 49-04-04-870-003-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Operation (TASK 49-04-04-870-802-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A. General (Subtask 49-04-04-870-004-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Detailed Theory of Operation (TASK 49-04-04-870-803-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A. General (Subtask 49-04-04-870-005-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. Annunciator Lamps (Subtask 49-04-04-870-006-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
C. Linear Switches (Subtask 49-04-04-870-007-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
D. Rotary Switches (Subtask 49-04-04-870-008-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TESTING AND FAULT ISOLATION
1. Planning Data (TASK 49-04-04-99C-801-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
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TABLE OF CONTENTS (cont)

LIST OF SECTIONS (cont)

Title Page

A. Reason for the Job (Subtask 49-04-04-99C-002-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001

B. Job Setup Data (Subtask 49-04-04-99C-003-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
2. Procedure (TASK 49-04-04-810-801-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002
A. Job Setup (Subtask 49-04-04-810-001-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002
B. Testing of the Illuminated Switch, Part No. 4060084-3 (Subtask 49-04-04-810-
002-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1003
C. Fault Isolation of the Illuminated Switch, Part No. 4060084-3 (Subtask 49-04-
04-810-003-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1006
D. Job Close-up (Subtask 49-04-04-810-004-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1006
SCHEMATIC AND WIRING DIAGRAMS
1. Planning Data (TASK 49-04-04-99C-802-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2001
A. Reason for the Job (Subtask 49-04-04-99C-004-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2001
B. Job Setup Data (Subtask 49-04-04-99C-005-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2001
2. Schematic and Wiring Diagrams (TASK 49-04-04-000-801-A01) . . . . . . . . . . . . . . . . . . . . . . . 2001
A. Job Setup (Subtask 49-04-04-000-001-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2001
B. Detail Drawings (Subtask 49-04-04-000-002-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2002
C. Schematic Diagrams (Subtask 49-04-04-000-003-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2002
D. Wiring Diagram (Subtask 49-04-04-000-004-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2002
E. Interconnect Diagram (Subtask 49-04-04-000-005-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . 2002
F. Wire Lists (Subtask 49-04-04-000-006-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2002
G. Job Close-up (Subtask 49-04-04-000-007-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2002
DISASSEMBLY
1. Planning Data (TASK 49-04-04-99C-803-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3001
A. Reason for the Job (Subtask 49-04-04-99C-006-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3001
B. Job Setup Data (Subtask 49-04-04-99C-007-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3001
2. Procedure (TASK 49-04-04-000-802-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3002
A. Job Setup (Subtask 49-04-04-000-008-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3002
B. Removal of the Cover and Switch Harness Assembly (Subtask 49-04-04-000-
009-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3002
C. Disassembly of the Body/Handle Assembly (Subtask 49-04-04-000-010-A01) . 3002
D. Disassembly of the Torsion Spring Assembly (Subtask 49-04-04-000-011-A01) 3003
E. Disassembly of the Bezel Assembly (Subtask 49-04-04-000-012-A01) . . . . . . . . . 3003
F. Job Close-up (Subtask 49-04-04-000-013-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3003
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TABLE OF CONTENTS (cont)

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TABLE OF CONTENTS (cont)

LIST OF FIGURES

Figure Description Page

INTRO-1 Symbols (GRAPHIC 49-04-04-99B-801-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO-1

1 Typical Illuminated Switch (GRAPHIC 49-04-04-99B-802-A01) . . . . . . . . . . . . . . . . . . . . . 1
2 Illuminated Switch Functional Schematic (GRAPHIC 49-04-04-99B-803-A01) . . . . 4
3 Switch Harness Assembly Wiring Diagram (GRAPHIC 49-04-04-99B-804-A01) . . 7
2001 Illuminated Switch, Detail (GRAPHIC 49-04-04-99B-805-A01) . . . . . . . . . . . . . . . . . . . . . . 2003
2002 Illuminated Switch, Schematic (GRAPHIC 49-04-04-99B-806-A01) . . . . . . . . . . . . . . . . 2005
IPL Figure

1 Illuminated Switch (GRAPHIC 49-04-04-99B-807-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10012

2 Switch Harness Assembly (GRAPHIC 49-04-04-99B-808-A01) . . . . . . . . . . . . . . . . . . . . . 10015
3 Body/Handle Assembly (GRAPHIC 49-04-04-99B-809-A01) . . . . . . . . . . . . . . . . . . . . . . . . 10018
4 Torsion Spring Assembly (GRAPHIC 49-04-04-99B-810-A01) . . . . . . . . . . . . . . . . . . . . . . 10022
5 Bezel Assembly (GRAPHIC 49-04-04-99B-811-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10024
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TABLE OF CONTENTS (cont)

LIST OF TABLES

Table Description Page

INTRO-1 Data Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO-2

1 Leading Particulars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Illuminated Switch Linear Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Illuminated Switch Rotary Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1001 Special Tools, Fixtures, and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
1002 Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002
1003 Online Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002
1004 Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1003
1005 Dielectric Withstanding Voltage Test (Handle In) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1004
1006 Dielectric Withstanding Voltage Test (Handle Out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1004
1007 Illuminated Switch Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1006
2001 Special Tools, Fixtures, and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2001
2002 Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2001
3001 Special Tools, Fixtures, and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3001
3002 Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3001
4001 Special Tools, Fixtures, and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001
4002 Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001
5001 Special Tools, Fixtures, and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001
5002 Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001
6001 Special Tools, Fixtures, and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6001
6002 Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6001
7001 Special Tools, Fixtures, and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001
7002 Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7002
8001 Fits and Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001
9001 Special Tools, Fixtures, and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001
9002 Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9002
15001 Special Tools, Fixtures, and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15001
15002 Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15001
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INTRODUCTION

1. How to Use This Manual (TASK 49-04-04-99F-801-A01)

A. General (Subtask 49-04-04-99F-001-A01)
(1) The instructions in this manual give the data necessary to do all recommended maintenance
functions to put the Illuminated Switch in serviceable condition. The instructions in this manual
do not give standard maintenance procedures that technicians must know.
(2) Honeywell recommends that you do the tests in TESTING AND FAULT ISOLATION (PGBLK
49-04-04-1000) before you disassemble the unit. These tests can show the condition of the
Illuminated Switch or most possible cause of a malfunction. If a malfunction occurs, repair
as necessary.
(3) Warnings, cautions, and notes in this manual give the data that follows:
• A WARNING gives a condition that, if you do not obey, can cause injury or death.
• A CAUTION gives a condition that, if you do not obey, can cause damage to the equipment.
• A NOTE gives data to make the work easier or gives directions to go to a procedure.
(4) Warnings and cautions go before the applicable paragraph or step. Notes follow the applicable
paragraph or step.
(5) All personnel who operate equipment and do the specified maintenance must know and
obey the safety precautions.
B. Symbols (Subtask 49-04-04-99F-002-A01)
(1) The symbols in Figure INTRO-1 (GRAPHIC 49-04-04-99B-801-A01) identify ESDS and
moisture sensitive devices in this manual, if applicable.

