Welch Allyn LS100 User manual

WELCH ALLYN
LS100 HALOGEN LIGHT
SERVICE MANUAL
WA
WELCH ALLYN
4341 State Street Road
P.O. Box 220
Skaneateles Falls, NY 13153-0220
Technical Service Dept:
Telephone: [phone]
Fax: [phone]
1

SERVICE MANUAL
FOR:
WELCH ALLYN
LS100 HALOGEN LIGHT
MODELS: 44100...Domestic
44110...Wall/Table mount
Copyright 1994,
Welch Allyn Co.
4341 State Street Road
P.O. Box 220
Skaneateles Falls, NY 13153-0220
Originator: Richard Settembre cad file name:440082B.WP5
ECN# 5-29487 SERVICE MANUAL PN 440088 REV.B
11/94
2

TABLE OF CONTENTS
FORWARD - - - - - - - - - - - - - - - - - - - - - - - - - - 3
SAFE SERVICE - - - - - - - - - - - - - - - - - - - - - - - 4
INDEX: FAILURE/CAUSE - - - - - - - - - - - - - - - - - - - 5 - 6
INDEX: REMOVAL/REPLACEMENT (R & R) PROCEDURES - - - - - - 7
REMOVAL/REPLACEMENT PROCEDURES - - - - - - - - - - - - - - 8 - 22
APPENDIX
SERVICE PARTS LIST AND EXPLODED DIAGRAM * * * * AA
WIRING DIAGRAM/SCHEMATIC DIAGRAM * * * * BB
REPAIR VERIFICATION TEST PROCEDURES * * * * CC
PACKAGING FOR SHIPMENT * * * * DD
LIST OF SAFETY/ADVISORY/USE LABELS * * * * EE
TOOLS (COMMON & SPECIAL) * * * * FF
PRODUCT UP-DATES * * * * GG
PRODUCT DESCRIPTION * * * * HH

FORWARD
This SERVICE MANUAL provides technical assistance to Welch
Allyn repair technicians for diagnosing, repairing, and testing
the WELCH ALLYN LS100 HALOGEN LIGHT. The manual's main content
areas cover: troubleshooting, step by step repair, adjustment, and
re-test procedures. The repair 'TASK' procedures (R & R ..
Removal and Replacement) are written to provide quick and easy
reference for repair technicians of different experience levels.
Required specifications and materials are listed at each step
where applicable. When reading this manual for the first time,
have an LS100 readily available for reference and practice. Read
each complete repair step on what to do (task statement), plus how
to do it (technique statement) before starting the repair or
practice.
Training for the LS100 should consist of detailed
demonstrations of required repair tasks, practice on LS100'S using
repair tooling and materials. Assess skill development through
observation of trainee practice on actual equipment. Set up
sessions to allow the trainee to practice the use of the
diagnostic, repair, adjustment, and re-testing procedures found in
this manual. The ability of the technician to develop and retain
new skills is in great part dependent on well prepared training
exercises. Each trainee must have the opportunity to practice the
procedure(s) after it has been demonstrated by the instructor.
More detailed background product information is found in the
APPENDIX section and as such will be a critical element in a
comprehensive service training program for technicians.
I M P O R T A N T :
Welch Allyn part numbers and 'M' (material) numbers appearing
in this manual are for the purpose of familiarizing new
technicians with Welch Allyn documentation conventions. Order
replacement parts, as always, by referencing your latest bill of
materials, parts catalog and assembly drawings. Part number
changes, product updates, or new test procedures should be noted
on the appropriate page of this manual by the manual owner.
Notices announcing these changes should be attached to PRODUCT
UPDATES APPENDIX.
HOW TO FIND CURRENT PART NUMBER INFORMATION:
REFER TO THE MOST RECENT ASSEMBLY DRAWING(S) FOR APPLICATION
INFORMATION ON PARTS, PROCESS, AND MATERIALS. FIND THE CURRENT
PART NUMBERS BY REFERRING TO THE CIRCLED NUMBERS ('BUBBLE'
NUMBERS) ON CURRENT ASSEMBLY DRAWINGS. FIND CORRESPONDING PART
NUMBER ON THE MANUFACTURING OR REPAIR BILL OF MATERIALS.
3

