Work Instructions: Light Module Assembly

Each step number includes corresponding pictures. Numbered parts are depicted on the technical drawing on page 3. Assembly instructions include a pre-populated printed circuit board (#6) as well as CREE LED light (#4) affixed with heat sink (#3). Operator should be qualified in soldering procedures and basic tools.

Steps:

1.)  Assemble Cover

i.  Insert two hex screws (#9) into like sized holes on opposite sides of the top cap (#1); Fasten top cap with one hex nut (#2) on each screw; Insert two washers (#12) and one more hex nut on each screw;

ii.  Insert DC Power jack (#7) into fit hole in the top cap so that wires are facing the inside of the assembly - tighten on the bottom end of the cap; Insert DPDT switch (#11) into remaining hole - tighten from top end of cap,

2.)  Place LED

i.  Slide Heat Sink (#3) onto Cover Assembly using the two hex screws (#9); the attached CREE LED (#4) should face the Top Cap (#1). Make sure the heat sink fits properly with the shortened end facing the DPDT Switch (#11) – if applied incorrectly the heat sink will not be level with the top cap.

3.)  Insert Patter Pack

i.  Insert 4 NMH Batteries into battery pack.

ii.  Slide battery pack (#5) between hex screws – battery pack may need to be filed down where in contact with hex screws to fit properly.

iii.  Make sure that connection wiring from DC Jack (#7), CREE LED (#4), and Battery Pack (#5) are exposed, they will be connected in the next step.

iv.  Tighten batter pack in place using one hex nut (#2) on each hex screw.

4.)  Connect PCB

i.  Slide populated PCB (#6) half way onto hex screws without fastening so that the component side is facing the top of the assembly.

ii.  Solder component wires to corresponding PCB pins accordingly:

Wire / PCB pin

a. Black CREE LED wire - LED –

b. Red CREE LED wire - LED +

c. Black Battery Wire - Vin –

d. Red Battery Wire - Vin +

e. Black Switch Wire - SW3

f.  Green Switch Wire - SW2

g. Red Switch Wire - SW1

h. Black DC Jack Wire - J –

i.  Red DC Jack Wire - J +

iii.  When all wires are correctly connected, carefully slide the PCB on to the assembly completely; apply a hex nut onto each hex screw to fasten PCB in place – be sure not to damage the PCB when tightening hex nuts.

5.)  Fasten Can Housing

i.  Place component assembly inside can housing (#10), inserting the hex screws into the holes in the bottom of the can; be careful not pull out any wire connections in this process.

ii.  Insert Lamp Hanger (#8) onto the length of hex screw at the bottom of the can housing; screw on a hex nut on each hex screw – securely tighten.

iii.  Apply silicone waterproofing sealant to the edge of the Top Cap where it meets the Can Housing.