Figure INTRO-1. (Sheet 1 of 1) Symbols (GRAPHIC 49-04-04-99B-801-A01)

C. Weights and Measurements (Subtask 49-04-04-99F-003-A01)
(1) All weights and measurements are in U.S. and SI (metric) values.
2. Customer Support (TASK 49-04-04-99F-802-A01)
A. Honeywell Aerospace Online Technical Publications Web Site (Subtask 49-04-04-99F-004-A01)
(1) If you have access to the Internet, go to the Honeywell Online Technical Publications web site
at http://portal.honeywell.com/wps/portal/aero/ to:
• Download or see publications online
• Make an order for a publication
• Tell Honeywell of a possible data error in a publication
• Report a discrepancy.
B. Complete Customer Care Center (Subtask 49-04-04-99F-005-A01)
(1) If you do not have access to the Honeywell Online Technical publications website, send an
e-mail message or a fax, or speak to a person at the Complete Customer CareCenter:
• E-mail: cas-publications-distribution@honeywell.com
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List of Acronyms and Abbreviations (cont)

Term Full Term

U.S.A. United States of America

ac alternating current
ccw counter clockwise
cm centimeters
cw clockwise
dc direct current
in-lb inch pounds
in. inches
mm millimeter
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DESCRIPTION AND OPERATION

1. Description (TASK 49-04-04-870-801-A01)

A. General (Subtask 49-04-04-870-001-A01)
(1) The Illuminated Switch is a firewall cut off and fire bottle firing mechanism for the aircraft APU.
The Illuminated Switch is mounted in the aircraft flight deck. The illuminated handle is labeled
APU FIRE and illuminates in an emergency condition.
(2) Refer to Figure 1 (GRAPHIC 49-04-04-99B-802-A01) for a typical Illuminated Switch. Refer to
Table 1 for the leading particulars.

Figure 1. (Sheet 1 of 1) Typical Illuminated Switch (GRAPHIC 49-04-04-99B-802-A01)

Table 1. Leading Particulars

Characteristic Specification
Length

• Handle in the stowed position • 6.11 in. (15.52 cm)

• Handle in activated position • 6.46 in. (16.41 cm)
• Handle fully extended • 6.71 in. (17.04 cm)
Width 1.52 in. (3.86 cm)
Height (without cable and connector) 0.90 in. (2.29 cm)
Power 28 V dc
Number of rotary poles 2
Rotary positions 3 indexed at 30 degrees
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Table 1. Leading Particulars (cont)

Characteristic Specification
Torque to rotate handle 7 ± 2 in-lb (0.791 ± 0.226 Nm)
Force to engage spring 12 ± 2 in-lb (1.356 ± 0.226 Nm)
Number of linear poles 6, double-pole, double-throw
Actuation force 8 ± 2 in-lb (0.904 ± 0.226 Nm)
Annunciator legibility 10,000 foot candles in bright sunlight
Connector HPN 4059250-12
Mating Connector HPN 4059251-12, Texas Instruments Part No.
FB0315-26

B. Job Setup Data (Subtask 49-04-04-99C-001-A01)

(1) The list that follows identifies Honeywell publications that are related to this section:

• ATA No. 49-04-01 (Pub. No. C15-2546-009), CMM, Auxiliary Power Unit Panel. (PN
4059028-902)

• ATA No. 49-04-02 (Pub. No. C15-2546-019), CMM, Auxiliary Power Unit Panel. (PN
4059028-920).

C. Chassis (Subtask 49-04-04-870-002-A01)

(1) The Illuminated Switch chassis consists of a body which contains linear and rotary switches.
The switches are mechanically coupled to a handle assembly which protrudes from the front of
the body. Various springs and levers control the operation of the handle.

(2) A connector on the bottom of the Illuminated Switch connects the Illuminated Switch to the unit
it is installed in. A flexible circuit can be used instead of the wire leads.

D. Subassemblies (Subtask 49-04-04-870-003-A01)

(1) Refer to Table 2 for the subassemblies of the Illuminated Switch.

Table 2. Subassemblies

Subassembly Part No.

Switch harness assembly 80-37802, AvTech Corporation, IPL Figure 2
(FIGURE 49-04-04-95-802-A01)
Body/handle assembly 80-37809, AvTech Corporation, IPL Figure 3
(FIGURE 49-04-04-95-803-A01)
Torsion spring assembly 80-37805, AvTech Corporation, IPL Figure 4
(FIGURE 49-04-04-95-804-A01)
Bezel assembly 80-37803, AvTech Corporation, IPL Figure 5
(FIGURE 49-04-04-95-805-A01)
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2. Operation (TASK 49-04-04-870-802-A01)

A. General (Subtask 49-04-04-870-004-A01)
(1) The Illuminated Switch handle contains four lamps which light in an emergency condition. The
Illuminated Switch APU FIRE lamps light opaque black letters on a translucent red background.
When a fire is detected, the APU FIRE lamps flash on and off at 2 Hz rate. The handle
has three positions. The handle is pulled outward to engage the linear and rotary switches
inside the body of the Illuminated Switch.
(2) The four lamps in the Illuminated Switch fire handle bezel illuminate to indicate a fire in the
APU. The lamps are powered by 28 V dc and illuminated when a ground is applied to
the appropriate pin.
(3) The Illuminated Switch controls two fire agent discharge cartridges. When the handle is
pulled out to position 2:
• The APU is put in emergency shutdown condition.
• The fire agent discharge cartridges are armed.
• The APU field is de-energized.
• The APU fuel valve is closed.
(4) When the handle is pulled to the fully extended position 3, it can be rotated cw or ccw. A cw
rotation discharges fire agent 1 into the APU compartment. A ccw rotation discharges fire
agent 2 into the APU compartment.

3. Detailed Theory of Operation (TASK 49-04-04-870-803-A01)

A. General (Subtask 49-04-04-870-005-A01)
(1) Refer to Figure 2 (GRAPHIC 49-04-04-99B-803-A01) in this section for the functional
schematic or Figure 2002 (GRAPHIC 49-04-04-99B-806-A01) for an electrical schematic
diagram of the Illuminated Switch. The Illuminated Switch contains:
• Annunciator lamps
• Linear switches
• Rotary switches.
(2) The linear and rotary function applies to the motion of the handle, which actuates the switches.
When the handle is pulled or turned the motion is transmitted to the switches through a
cam-style yoke. Switches SW 1 (rotary), SW 2 (rotary), SW 3 (linear), and SW 4 (linear) are all
the same part number and contacts. Switches SW 5 (linear), SW 6 (linear), and SW 7 (linear)
are all the same part number and contacts.
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Figure 2. (Sheet 1 of 1) Illuminated Switch Functional Schematic (GRAPHIC 49-04-04-99B-803-A01)

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B. Annunciator Lamps (Subtask 49-04-04-870-006-A01)

(1) The 28 V dc power for the four annunciator T-1 28-Volt midget lamps is applied on the
connector pin 16 (wire color WHT/BLK). To light the lamps, a ground is asserted on connector
pin 14 (wire color WHT/RED). The lamps are replaced by removal of the APU FIRE lens and
taking the defective lamp out of the appropriate socket.
C. Linear Switches (Subtask 49-04-04-870-007-A01)
(1) Refer to Figure 3 (GRAPHIC 49-04-04-99B-804-A01) for a wiring diagram of the switch
harness assembly. There are six linear switches inside the Illuminated Switch, SW3 thru SW 8.
Each linear switch has two poles. When the handle is pulled to position 2, each linear switch
contact is thrown to the opposite pole. It takes 8 ± 2 in-lb of force to pull the handle from
position 1 to postion 2.
(2) Refer to Table 3 for the linear switches and the function of each switch.