WEAR EYE PROTECTION WHEN SERVICING THIS PRODUCT !
*** SAFE SERVICE ***
DISCONNECT power cord from A.C. power source before initial
disassembly of LS100 Light. OBSERVE cautions / warnings in owners
manual and printed on the product itself.
COMPLY with all safety codes and practices for this type of
product. COMPLY with all safety regulations at your work place.
PERFORM all recommended Welch Allyn service test procedures
to assure the LS100 meets all safety, performance and reliability
requirements.
EXAMINE AND REPAIR OR REPLACE as required, any and all worn
or questionable wiring, components, connections, connectors,
warning labels, insulation and other items necessary for the
continued safe operation of this product.
DO NOT TOUCH halogen lamps or nearby parts during or
immediately after operation. WAIT AT LEAST TWENTY MINUTES (20
MIN.) BEFORE TOUCHING HALOGEN LAMPS. VERY HIGH TEMPERATURES will
cause severe burns! Fractured or broken lamps may cause injury.
To prevent cuts, REMOVE such lamps by HOLDING them with a cloth or
wear work gloves. WEAR SAFETY GLASSES!
DO NOT LOOK DIRECTLY AT or TOUCH operating lamps!
*** QUALITY SERVICE ***
MODIFY your SERVICE Manual by notating changes and revisions
of part numbers and procedures. Enter this information on the
appropriate page...and include a copy of the notification in your
Appendix "Product Updates".
READ AND UNDERSTAND customer comments and complaints on
accompanying documentation (P.O. or other correspondence).
IF AN INJURY OR ILLNESS TO PATIENT OR USER, OR HAZARDOUS
MALFUNCTION HAS OCCURRED OR IS SUSPECTED, DO NOT DISASSEMBLE,
REASSEMBLE, ALTER OR REPAIR THE PRODUCT IN ANY WAY...INSTEAD, GIVE
THE UNIT AND ALL ACCOMPANYING PAPERWORK TO YOUR REPAIR SUPERVISOR.
Appropriate action per approved Welch Allyn policy will be taken.
When performing a complete inspection, LOOK for : missing
parts, product defects, damage, tampering, unsafe condition of
wiring or any component. ENTER all findings and test data along
with repair status in the appropriate file.
Most of the repairs can be performed on a foam covered work
bench. Place the LS100 in holding fixture for repairs. Take all
actions to prevent scratching the bezel.
4

INDEX: FAILURE / CAUSE
ALSO REFER TO:
ELECTRICAL SCHEMATIC, SERVICE PARTS DRAWING NOS.PN 440045 AND
440120.
Lamp does not illuminate.....no voltage at A.C. source.
CHECK measure and restore voltage.
.....lamp filament burned, "OPEN"
circuit.
Visually inspect filament. REPLACE
open lamp.
.....defective switch, "OPEN" circuit
CHECK voltage across switch in
closed position. If voltage is 13.5
v.a.c. to 15.0 +/- 0.3 V.A.C., then
switch is defective. REPLACE switch.
.....defective transformer, "OPEN"
primary or secondary windings or
defective or "failed OPEN" thermal
protection device in transformer
primary winding.
CHECKcontinuity/ohms of transformer
primary winding. REPLACE if 'open'.
There is NO fuse or circuit breaker
in the LS100. When the temperature
of the transformer primary winding
decreases to a pre-set value as
determined by the manufacturer, the
automatic thermal protection device
will automatically restore to a
closed or 'passing' condition.
.... "OPEN" circuit in power cord or
connecting wires and connectors.
REPLACE defective component.
Lamp is not bright .... Wrong lamp or supply voltage
.... high resistance in wiring
.... defective transformer
Lamp turns off after
short time illuminated ....transformer is operating at high
temperature thus activating
internal thermal protection device.
REPLACE transformer.
....lamp is of too high wattage,(over
22 watts) and is overloading
transformer. INSTALL correct lamp.
Lamp is intermittent
when LS100 is touched or
moved .... loose connection in wiring or lamp
is loose in lamp socket. RESTORE
connections/REPLACE socket.
5