Table 3. Illuminated Switch Linear Switches

Switch Wires Function
SW 3 GRN Fire agent arm power
RED
SW 4 ORG Fire agent arm power
YEL
SW 5 VIO APU off
BLUE
SW 6 GRY dc ground for fire agent lamps
WHT
SW 7 WHT/BRN/ORG Fire handle ground enable signal
BRN
BLK
SW 8 WHT/GRY/BLU Reserved for a spare fire handle
WHT/VIO
WHT/ORN
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Figure 3. (Sheet 1 of 1) Switch Harness Assembly Wiring Diagram (GRAPHIC 49-04-04-99B-804-A01)

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Table 1002. Consumable Materials

Number Name
Not applicable Not applicable

(4) The list that follows identifies Honeywell publications that are related to this section:
• ATA No. 49-04-01 (Pub. No. C15-2546-009), CMM, Auxiliary Power Unit Panel. (PN
4059028-902)
• ATA No. 49-04-02 (Pub. No. C15-2546-019), CMM, Auxiliary Power Unit Panel. (PN
4059028-920)
• Pub. No. C44-9000-001, Catalog of Test Programs and Operational Software (TPOS).

2. Procedure (TASK 49-04-04-810-801-A01)

A. Job Setup (Subtask 49-04-04-810-001-A01)
WARNING: BEFORE YOU USE A MATERIAL, REFER TO THE MANUFACTURERS’ MATERIAL
SAFETY DATA SHEETS. SOME MATERIALS CAN BE DANGEROUS.
CAUTION: DO NOT USE MATERIALS THAT ARE NOT EQUIVALENT TO HONEYWELL SPECIFIED
MATERIALS. MATERIALS THAT ARE NOT EQUIVALENT CAN CAUSE DAMAGE TO THE
EQUIPMENT AND CAN MAKE THE WARRANTY NOT APPLICABLE.
CAUTION: THE ILLUMINATED SWITCH CONTAINS ESDS ITEMS. USE INDUSTRY APPROVED
PRECAUTIONS.
(1) Obey the precautions.
(2) If you have access to the Internet, go to the Honeywell Online Technical Publications web site
at http://portal.honeywell.com/wps/portal/aero/. Refer to the web site for online test procedures,
test program revisions, and software-related hardware adapter modifications.
(a) There are no ATLAS test procedures for the Illuminated Switch.
(b) There are no online test procedures for the Illuminated Switch.
(3) If you do not have access to the Internet, refer to the customer support data in the
INTRODUCTION (PGBLK 49-04-04-0).
(4) Refer to Table 1003 for a list of online test procedures that are applicable to this manual.

Table 1003. Online Test Procedures

Procedure Part Number Used on Part Number
Not applicable Not applicable

(5) The best way to test the Illuminated Switch is to install it in the appropriate auxiliary power unit
panel (APUP) and make sure of correct operation. The appropriate APUPs are:
• APUP PN 4059028-902)
• APUP PN 4059028-920).
(6) Refer to Table 1004 for a list of test procedures that are included in this section.
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Table 1004. Test Procedures

Procedure Part Name Revision Used On Part Number Reference
Dielectric Withstanding Not applicable 4060084-3 Not applicable
Voltage Tests
Insulation Resistance Not applicable 4060084-3 Not applicable
Tests
Functional Tests Not applicable 4060084-3 Not applicable
Photopic Tests Not applicable 4060084-3 Not applicable

(7) The test procedures give instructions to make the test setup for each test.
B. Testing of the Illuminated Switch, Part No. 4060084-3 (Subtask 49-04-04-810-002-A01)
(1) Dielectric Withstanding Voltage Tests
CAUTION: THIS TEST CAN CAUSE DETERIORATION OF THE ILLUMINATED SWITCH
AND REPEATED APPLICATION AT FULL VOLTAGE IS NOT RECOMMENDED.
IF A SECOND TEST IS REQUIRED, LOWER THE VOLTAGE TO 750 V
ALTERNATING CURRENT.
(a) General
1 A leakage current of 10 milliamps under a voltage stress of 1000 V ac between
any circuit and the case is allowed. A leakage current of 10 milliamps under a
voltage stress of 1000 V ac between any isolated circuit to any other isolated
circuit is allowed.
2 The Model No. 4045A1 Hi-pot tester, Associated Research Services Inc. (CAGE
1VS79) is internally set up to detect a leakage current of any current greater than 1
milliamp by generating an audible tone.
(b) Dielectric Withstanding Voltage Test Procedure
NOTE: Do the following steps with the handle in the IN position. Refer to Table
1005 for the handle-in voltage test.
1 Attach Part No. 06-37803 Shorting cable, AvTech Corp. (CAGE 30242) to the
Illuminated Switch under test.
2 Connect the black lead of Model No. 4045A1 Hi-pot tester, Associated Research
Services Inc. (CAGE 1VS79) to the case of the Illuminated Switch.
3 Connect the red lead of Model No. 4045A1 Hi-pot tester, Associated Research
Services Inc. (CAGE 1VS79) to the end of Part No. 06-37803 Shorting cable,
AvTech Corp. (CAGE 30242).
4 Turn the power switch on Model No. 4045A1 Hi-pot tester, Associated Research
Services Inc. (CAGE 1VS79) to the ON position and slowly raise the voltage to the
Illuminated Switch until 1000 V ac is achieved. Hold the voltage for 30 seconds.
The leakage current must not be greater than 10 milliamps.
5 Remove Part No. 06-37803 Shorting cable, AvTech Corp. (CAGE 30242) from
the Illuminated Switch.
6 Attach Part No. 06-37802 Fanned cable, AvTech Corp. (CAGE 30242) to the
Illuminated Switch.
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7 Repeat the steps 2 thru 6, applying 1000 V ac between each pair of leads listed
in Table 1005. For each of the two circuits tested, the leakage current must not
be greater than 10 milliamps.
8 Repeat steps 1 thru 7 with the handle OUT. Refer to Table 1006 for the handle-out
voltage test.

Table 1005. Dielectric Withstanding Voltage Test (Handle In)

Black Lead 2 4 5 6 8 9 10 11 13 14 15 17 19 25
Red Lead
1 X X X X X X X X X X X X X X
2 X X X X X X X X X X X X X
4 X X X X X X X X X X X X
5 X X X X X X X X X X X
6 X X X X X X X X X X
8 X X X X X X X X X
9 X X X X X X X X
10 X X X X X X X
11 X X X X X X
13 X X X X X
14 X X X X
15 X X X
17 X X
19 X

Table 1006. Dielectric Withstanding Voltage Test (Handle Out)

Black Lead 6 16
Red Lead
7 X
18 X

(2) Insulation Resistance Tests

(a) Do the following steps with the handle IN. Refer to Table 1005 for the handle-in tests.
1 Attach the Part No. 06-37802 Fanned cable, AvTech Corp. (CAGE 30242) to
the Illuminated Switch.
2 Place the test leads on Model No. 1000N Insulation resistance tester, Associated
Research Services Inc. (CAGE 1VS79) on each lead listed in Table 1005.
3 Turn Model No. 1000N Insulation resistance tester, Associated Research Services
Inc. (CAGE 1VS79) ON. Any reading on the tester less than 100 megohms at 50 V
dc (or any measured current greater than 5 microamps at 500 V dc) is a failure of
this portion of the insulation resistance test.
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4 Remove Part No. 06-37802 Fanned cable, AvTech Corp. (CAGE 30242).
5 Attach Part No. 06-37803 Shorting cable, AvTech Corp. (CAGE 30242) to the
Illuminated Switch.
6 Place the black test lead from Model No. 1000N Insulation resistance tester,
Associated Research Services Inc. (CAGE 1VS79) on the case of the Illuminated
Switch.
7 Place one red lead from Model No. 1000N Insulation resistance tester, Associated
Research Services Inc. (CAGE 1VS79) on the end of Part No. 06-37803 Shorting
cable, AvTech Corp. (CAGE 30242).
8 Turn Model No. 1000N Insulation resistance tester, Associated Research Services
Inc. (CAGE 1VS79) ON. Any reading on the tester less than 100 megohms at 50 V
dc (or any measured current greater than 5 microamps at 500 V dc) is a failure of
this portion of the insulation resistance test.
9 Repeat steps 1 thru 8 with the handle OUT. Refer to Table 1006 for the handle-out
tests.
(3) Functional Tests
(a) Do the following steps as a functional test of the Illuminated Switch.
1 Attach the Illuminated Switch to Model No. 05-37801 Function test box, AvTech
Corp. (CAGE 30242) and apply 28 V dc from the Power supply, 30 Volts dc at 3.0
amperes, Optional source.
2 Use Model No. 73 Digital Voltmeter, Fluke Corp. (CAGE 02WJ6) to make sure the
voltage to the FTB is correct.
3 Push the lamp test button on the FTB to make sure all the indicators on the FTB
are functional.
4 Start the test with the fire handle pushed all the way IN.
5 Turn the FTB ON. Make sure the HANDLE IN (LEDs 7 and 8), on the FTB are
illuminated.
6 Pull the fire handle out to the first detent position. Make sure HANDLE OUT (LEDs
3 thru 8) on the FTB are illuminated. The HANDLE IN (LEDs 7 and 8) should
be extinguished.
7 Fully extend the fire handle. The LEDs 3 thru 8 on the FTB should stay illuminated.
NOTE: The cw and ccw LEDs on the FTB should illuminate decisively during
this test.
8 With the fire handle fully extended, rotate the handle in a cw direction. Make sure
the CW LED on the FTB is illuminated.
9 Relax the handle to return to the first detent position. Make sure the CW LED
on the FTB is extinguished.
10 Fully extend the fire handle. The LEDs 3 thru 8 on the FTB should be illuminated.
11 With the fire handle fully extended, rotate the handle in a ccw direction. Make sure
the CCW LED on the FTB is illuminated.
12 Relax the handle to return to the first detent position. Make sure the CCW LED
on the FTB is extinguished.
13 Repeat steps 1 thru 12 four times to make sure there is no intermittent operation.
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14 Pull the handle out and rotate in a cw and ccw direction four times to make sure the
rotary switching is smooth and uncompromised in a vertical direction. Make sure
the rotary switch lever does not bind during actuation.
(4) Photopic Tests
(a) Make sure the fire handle lights and has even illumination.
C. Fault Isolation of the Illuminated Switch, Part No. 4060084-3 (Subtask 49-04-04-810-003-A01)
(1) Do fault isolation (diagnostics) on the Illuminated Switch as part of the test procedure.
(2) There are two repairable conditions for the Illuminated Switch:
• Physical damage to the bezel or mechanical malfunctions
• Electrical malfunction.
(3) If no outward physical damage is seen, refer to the DISASSEMBLY (PGBLK 49-04-04-3000)
section and inspect the internal parts. Repair consists of replacement of the damaged parts.
(4) Use Model No. 05-37801 Function test box, AvTech Corp. (CAGE 30242) to do the electrical
tests and to confirm proper operation.
(5) Refer to Table 1007 to troubleshoot the Illuminated Switch.

Table 1007. Illuminated Switch Troubleshooting Table

Trouble Probable Cause Remedy
No handle illumination Blown bulbs Replace the handle bulbs
Broken wire Check the wires
Broken optional flex circuit Replace the wires
Inspect the flex circuit (optional) for broken runs.
Check continuity across the optional flex circuit.
No linear switch function Defective switch Check continuity across the switch contacts
Broken wire Replace the switch
Broken optional flex circuit Replace the wires
Check continuity across the optional flex circuit.
No rotary switch function Defective switch Check continuity across the switch contacts
Broken wire Replace the switch
Broken optional flex circuit Replace the wires
Check continuity across the optional flex circuit.
Handle binds Internal mechanical part Disassemble and inspect for damage
failure Replace the defective parts

D. Job Close-up (Subtask 49-04-04-810-004-A01)

(1) Not applicable.
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SCHEMATIC AND WIRING DIAGRAMS

1. Planning Data (TASK 49-04-04-99C-802-A01)

A. Reason for the Job (Subtask 49-04-04-99C-004-A01)
(1) This section gives schematic and wiring diagrams for the Illuminated Switch.
(2) Use these diagrams as an aid to fault isolate the Illuminated Switch.
B. Job Setup Data (Subtask 49-04-04-99C-005-A01)
(1) You can use equivalent alternatives for the special tools, fixtures, equipment, and consumable
materials. The user must find equivalent alternatives.
(2) Refer to Table 2001 for the specified special tools, fixtures, and equipment in this section.
If this section refers to online data, refer to that data for the specified special tools, fixtures,
and equipment.
Table 2001. Special Tools, Fixtures, and Equipment
Number Name
Not applicable Not applicable

WARNING: BEFORE YOU USE A MATERIAL, REFER TO THE MANUFACTURERS’ MATERIAL

SAFETY DATA SHEETS. SOME MATERIALS CAN BE DANGEROUS.
CAUTION: DO NOT USE MATERIALS THAT ARE NOT EQUIVALENT TO HONEYWELL
SPECIFIED MATERIALS. MATERIALS THAT ARE NOT EQUIVALENT CAN
CAUSE DAMAGE TO THE EQUIPMENT AND CAN MAKE THE WARRANTY NOT
APPLICABLE.
(3) Refer to Table 2002 for the specified consumable materials in this section. If this section refers
to online data, refer to that data for the specified consumable materials.
NOTE: For the wire color identified by (-C), refer to the applicable wire list.
Table 2002. Consumable Materials
Number Name
Not applicable Not applicable

(4) The list that follows identifies Honeywell publications that are related to this section:
• Pub. No. A62-0119-001, Honeywell Material Number (HMN) Codes.
2. Schematic and Wiring Diagrams (TASK 49-04-04-000-801-A01)
A. Job Setup (Subtask 49-04-04-000-001-A01)
WARNING: BEFORE YOU USE A MATERIAL, REFER TO THE MANUFACTURERS’ MATERIAL
SAFETY DATA SHEETS. SOME MATERIALS CAN BE DANGEROUS.
CAUTION: DO NOT USE MATERIALS THAT ARE NOT EQUIVALENT TO HONEYWELL SPECIFIED
MATERIALS. MATERIALS THAT ARE NOT EQUIVALENT CAN CAUSE DAMAGE TO THE
EQUIPMENT AND CAN MAKE THE WARRANTY NOT APPLICABLE.
CAUTION: THE ILLUMINATED SWITCH CONTAINS ESDS ITEMS. USE INDUSTRY APPROVED
PRECAUTIONS.
(1) Obey the precautions.
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(2) If you have access to the Internet, go to the Honeywell Online Technical Publications web site
at http://portal.honeywell.com/wps/portal/aero/.
(a) For the drawings included in this CMM:
1 Find the publication search link.
2 Enter the CMM publication number in the publication number window.
3 Click Search.
4 If necessary, make a selection of the applicable publication number (not the
PDF file).
(3) If you do not have access to the Internet, refer to the customer support data in the
INTRODUCTION (PGBLK 49-04-04-0) section of this CMM.
(a) To get a copy of the HMN codes, give the customer support personnel:
• The Honeywell Material Number (HMN) Codes publication number, Honeywell Pub.
No. A62-0119-001.
B. Detail Drawings (Subtask 49-04-04-000-002-A01)
(1) The detail drawing of the Illuminated Switch is given in Figure 2001 (GRAPHIC
49-04-04-99B-805-A01).
C. Schematic Diagrams (Subtask 49-04-04-000-003-A01)
(1) The schematic diagrams for the Illuminated Switch is given in Figure 2002 (GRAPHIC
49-04-04-99B-806-A01).
D. Wiring Diagram (Subtask 49-04-04-000-004-A01)
(1) The wiring diagram for the switch harness assembly in the Illuminated Switch is given in
Figure 2003.
E. Interconnect Diagram (Subtask 49-04-04-000-005-A01)
(1) There is no interconnect diagram for the Illuminated Switch.
F. Wire Lists (Subtask 49-04-04-000-006-A01)
(1) There are no online wire lists for the Illuminated Switch.
G. Job Close-up (Subtask 49-04-04-000-007-A01)
(1) Not applicable.
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Figure 2001. (Sheet 1 of 1) Illuminated Switch, Detail (GRAPHIC 49-04-04-99B-805-A01)