INDEX: FAILURE / CAUSE CONTINUED
Switch produces arc or
flash when operated ....switch is defective or wiring
connections are not secure.
Fails Dielectric strength....replace transformer/power cord
assembly
Fails ground continuity
testing ....1. remove the base mount plate and
inspect the ground connection
between the power cord ground pin
and the base plate. Test for
Continuity.
2. if step 1 above shows good
connection, then the 'open circuit'
is in the power cord. Replace
entire transformer/power cord
assembly.
Fails leakage current
testing ....replace the entire transformer/power
cord assembly.
LS100 WALL / TABLE MOUNT TROUBLESHOOTING
No light output .... broken lamp (broken pins, filament,
glass envelope,) REPLACE lamp.
....defective switch (failed open),
replace switch. Note: there should
be 14.0 Vac +/-.5 Vac the
transformer output (no load). Lamp
resistanceis about one ohm.
....no transformer output (defective
transformer or transformer fuse.)
REPLACE defective component.
....transformer output (secondary) ohms
above 1.2 ohms..defective winding.
REPLACE transformer.
....transformer input (primary) ohms
above 25 ohms (75 ohms for export
models), defective (open) primary
or thermal fuse. REPLACE
transformer.
....cable broken. INSPECT , REPLACE
transformer.
Transformer is hot ....no load output of transformer is
less than 14.0 volts. Defective
transformer. REPLACE transformer.
6

INDEX: REMOVAL AND REPLACEMENT (R & R) PROCEDURES
CAUTION : DISCONNECT LS100 FROM A.C. POWER SOURCE
BEFORE SERVICING TO
AVOID ELECTRICAL SHOCK HAZARD
Component: Page:
AHalogen Lamp - - - - - 8
BPower Switch - - - - - 9
C Transformer/Power Cord Assembly- - - - - 10-11
D Bezel - - - - - 11-13
E Reflector - - - - - 13-14
F Light Cap - - - - - 14
G Hinge 'Stand-off' - - - - - 15
H Lamp Socket - - - - - 15
I Light Housing - - - - - 16
JFlexible 'Gooseneck' Assembly - - - - - 17-18
KPole - - - - - 18-19
LWall and table mount LS100 - - - - - 20
MGooseneck for model Wall/Table - - - - - 21
NTable bracket assembly - - - - - 22
ECN# 5-29487 SERVICE MANUAL PN 440088 REV.B 11/94
7

CAUTION: DISCONNECT LS100 FROM POWER SOURCE BEFORE SERVICING
A HALOGEN LAMP (R & R) PN06300
A1. OPEN LIGHT CAP PN44024
PRESS TWO TABS OR DETENTS ON OPPOSITE SIDES OF LIGHT
CAP WHILE AT THE SAME TIME LIFTING LIGHT CAP. PULL OPEN
TO EXPOSE LAMP AND LAMP SOCKET.
A2. REMOVE HALOGEN LAMP PN06300
CAUTION: EXERCISE CAUTION SINCE LAMP QUARTZ ENVELOPE MAY BE:
FRACTURED, CRACKED, OR HOT. USE A CLOTH TO HOLD THE
OLD LAMP WHEN PULLING OLD LAMP OUT OF SOCKET. DO NOT
TWIST LAMP...THIS WILL BREAK THE PINS FROM THE LAMP.
SUPPORT LIGHT CAP WITH ONE HAND AND GENTLY PULL OLD
LAMPSTRAIGHT OUT WITH THE OTHER HAND. REMOVE BROKEN
LAMP PARTS OR PINS FROM SOCKET WITH A LONG NOSE PLIERS.
A3. REPLACE LAMP WITH NEW HALOGEN LAMP PN06300
DO NOT TOUCH NEW LAMP WITH YOUR FINGERS. FINGER GREASE
OR OTHER CONTAMINANTS WILL DARKEN ON THE QUARTZ
ENVELOPE AND CAUSE DISCOLORATION AND PREMATURE FAILURE
OF THE REPLACEMENT LAMP. CLEAN LAMP BEFORE PLACING IN
SOCKET. USE A TISSUE OR OTHER CLEAN CLOTH TO HOLD THE
LAMP WITHWHILE INSERTING IT INTO THE SOCKET. SUPPORT
LIGHT CAP WITH YOUR OPPOSITE HAND WHILE INSERTING LAMP
STRAIGHT INTO LAMP SOCKET. VERIFY PROPER ALIGNMENT AND
A SECURE CONNECTION BETWEEN LAMP AND LAMP SOCKET.
A4. RESTORE LIGHT CAP TO ORIGINAL CLOSED POSITION
CLOSE THE LIGHT CAP AND VERIFY THAT BOTH TABS HAVE
FULLY ENGAGED TO SECURE THE LIGHT CAP IN CLOSED
POSITION. TEST BY TRYING TO OPEN LIGHT CAP WITHOUT
DEPRESSING TABS. LIGHT CAP SHOULD NOT OPEN.
A5. VERIFY REPAIR
CONNECT LS100 TO POWER SOURCE AND TURN LIGHT ON. ALLOW
NEW LAMP TO OPERATE AT LEAST FIVE MINUTES TO 'BURN IN'.
T E C H N I C I A N N O T E S :
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8