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Figure 2002. (Sheet 1 of 1) Illuminated Switch, Schematic (GRAPHIC 49-04-04-99B-806-A01)

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DISASSEMBLY

1. Planning Data (TASK 49-04-04-99C-803-A01)

A. Reason for the Job (Subtask 49-04-04-99C-006-A01)
(1) Use these procedures to remove parts from the Illuminated Switch to do the cleaning, checks,
and repair. Do only those procedures of disassembly that are necessary to remove defective
parts and to correct malfunctions.
(2) The figure and item numbers given in the disassembly procedure show where to find the parts
in the ILLUSTRATED PARTS LIST (IPL 49-04-04-10000).
(3) Before disassembly, use TESTING AND FAULT ISOLATION (PGBLK 49-04-04-1000)
to examine the condition of the Illuminated Switch or to find the most possible cause of
malfunctions. Do this to prevent disassembly that is not necessary.
(4) As an aid for assembly, tag the items that are disconnected to show where the connections
were made. Include data for special conditions of a connection, such as the polarity and the
position of the items. Identify the tie points for the motherboard wire assembly to prevent
damage to the wire insulation during assembly.
B. Job Setup Data (Subtask 49-04-04-99C-007-A01)
(1) You can use equivalent alternatives for the special tools, fixtures, equipment, and consumable
materials. The user must find equivalent alternatives.
(2) Refer to Table 3001 for the specified special tools, fixtures, and equipment in this section.
If this section refers to online data, refer to that data for the specified special tools, fixtures,
and equipment.

Table 3001. Special Tools, Fixtures, and Equipment

Number Name
Tweezers, Optional source

WARNING: BEFORE YOU USE A MATERIAL, REFER TO THE MANUFACTURERS’ MATERIAL

SAFETY DATA SHEETS. SOME MATERIALS CAN BE DANGEROUS.
CAUTION: DO NOT USE MATERIALS THAT ARE NOT EQUIVALENT TO HONEYWELL
SPECIFIED MATERIALS. MATERIALS THAT ARE NOT EQUIVALENT CAN
CAUSE DAMAGE TO THE EQUIPMENT AND CAN MAKE THE WARRANTY NOT
APPLICABLE.
(3) Refer to Table 3002 for the specified consumable materials in this section. If this section refers
to online data, refer to that data for the specified consumable materials.

Table 3002. Consumable Materials

Number Name
Not applicable Not applicable

(4) The list that follows identifies Honeywell publications that are related to this section:
• Not applicable.
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2. Procedure (TASK 49-04-04-000-802-A01)

A. Job Setup (Subtask 49-04-04-000-008-A01)
WARNING: BEFORE YOU USE A MATERIAL, REFER TO THE MANUFACTURERS’ MATERIAL
SAFETY DATA SHEETS. SOME MATERIALS CAN BE DANGEROUS.
CAUTION: DO NOT USE MATERIALS THAT ARE NOT EQUIVALENT TO HONEYWELL SPECIFIED
MATERIALS. MATERIALS THAT ARE NOT EQUIVALENT CAN CAUSE DAMAGE TO THE
EQUIPMENT AND CAN MAKE THE WARRANTY NOT APPLICABLE.
CAUTION: THE ILLUMINATED SWITCH CONTAINS ESDS ITEMS. USE INDUSTRY APPROVED
PRECAUTIONS.
CAUTION: THE REMOVAL AND INSTALLATION OF RIVETS OR HELICOILS CAN CAUSE DAMAGE
TO THE EQUIPMENT. IF IT IS NECESSARY TO REMOVE OR INSTALL RIVETED
COMPONENTS THE WORK SHOULD BE DONE BY WEST COAST SPECIALTIES
OR AN APPROPRIATE MACHINE SHOP.
CAUTION: THE INCORRECT USE OF THE TOOLS NEEDED TO REMOVE OR INSTALL RIVETS
OR HELICOILS CAN CAUSE DAMAGE TO THE EQUIPMENT. MAKE SURE THAT
ALL PERSONNEL WHO DO MAINTENANCE ON THE ILLUMINATED SWITCH ARE
FAMILIAR WITH THE USE OF THESE WEST COAST SPECIALTIES TOOLS. IF NOT,
THE WORK SHOULD BE DONE BY WEST COAST SPECIALTIES OR AN APPROPRIATE
MACHINE SHOP.
(1) Obey the precautions.
(2) Refer to the REPAIR (PGBLK 49-04-04-6000) section to replace the annunciator lamps.
B. Removal of the Cover and Switch Harness Assembly (Subtask 49-04-04-000-009-A01)
(1) Refer to IPL Figure 1 for all the item numbers unless specified differently.
(2) Remove screw (item 15) which holds the rear cap (item 20) to the body/handle assembly
(item 55).
(3) Remove the cover (item 35).
(4) Remove the wire guard (item 45) from under the wires and on top of the switches.
(5) De-solder the wires from the light harness to the connector (black-16 and red-14).
(6) Remove four rivets (item 30) which hold the switch harness assembly (item 50) to the
body/handle assembly (item 55).
(7) Remove the switch harness assembly (item 50).
C. Disassembly of the Body/Handle Assembly (Subtask 49-04-04-000-010-A01)
(1) Refer to IPL Figure 3 (FIGURE 49-04-04-95-803-A01) for all the item numbers unless specified
differently.
(2) Remove the shrink wrap screw on the back of the switch block (item 90).
(3) Separate the contact block of the light harness assembly (item 20) from the handle.
(4) Pull the wires in the harness assembly through the blue shrink tubing and remove the wires
from the handle.
(5) Remove the retaining ring (item 25) from the handle assembly (item 45).
(6) Remove two roll pins (item 5) and spring levers (item 10) from the sides of the flipper guide
(item 60).
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(7) Remove two plunger assemblies, which consist of the plunger tail (item 65), plunger tip (item
75) and flip-flop spring (item 70) from both sides of the flip-flop block assembly (item 80).
(8) Remove the shaft screw (item 30) from the end of the handle assembly (item 45) and remove
the handle assembly (item 45).
(9) Remove the washer (item 35) between the switch block (item 90) and the flip-flop block
assembly (item 80).
(10) Separate the flip-flop block assembly (item 80) from the flipper guide (item 60).
(11) Remove the main compression spring (item 40) from the flipper guide (item 60) assembly.
(12) Use Tweezers, Optional source, to remove the shaft washer (item 50) from the flipper guide
(item 60).
(13) Remove four rivets (item 85) which hold the flipper guide (item 60) to the torsion spring
assembly (item 105) and remove the flipper guide (item 60) from the torsion spring assembly
(item 105).
(14) Remove four rivets (item 85) which hold the switch block (item 90) to the torsion spring
assembly (item 105) and remove the switch block (item 90) from the torsion spring assembly
(item 105).
(15) Remove the switch lever assembly (item 95) from the top of the switch lever springs (item 100).
(16) Remove two switch lever springs (item 100) from the spring idents on the bottom of the
torsion spring assembly (item 105).
D. Disassembly of the Torsion Spring Assembly (Subtask 49-04-04-000-011-A01)
(1) Refer to IPL Figure 4 (FIGURE 49-04-04-95-804-A01) for all the item numbers unless specified
differently.
(2) Remove the front washer (item 15) from between the stop-wing (item 35) and the base (item
40).
(3) Remove the short roll pin (item 30) and the long roll pin (item 25) from the stop-wing (item 35).
(4) Remove the two tuning set screws (item 10) from the stop-wing (item 35).
(5) Remove the stop-wing (item 35) and the torsion spring (item 20) from the base (item 40).
E. Disassembly of the Bezel Assembly (Subtask 49-04-04-000-012-A01)
(1) Refer to IPL Figure 5 (FIGURE 49-04-04-95-805-A01) for all the item numbers unless specified
differently.
(2) Remove four lamps (item 55) into the rear of the bezel assembly.
(3) Remove the bail (item 5) from the bail slot of the bulb block (item 60).
(4) Remove two sleeves (item 30), two bezel release buttons (item 35) and two release button
springs (item 40) from both sides of the bulb block (item 60).
(5) Remove the bezel spacer (item 20).
(6) Push the lens (item 15) out of the bezel (item 10).
(7) Separate the upper contact (item 50) from the bulb block (item 60).
NOTE: The upper contact is heat staked to the bulb block.
(8) De-solder the socket (item 45) and remove the socket from upper contact (item 50).
F. Job Close-up (Subtask 49-04-04-000-013-A01)
(1) Not applicable.
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CLEANING

1. Planning Data (TASK 49-04-04-99C-804-A01)

A. Reason for the Job (Subtask 49-04-04-99C-008-A01)
(1) Use these procedures to remove dust, dirt, and unwanted oil and grease. Be careful not to
cause damage to the parts when you do these procedures.
(2) Do the procedures in a clean location. When you use pressurized air to clean assemblies
and parts, do not use more air pressure than is necessary.
(3) After you clean the assemblies and parts, supply protection from moisture, dust, and other
contamination until you do a visual check and assemble the component.
B. Job Setup Data (Subtask 49-04-04-99C-009-A01)
(1) You can use equivalent alternatives for the special tools, fixtures, equipment, and consumable
materials. The user must find equivalent alternatives.
(2) Refer to Table 4001 for the specified special tools, fixtures, and equipment in this section.
If this section refers to online data, refer to that data for the specified special tools, fixtures,
and equipment.

Table 4001. Special Tools, Fixtures, and Equipment

Number Name
4/0 Crocus cloth (Optional source)
soft-bristle brush
stiff-bristle brush

WARNING: BEFORE YOU USE A MATERIAL, REFER TO THE MANUFACTURERS’ MATERIAL

SAFETY DATA SHEETS. SOME MATERIALS CAN BE DANGEROUS.
CAUTION: DO NOT USE MATERIALS THAT ARE NOT EQUIVALENT TO HONEYWELL
SPECIFIED MATERIALS. MATERIALS THAT ARE NOT EQUIVALENT CAN
CAUSE DAMAGE TO THE EQUIPMENT AND CAN MAKE THE WARRANTY NOT
APPLICABLE.
(3) Refer to Table 4002 for the specified consumable materials in this section. If this section refers
to online data, refer to that data for the specified consumable materials.

Table 4002. Consumable Materials

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INSPECTION / CHECK

1. Planning Data (TASK 49-04-04-99C-805-A01)

A. Reason for the Job (Subtask 49-04-04-99C-010-A01)

(1) Use these procedures to find damaged or worn parts and parts that show signs of near
failure. Do these checks during TESTING AND FAULT ISOLATION (PGBLK 49-04-04-1000),
DISASSEMBLY (PGBLK 49-04-04-3000), and ASSEMBLY (PGBLK 49-04-04-7000).

(2) Replace all damaged or worn parts. This prevents possible failures of the equipment.

B. Job Setup Data (Subtask 49-04-04-99C-011-A01)

(1) You can use equivalent alternatives for the special tools, fixtures, equipment, and consumable
materials. The user must find equivalent alternatives.

(2) Refer to Table 5001 for the specified special tools, fixtures, and equipment in this section.
If this section refers to online data, refer to that data for the specified special tools, fixtures,
and equipment.

Table 5001. Special Tools, Fixtures, and Equipment

Number Name
Not applicable Not applicable

WARNING: BEFORE YOU USE A MATERIAL, REFER TO THE MANUFACTURERS’ MATERIAL

SAFETY DATA SHEETS. SOME MATERIALS CAN BE DANGEROUS.

CAUTION: DO NOT USE MATERIALS THAT ARE NOT EQUIVALENT TO HONEYWELL

SPECIFIED MATERIALS. MATERIALS THAT ARE NOT EQUIVALENT CAN
CAUSE DAMAGE TO THE EQUIPMENT AND CAN MAKE THE WARRANTY NOT
APPLICABLE.

(3) Refer to Table 5002 for the specified consumable materials in this section. If this section refers
to online data, refer to that data for the specified consumable materials.

Table 5002. Consumable Materials

Number Name
Not applicable Not applicable

(4) The list that follows identifies Honeywell publications that are related to this section:

• Not applicable.
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2. Procedure (TASK 49-04-04-210-801-A01)

A. Job Setup (Subtask 49-04-04-210-001-A01)
WARNING: BEFORE YOU USE A MATERIAL, REFER TO THE MANUFACTURERS’ MATERIAL
SAFETY DATA SHEETS. SOME MATERIALS CAN BE DANGEROUS.
CAUTION: DO NOT USE MATERIALS THAT ARE NOT EQUIVALENT TO HONEYWELL SPECIFIED
MATERIALS. MATERIALS THAT ARE NOT EQUIVALENT CAN CAUSE DAMAGE TO THE
EQUIPMENT AND CAN MAKE THE WARRANTY NOT APPLICABLE.
CAUTION: THE ILLUMINATED SWITCH CONTAINS ESDS ITEMS. USE INDUSTRY APPROVED
PRECAUTIONS.
(1) Obey the precautions.
B. Check of the Illuminated Switch (Subtask 49-04-04-210-002-A01)
(1) Examine all surfaces (covers included) for twisted, bent, or dented areas. The pieces must
fit together correctly. The covers must not compress the wires or cause a blockage in the
movement of a part.
(2) Check the operation of the handle. Pull the handle out and rotate in a cw and ccw direction to
make sure the rotary switching is smooth and uncompromised in a vertical direction. Make
sure the rotary switch lever does not bind during actuation.
(3) Examine the exterior and interior of the Illuminated Switch. The Illuminated Switch must be
clean and have no dirt, loose particles, solder splashes, and other unwanted materials. Painted
surfaces must not be worn or have scratches.
(4) Examine the solder connections. Make sure that the solder is applied correctly and that the
connections are correctly attached. Make sure that the solder joints are tight and do not have
scratches, rough surfaces, sharp edges, dullness, bridges, or blisters. Solder joints must show
signs of wetting (molten solder that bonds and flows on a metal surface to a smooth layer) and
bonding (the solder bonds to the soldered surface at a small contact angle).
(5) Examine the electrical components. Components that have cracks, have changed in color,
and show signs they became too hot can be defective. Replace these components, or do
electrical checks to make sure that their condition is correct.
(6) Examine the electrical insulation. The insulation must be flexible, not rigid or broken, and have
no surfaces that are burned. Make sure that the wires do not touch sharp edges and surfaces
that could cause damage to the insulation.
CAUTION: DO NOT TOUCH THE CONNECTOR OR COMPONENT PINS UNLESS YOU ARE
GROUNDED. ELECTROSTATIC DISCHARGE CAN CAUSE DAMAGE TO THE
COMPONENTS.
(7) Examine the connector pins. The pins must not be bent or damaged. Make sure that the
connectors are tightly engaged.
(8) Examine the installed parts. Make sure that all parts are installed correctly, and the attached
hardware is in position and is tight. Make sure that the position and polarity are correct.
(9) Examine the metal parts. Make sure that there is no corrosion, rust, or other structural damage.
(10) Examine the threaded parts. There must be no cross-threads or burrs.
(11) Examine the identification plate. Make sure that the identification plate is tightly attached
and you can read it.
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C. Job Close-up (Subtask 49-04-04-210-003-A01)

(1) Not applicable.
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4060084

REPAIR

1. Planning Data (TASK 49-04-04-99C-806-A01)

A. Reason for the Job (Subtask 49-04-04-99C-012-A01)

(1) Use these procedures for the Illuminated Switch to replace defective parts and replace or
repair defective subassemblies.