CAUTION: DISCONNECT LS100 FROM POWER SOURCE BEFORE SERVICING
BPOWER SWITCH (R & R) PN440029
B1. REMOVE SWITCH PN44029
APPLY A SMALL PIECE OF MASKING TAPE AT ONE END OF THE
SWITCH TO PROTECT THE LIGHT HOUSING TOP FROM MARKING BY
TOOLS DURING SWITCH REMOVAL. PULL SWITCH OUT OF THE
LIGHT HOUSING PN440023-2 BY PRYING UPWARDS AT THE END
OF THE SWITCH WITH A THIN EDGE SUCH AS A PUTTY KNIFE.
B2. DISCONNECT WIRES FROM SWITCH
UNPLUG BOTH WIRES FROM THE BOTTOM OF THE SWITCH.
B3. INSTALL NEW SWITCH
ATTACH WIRES AND PRESS SWITCH INTO LIGHT HOUSING,
MAKING SURE THAT THE "0" LABEL ON THE TOP OF THE SWITCH
IS TOWARDS THE GOOSENECK. SINCE THESE WIRES CARRY 12
VOLTS A.C., THE WIRES MAY BE ATTACHED TO THE SWITCH IN
EITHER POSITION. REFER TO WIRING DIAGRAM IN APPENDIX
BB.
B4. VERIFY REPAIR
CONNECT LS100 TO POWER SOURCE AND OPERATE THE LAMP A
NUMBER OF TIMES TO DETERMINE THAT THE SWITCH IS
OPERATING PROPERLY.
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CAUTION: DISCONNECT LS100 FROM POWER SOURCE BEFORE SERVICING
CTRANSFORMER/POWER CORD ASSEMBLY (R & R) PN----*
* part number for country of use, see parts list in catalog.
C1. REMOVE BASE MOUNT PLATE PN440035-501
UNPLUG THE A.C. POWER CORD AND PLACE THE LS100 IN A
HORIZONTAL POSITION. UN-SCREW FIVE (5) FASTENERS (1/4-
20) PN106140-1 STARTING WITH THE CENTER FASTENER. IT IS
SECURED WITH LOCKTITE 262-31 (RED PN M30328), AND WILL
REQUIRE MORE TORQUE (OR HEAT FROM SOLDERING IRON
APPLIED TO SCREW HEAD) TO UNFASTEN. THE CENTER SCREW
IS THREADED INTO AN ALUMINUM INSERT IN THE BASE OF THE
POLE. (NOT A SEPARATE PART NUMBER). HOLD THE POLE
FIRMLY WITH ONE HAND WHILE LOOSENING THE CENTER SCREW
WITH A VISE-GRIP LOCKING PLIERS (FOR PHILLIPS SCREWS
USE A VISE GRIP..FOR MODELS THAT HAVE OTHER TYPES OF
FASTENERS, USE APPROPRIATE TOOL). SUPPORT THE BASE
PLATE WHEN IT SEPARATES FROM THE PLASTIC BASE. THIS
WILL PROTECT THE WIRES AND CONNECTIONS FROM BEING
PULLED BY THE WEIGHT OF THE TRANSFORMER AND METAL BASE
PLATE. IF REPLACING BASE PLATE, TRANSFER MANUFACTURE
DATE AND LABEL TO NEW BASE.
9