(2) Do only those procedures of DISASSEMBLY (PGBLK 49-04-04-3000) that are necessary to
make repairs. When new parts are necessary, refer to the ILLUSTRATED PARTS LIST (IPL
49-04-04-10000) for the correct part numbers and quantities.

B. Job Setup Data (Subtask 49-04-04-99C-013-A01)

(1) You can use equivalent alternatives for the special tools, fixtures, equipment, and consumable
materials. The user must find equivalent alternatives.

(2) Refer to Table 6001 for the specified special tools, fixtures, and equipment in this section.
If this section refers to online data, refer to that data for the specified special tools, fixtures,
and equipment.

Table 6001. Special Tools, Fixtures, and Equipment

Number Name
Not applicable Not applicable

WARNING: BEFORE YOU USE A MATERIAL, REFER TO THE MANUFACTURERS’ MATERIAL

SAFETY DATA SHEETS. SOME MATERIALS CAN BE DANGEROUS.

CAUTION: DO NOT USE MATERIALS THAT ARE NOT EQUIVALENT TO HONEYWELL

SPECIFIED MATERIALS. MATERIALS THAT ARE NOT EQUIVALENT CAN
CAUSE DAMAGE TO THE EQUIPMENT AND CAN MAKE THE WARRANTY NOT
APPLICABLE.

(3) Refer to Table 6002 for the specified consumable materials in this section. If this section refers
to online data, refer to that data for the specified consumable materials.

Table 6002. Consumable Materials

Number Name
Not applicable Not applicable

(4) The list that follows identifies Honeywell publications that are related to this section:

• ATA No. 20-00-03 (Pub. No. A09-1100-004), Standard Repair Procedures for Honeywell
Avionics Equipment Instruction Manual.
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4060084

ASSEMBLY

1. Planning Data (TASK 49-04-04-99C-807-A01)

A. Reason for the Job (Subtask 49-04-04-99C-014-A01)

(1) Use these procedures to assemble the Illuminated Switch. Do only those procedures that are
applicable to the disassembly done.

(2) The figure and item numbers given in the assembly procedure show where to find the parts
in the ILLUSTRATED PARTS LIST (IPL 49-04-04-10000).

(3) Refer to the data written during disassembly for the location of tie points and where to connect
the components and wires.

B. Job Setup Data (Subtask 49-04-04-99C-015-A01)

(1) You can use equivalent alternatives for the special tools, fixtures, equipment, and consumable
materials. The user must find equivalent alternatives.

(2) Refer to Table 7001 for the specified special tools, fixtures, and equipment in this section.
If this section refers to online data, refer to that data for the specified special tools, fixtures,
and equipment.

Table 7001. Special Tools, Fixtures, and Equipment

Number Name
C-clamp used to assemble the torsion spring
assembly, Optional source
Tweezers, Optional source
Vise, Optional source
No. 3695-06 Tang break-off tool, Optional source
No. 7551-06, size 6-32 Helicoil tool, Optional source
Part No. 15-37804-4 Alignment tool, AvTech Corp. (CAGE 30242)
Part No. 15-37805-2 Board used to assemble the torsion spring assembly,
AvTech Corp. (CAGE 30242)
Part No. 15-37807-1 Rivet jig, West Coast Specialties (CAGE 51074)
Part No. 15-37808-1 Rivet fixture, West Coast Industries (CAGE 51074)
Part No. 15-37809-1 Compression tool, AvTech Corp. (CAGE 30242)
Part No. 15-37811 Insertion tool, AvTech Corp. (CAGE 30242)
Part No. 15-37825 Retaining ring insertion tool, AvTech Corp. (CAGE
30242)
T350 Rivet punch, Optional source
UP802726

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COMPONENT MAINTENANCE MANUAL

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WARNING: BEFORE YOU USE A MATERIAL, REFER TO THE MANUFACTURERS’ MATERIAL

SAFETY DATA SHEETS. SOME MATERIALS CAN BE DANGEROUS.
CAUTION: DO NOT USE MATERIALS THAT ARE NOT EQUIVALENT TO HONEYWELL
SPECIFIED MATERIALS. MATERIALS THAT ARE NOT EQUIVALENT CAN
CAUSE DAMAGE TO THE EQUIPMENT AND CAN MAKE THE WARRANTY NOT
APPLICABLE.
(3) Refer to Table 7002 for the specified consumable materials in this section. If this section refers
to online data, refer to that data for the specified consumable materials.

Table 7002. Consumable Materials

Number Name
RMA solder flux, Optional source
RMA solder, Optional source
Sta-Lube, Grease, CRC Industries Inc. (CAGE
023V4)
Vibratite, thread locker, used to assemble the torsion
spring assembly, ND Industries (Cage 4Y667)
HMN 1113678 Isopropanol, Technical, per MIL TT-I-735, Grade B,
Optional source
HMN 9730178 Retaining compound (MIL-S-22473, grade A), Loctite
Corp, Rocky Hill, CT (05972)

(4) The list that follows identifies Honeywell publications that are related to this section:
• Not applicable.
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4060084

E. Installation of the Switch Harness Assembly and Cover. (Subtask 49-04-04-400-005-A01)

(1) Refer to IPL Figure 1 (FIGURE 49-04-04-95-801-A01) for all the item numbers unless specified
differently.
(2) Put the switch harness assembly (item 50) into the body/handle assembly (item 55) with
four rivets (item 30).
(3) Route the wires from the light harness to the connector and solder the wires (black-16 and
red-14) to the connector pins. Keep slack in the wires so they can be tied and bundled.
(4) Put the wire guard (item 45) under the wires and on top of the switches.
(5) Center the cover insulator (item 40) inside the cover (item 35).
(6) Clean the inside cover with HMN 1113678 Isopropanol, Technical, per MIL TT-I-735, Grade
B, Optional source.
(7) Install the cover (item 35).
(8) Split the wires on each side of the stub, in the middle.
(9) Attach the rear cap (item 20) to the body/handle assembly (item 55) with the screw (item 15).
(10) Shrink the heat shrink tubing.
F. Post Assembly Tests (Subtask 49-04-04-400-006-A01)
(1) The handle on the Illuminated Switch must meet the following specifications:
• Torque to rotate handle: 7 ± 2 in-lb (0.791 ± 0.226 Nm)
• Force to engage spring: 12 ± 2 in-lb (1.36 ± 0.226 Nm)
• Actuation force: 8 ± 2 in-lb (0.904 ± 0.226 Nm).
(2) Do the functional tests in TESTING AND FAULT ISOLATION (PGBLK 49-04-04-1000) to make
sure the Illuminated Switch operates properly.
G. Job Close-up (Subtask 49-04-04-400-007-A01)
(1) Not applicable.
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COMPONENT MAINTENANCE MANUAL

4060084

FITS AND CLEARANCES

1. Planning Data (TASK 49-04-04-99C-808-A01)

A. Reason for the Job (Subtask 49-04-04-99C-016-A01)
(1) This section gives the fits and clearances used when the Illuminated Switch was made.
B. Job Setup Data (Subtask 49-04-04-99C-017-A01)
(1) Not applicable.
2. Procedure (TASK 49-04-04-220-801-A01)
A. Job Setup (Subtask 49-04-04-220-001-A01)
CAUTION: THE ILLUMINATED SWITCH CONTAINS ESDS ITEMS. USE INDUSTRY APPROVED
PRECAUTIONS.
(1) Obey the precautions.
B. Fits and Clearances of the Illuminated Switch (Subtask 49-04-04-220-002-A01)
(1) Refer to Table 8001 when you do the procedures in REPAIR (PGBLK 49-04-04-6000) and
ASSEMBLY (PGBLK 49-04-04-7000).

Number Name
Part No. 15-37809-1 Compression tool, AvTech Corp. (CAGE 30242)
Part No. 15-37811 Insertion tool, AvTech Corp. (CAGE 30242)
Part No. 15-37825 Retaining ring insertion tool, AvTech Corp. (CAGE
30242)
T350 Rivet punch, Optional source

WARNING: BEFORE YOU USE A MATERIAL, REFER TO THE MANUFACTURERS’ MATERIAL

SAFETY DATA SHEETS. SOME MATERIALS CAN BE DANGEROUS.
CAUTION: DO NOT USE MATERIALS THAT ARE NOT EQUIVALENT TO HONEYWELL
SPECIFIED MATERIALS. MATERIALS THAT ARE NOT EQUIVALENT CAN
CAUSE DAMAGE TO THE EQUIPMENT AND CAN MAKE THE WARRANTY NOT
APPLICABLE.
(3) Refer to Table 9002 for the specified consumable materials in this manual. If this manual refers
to online data, refer to that data for the specified consumable materials.

WARNING: BEFORE YOU USE A MATERIAL, REFER TO THE MANUFACTURERS’ MATERIAL

SAFETY DATA SHEETS. SOME MATERIALS CAN BE DANGEROUS.
CAUTION: DO NOT USE MATERIALS THAT ARE NOT EQUIVALENT TO HONEYWELL
SPECIFIED MATERIALS. MATERIALS THAT ARE NOT EQUIVALENT CAN
CAUSE DAMAGE TO THE EQUIPMENT AND CAN MAKE THE WARRANTY NOT
APPLICABLE.
(3) Refer to Table 15002 for the specified consumable materials in this section. If this section
refers to online data, refer to that data for the specified consumable materials.

Table 15002. Consumable Materials

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3. Vendor List

Code Vendor

01295 TEXAS INSTRUMENTS INC, SEMICONDUCTOR GROUP DIV, 6414 HWY 75 S, MS 837,
SHERMAN, TX 75090
1A699 LEE SPRING CO, 1462 62ND ST, BROOKLYN, NY 11219-5448
21649 OTTO ENGINEERING INC, OTTO CONTROLS DIV, 2 EAST MAIN ST, CARPENTERSVILLE,
IL 60110-2624
30242 AVTECH CORP, 3400 WALLINGFORD AVE N, SEATTLE, WA 98103-9041
4J007 MSC INDUSTRIAL DIRECT CO INC, 75 MAXESS RD, MELVILLE, NY 11747-3151
58774 WAMCO INC, 11555A COLEY RIVER CIRCLE, FOUNTAIN VALLEY, CA 92708-4272
58960 HONEYWELL INTL INC, 21111 N 19TH AVE, PHOENIX, AZ 85027-2708
7J101 OLANDER CORP, 14101 NE 186TH ST, WOODINVILLE, WA 98072-6841
96906 MILITARY STANDARDS
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COMPONENT MAINTENANCE MANUAL

Numerical Index
AIRLINE FIG. TTL
PART NUMBER PART NO. ITEM REQ

B3-12141 2 10 5
B3-12142 2 5 3
FBR0315-26 2 15 1
LC042D3M 3 70 2
MS16535-23 3 55 4
85 4
MS16535-84 1 25 4
MS20450C6AD18 1 30 4
MS35206-215 1 15 1
NAS620-416L 3 35 1
N5000-31 3 25 1
OL6839AS15-297 5 55 4
02316800 4 10 2
3585-06N207 4 5 4
4R37SPP0 3 5 2
4060084-3 SEE 90-37801-3
44-22365 5 45 1
450-7007-01-03-00 SEE 44-22365
70-37802 5 60 1
70-37803 5 10 1
70-37806 5 15 1
70-37807 5 50 1
70-37808 3 90 1
70-37810 1 40 1
70-37811 1 45 1
70-37812 5 20 1
70-37814 3 60 1
70-37819 1 35 1
70-37821 3 75 2
70-37822-1 3 65 2
70-37830 3 30 1
70-37831 3 50 1
70-37834 5 5 1
70-37839 3 100 2
70-37840 3 40 1
70-37841 1 -10 1
70-37842 5 35 2
70-37843 5 30 2
70-37844 5 25 4
70-37845 5 40 2
70-37846 4 20 1
70-37851 1 20 1
70-37855 4 35 1
70-37856 4 15 1
70-37864 3 10 2
70-37865 4 40 1
70-37866 1 -5 1
80-37801 3 20 1
80-37802 1 50 1
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Numerical Index
AIRLINE FIG. TTL
PART NUMBER PART NO. ITEM REQ

2 -1 RF
80-37803 3 15 1
5 -1 RF
80-37804 3 45 1
80-37805 3 105 1
4 -1 RF
80-37806 3 95 1
80-37807 3 80 1
80-37809 1 55 1
3 -1 RF
9R50ROL0 4 30 1
9R75ROL0 4 25 1
90-37801-3 1 -1 RF
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COMPONENT MAINTENANCE MANUAL
4060084

IPL Figure 2. (Sheet 1 of 1) Switch Harness Assembly

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UNITS
FIG. AIRLINE EFF. PER
ITEM PART NUMBER STOCK NO. 1234567 NOMENCLATURE CODE ASSY

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UNITS
FIG. AIRLINE EFF. PER
ITEM PART NUMBER STOCK NO. 1234567 NOMENCLATURE CODE ASSY

65 70-37822-1 .PLUNGER TAIL ................................ 2

(V30242)
70 LC042D3M .SPRING ...................................... 2
FLIPFLOP
(TRUE PN LC-042D-3-M)
(V1A699)
(PN 44-20001)
75 70-37821 .PLUNGER TIP ................................. 2
(V30242)
80 80-37807 .BLOCK ASSEMBLY ............................. 1
FLIPFLOP
(V30242)
85 MS16535-23 .RIVET ....................................... 4
(V96906)
(PN 44-29310)
90 70-37808 .SWITCH BLOCK ............................... 1
(V30242)
95 80-37806 .SWITCH LEVER ASSEMBLY ...................... 1
(V30242)
100 70-37839 .SPRING ...................................... 2
SWITCH LEVER
(V30242)
105 80-37805 .TORSION SPRING ASSEMBLY .................... 1
(V30242)
(SEE IPL FIGURE 4 (FIGURE 49-04-04-95-804-A01)
FOR DETAILS)

- ITEM NOT ILLUSTRATED

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