CAUTION: DISCONNECT LS100 FROM POWER SOURCE BEFORE SERVICING
TRANSFORMER/POWER CORD ASSEMBLY (R & R) CONTINUED
CAUTION: IF JUST REMOVING THE POLE, AND THE TRANSFORMER WILL BE
RE-USED, AS IN PROCEDURE 'K', DO NOT CUT WIRES UNTIL
READING PROCEDURE 'K' STEP 2.
C2. DISCONNECT AND REMOVE OLD TRANSFORMER
CUT THE SECONDARY WIRES AS CLOSE TO THE TRANSFORMER AS
POSSIBLE. TRANSFORMER SECONDARY WIRES HAVE NO SPLICES.
DRILL OFF TWO 1/8" POP RIVETS PN106125-1 TO SEPARATE
TRANSFORMER COVER PN440037 (CONTAINING THE TRANSFORMER)
FROM THE BASE PLATE. THE COVER WILL BE RE-USED.
UNSCREW GROUNDING NUT FROM BASEPLATE GROUNDING STUD AND
REMOVE GREEN WIRE. DRILL TWO 1/8" POP RIVETS PN106125-2
OFF TO SEPARATE TRANSFORMER FROM TRANSFORMER COVER.
* IF A NEW REPLACEMENT BASE PLATE IS TO BE INSTALLED,
TRANSFER MANUFACTURE DATE AND WARNING STICKER TO THE
NEW BASEPLATE AT THIS PART OF THE PROCEDURE.
C3. INSTALL REPLACEMENT TRANSFORMER
VERIFY CORRECT VOLTAGE REQUIREMENT OF THE REPLACEMENT
TRANSFORMER WITH REFERENCE TO THE PART NUMBER. RIVET
REPLACEMENT TRANSFORMER TO COVER, AND COVER TO
BASEPLATE.IF NECESSARY, TRIM/CUT OFF EXCESS TRANSFORMER
SECONDARY WIRE TO REDUCE THE LENGTH OF UNNECESSARY WIRE
WHICH WILL BE PUT BACK INTO BASE OF LS100. IF YOU CUT
OFF TOO MUCH WIRE, THERE WILL BE INSUFFICIENT ROOM
BETWEEN THE BASE AND THE BASEPLATE TO GET YOUR HANDS IN
TO CRIMP ON THE CONNECTORS. INSPECT POLE BASE GROMMET
PN440043-1 AND REPLACE IF CRACKED, WORN, OR MISSING.
ELECTRICALLY CONNECT AND RESTORE WIRING BETWEEN
TRANSFORMER SECONDARY AND LAMP WIRING FROM THE POLE.
REFER TO WIRING DIAGRAM IN APPENDIX BB. CONNECT EACH
TRANSFORMER SECONDARY WIRE TO THE CORRESPONDING LAMP
SUPPLY WIRE AS IN WIRING DIAGRAM. DO NOT MAKE A DIRECT
CONNECTION (SHORT CIRCUIT) BETWEEN THE TWO TRANSFORMER
SECONDARY WIRES. USE CLOSED END 'CRIMP' CONNECTORS
PN711036. STRIP, CRIMP, AND INSPECT TO VERIFY NO
EXPOSED CONDUCTORS. RESTORE GROUND CONNECTION TO
BASEPLATE WELDED STUD WITH EXTERNAL TOOTH
# 6 LOCKWASHER PN745147. DO NOT OMIT LOCKWASHER.
IF NEW BASEPLATE IS USED, TRANSFER THE ORIGINAL DATE OF
MANUFACTURE TO THE NEW REPLACEMENT PART. (USE MARKING
PEN OR DATE STAMPER). IF APPLICABLE, TRANSFER ANY
REPAIR RELATED NOTES THAT WERE WRITTEN ON THE INSIDE OF
THE BASE PLATE, SUCH AS A REPAIR TRACKING NUMBER.
10

TRANSFORMER/POWER CORD ASSEMBLY (R & R) CONTINUED
C4.ATTACH BASE PLATE TO WEIGHTED BASE.
PLACE A.C. POWER CORD IN THE 'S' GROOVE (STRAIN
RELIEF) OF THE WEIGHTED BASE. ATTACH BASE PLATE WITH
FOUR OUTER FASTENERS FIRST. BEFORE TIGHTENING OUTER 4
FASTENERS, RE-CHECK THAT A.C. POWER CORD IS STILL IN
'S' GROOVE. APPLY LOCKTITE #262-31 PN M30328, TO CENTER
FASTENER. INSPECT THAT NO WIRES WILL BE TRAPPED
BETWEEN POLE BOTTOM AND BASE PLATE. INSERT AND TORQUE
CENTER FASTENER TO 37 INCH/LBS +/- 2 INCH/LBS.
C5. VERIFY REPAIR
CONNECT LS100 TO APPROPRIATE A.C. POWER OUTLET AND
ILLUMINATE LAMP FOR APPROXIMATELY 15 MINUTES. OBSERVE
FOR ILLUMINATION, NO EXCESSIVE HEAT OR A.C. CYCLE
SOUND OR 'HUM' FROM TRANSFORMER. PERFORM APPROPRIATE
TEST, A02476 TEST, OR A02477 TEST.
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DBEZEL (R & R) PN440021
D1. PRY BEZEL *
SEE FIGURE 1. HOLD THE LIGHT HOUSING ASSEMBLY SO THAT
THE BEZEL IS FACING UP, AND THE GOOSENECK IS AT THE
TOP. WITH ONE HAND HOLDING THE LIGHT HOUSING, PRY THE
BEZEL OFF WITH A THIN FLAT-BLADE SCREWDRIVER TIP IN A
GAP SHOWN AT CIRCLE IN FIG.1. SEPARATE BEZEL FROM
LIGHT HOUSING WITH FINGERS WHILE CAREFULLY PRYING WITH
SCREWDRIVER AT ALTERNATE LOCATIONS SHOWN BY CIRCLES IN
FIG. 1. THIS CAN BE DONE GENTLY AND WITH NO MARRING OR
DAMAGE TO EITHER THE BEZEL OR LIGHT HOUSING.
*THERE ARE FOUR SETS OF 3 RETAINING DETENTS MOLDED
INTOTHE BEZEL WHICH HOLD IT INTO THE LIGHT HOUSING.
THEYARE 90 DEGREES APART AND CAN BE DEFEATED BY
CAREFUL PRYING. DO NOT: BREAK OFF DETENTS,
HOUSING.
11

BEZEL
(R & R)
CONTINUED
FIG. 1
D
2. REMOVE BEZEL
WHEN ALL FOUR LOCATIONS
DISENGAGED FROM THE LIGHT OF BEZEL RETAINING
TABS ARE
HOUSING,
REMOVE BEZEL.
D 3.
REPLACE BEZEL
INSPECT LAMP, REFLECTOR, AND THE BEZEL FOR ANY DIRT,
DUST,
AND OR FINGERPRINTS.
CLEAN PER INSTRUCTIONS IN
OWNER'S GUIDE BEFORE RE-ASSEMBLY. PUT
BEZEL OVER
LIGHT HOUSING AS SHOWN IN FIG. 2a BELOW. NOTE THAT THE
DETENT TABS ON THE BEZEL ARE IN AN UP/DOWN/LEFT/RIGHT
ORIENTATION. BY STARTING OUT THIS WAY, THE WELCH ALLYN
LABEL WILL BE 'RIGHT-SIDE-UP' AS SHOWN, AFTER THE BEZEL
IS ROTATED 45 DEGREES COUNTER-CLOCKWISE AND LOCKED IN
PLACE. SEE FIG. 2b BELOW.
I
FIG. 2 aFIG. 2 b
12

BEZEL (R & R) CONTINUED
D
____
____
E
E
E
_
_
3.
CONTINUED
PRESS GENTLY AND EVENLY TO INTERLOCK THE BEZEL TO THE
LIGHT HOUSING. SEE FIG. 2 b.
ROTATE BEZEL COUNTER-CLOCKWISE APPROXIMATELY 45 DEGREES.
THREE CLICKS WILL BE HEARD AS EACH OF THE THREE SETS OF
DETENTS LOCKS IN PLACE. THE WELCH
APPEAR AS SHOWN IN FIG. 2 b.
_
REFLECTZR (R & R) PN440005
1. REMOVE HALOGEN LAMP, BEZEL.
PRIOR PROCEDURES: Al & A2 /
D1 & D2
ALLYN LOGO SHOULD
2. REMOVE REFLECTOR
SEE FIG. 3. HOLD THE LIGHT HOUSING ASSEMBLY SO THAT THE
REFLECTOR IS FACING UP AND THE GOOSENECK IS AT THE TOP
AS SHOWN IN FIG. 3. WITH ONE HAND ON THE LIGHT HOUSING,
PLACE A THIN FLAT-BLADE SCREWDRIVER TIP IN A GAP AT THE
UPPER RIGHT POSITION (SHOWN IN FIG. 3 AT CIRCLE)
BETWEEN THE OUTER PERIMETER OF THE REFLECTOR AND THE
INSIDE SURFACE OF THE LIGHT HOUSING. PRY REFLECTOR
DETENTS OUT OF ENGAGEMENT TO ENABLE YOU TO PUT YOUR
FINGERS UNDER THE REFLECTOR FLANGE AT THE TOP. NOW
INSERT THE SCREWDRIVER AT THE LOWER RIGHT, AND DISENGAGE
DETENTS THERE BY PRYING AS BEFORE. PULL UP WITH YOUR
FINGERS TO DISENGAGE AND REMOVE REFLECTOR. DO NOT MAR
REFLECTOR OR LIGHT HOUSING WITH SCREWDRIVER. DO NOT
SMUDGE OR SCRATCH MIRRORED SURFACE OF REFLECTOR.
FIG. 3
13

REFLECTOR (R & R) CONTINUED
E3. REPLACE REFLECTOR
VERIFY THAT ALL WIRES ARE ON THE SWITCH SIDE OF THE
LIGHT HOUSING AND WILL NOT BE PINCHED OR CUT WHEN
REFLECTOR IS PRESSED INTO PLACE. ALIGN REFLECTOR TO
ITS ORIGINAL POSITION AND PRESS IT FIRMLY AND EVENLY
INTO THE LIGHTHEAD. CONFIRM THAT IT IS FULLY ENGAGED
AROUND ENTIRE CIRCUMFERENCE. CLEAN REFLECTOR MIRRORED
SURFACE PER INSTRUCTIONS IN OWNER'S GUIDE.
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FLIGHT CAP PN440024 (R & R)
F1. OPEN LIGHT CAP.
PRESS DETENTS ON OPPOSITE SIDES OF LIGHT CAP AND LIFT
CAP UP.
F2. SEPARATE LIGHT CAP FROM HINGE STANDOFF
REMOVE TWO SCREWS PN106124-4 AND PRESS DETENTS TO
SEPARATE THE LIGHT CAP FROM THE HINGE STANDOFF.
F3. REPLACE LIGHT CAP
ALIGN HINGE STANDOFF OVER LIGHT CAP SO IT DOES NOT
OBSCURE MOLDED IN PRINTED CAUTION STATEMENT ON
UNDERSIDEOF LIGHT CAP. REASSEMBLE IN REVERSE ORDER OF
DISASSEMBLY.
F4. VERIFY REPAIR
INSPECT WIRING TO DETERMINE THAT NO WIRES ARE PINCHED
OR DAMAGED AND THAT LIGHT CAP CLOSES WITHOUT
DIFFICULTY.
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14

CAUTION: DISCONNECT LS100 FROM POWER SOURCE BEFORE SERVICING
GHINGE STANDOFF (R & R) PN440022-1
G1. REMOVE LAMP
G2. REMOVE BEZEL
G3. REMOVE REFLECTOR
G4. REMOVE LIGHT CAP
G5. DISCONNECT WIRES
DISCONNECT BOTH WHITE LAMP SOCKET WIRES FROM: a)SWITCH,
b)SECONDARY WIRE.
G6. REMOVE HINGE STANDOFF/LAMP SOCKET ASSEMBLY FROM
LAMP HOUSING PN440023-2
ROTATE HINGE STANDOFF ASSEMBLY 90 DEGREES AND LIFT UP
AND OUT OF LIGHT HOUSING.
G7. REMOVE LAMP SOCKET FROM HINGE STANDOFF
UNSCREW TWO LAMP SOCKET RETAINING SCREWS PN106124-5,
AND MANIPULATE SOCKET WIRES TOWARDS SOCKET TO EXPOSE
THEM FOR CUTTING. CUT WIRES AND REMOVE AND DISCARD
SOCKET AND SOCKET WIRE.
G8. REPLACE HINGE STANDOFF
INSTALL REPLACEMENT LAMP SOCKET PN440027 BY ROUTING
WIRING THROUGH HINGE STANDOFF AS PER THE ORIGINAL.
ATTACH NEW CRIMP CONNECTORS (PN106134-1 AND PN483308)
TO SOCKET WIRES. REASSEMBLE IN REVERSE ORDER OF
DISASSEMBLY.
REFER TO WIRING DIAGRAM IN APPENDIX BB.
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HLAMP SOCKET PN440027 (R & R)
SEE 'HINGE STANDOFF (R & R)'
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15

CAUTION: DISCONNECT LS100 FROM POWER SOURCE BEFORE SERVICING
ILIGHT HOUSING PN440023-2 (R & R)
I1. REMOVE LAMP
I2. REMOVE BEZEL
I3. REMOVE REFLECTOR
I4. DISCONNECT ALL WIRE CONNECTIONS
REMOVE WIRES FROM SWITCH, AND POLE WIRES TO SOCKET.
DO NOT CUT OFF CONNECTORS.
I5. REMOVE LIGHT CAP
I6. REMOVE SWITCH
I7. REMOVE HINGE STANDOFF
I8. SEPARATE LIGHT HOUSING FROM GOOSENECK
UN-TIE WIRE KNOT. UNSCREW SOCKET-HEAD CAP SCREW (4-40
X.125") PN106119-3 USING A 3/32" HEX KEY TOOL. THIS
SCREW PROVIDES ROTATION-STOP AND RETAINING FUNCTION AND
IS FOUND AT THE END OF THE GOOSENECK WITHIN THE LIGHT
HOUSING. PULL THE GOOSENECK OUT OF THE LIGHT HOUSING.
UNSCREW THE WHITE TIGHTENING COLLAR PN440068-1 AND
REMOVE THE ROTATIONAL-STOP HEAD PN440069-1.
I9. REPLACE LIGHT HOUSING.
REASSEMBLE IN REVERSE ORDER OF DISASSEMBLY. THE
ROTATIONAL-STOP HEAD SHAFT IS FLAT ON ONE SIDE AS IS
THE HOLE IN THE LIGHT HOUSING. LOCKTITE 262-21
(PN M30328) IS USED ON SOCKET-HEAD CAP SCREWS (4-40 X
.125) PN106119-3. MOLYCOAT 33 GREASE (PN M11041) IS
USED ON THE 'O' RINGS OF THE ROTATION STOP HEAD AT THE
TOP OF THE GOOSENECK. REFER TO WIRING DIAGRAM IN
APPENDIX BB.
I10. VERIFY REPAIR
CONNECT LS100 TO POWER SOURCE AND TURN ON. TEST FOR
ROTATION AND ROTATION-STOP WITH NO SQUEAKING.
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16

CAUTION: DISCONNECT LS100 FROM POWER SOURCE BEFORE SERVICING
JGOOSENECK ASSEMBLY PN440007-503 (R & R)
J1. REMOVE LIGHT HOUSING
PRIOR PROCEDURE 'I'
J2. REMOVE GOOSENECK FROM POLE
CUT OFF TWO CONNECTORS PN483308 RIGHT AT THE CONNECTORS
O FACILITATE REMOVAL OF THE GOOSENECK OVER THE WIRES.
PRY TWO PRONGS LOCATED AT UPPER END OF THE POLE OUTWARD
ONLY ENOUGH TO DISENGAGE INSERT SLEEVE PN440065 TO
ELEASE GOOSENECK. THIS WILL USUALLY REQUIRE ONLY
SLIGHT BENDING SO THEY ARE FLUSH OR EVEN WITH THE POLE
OUTSIDE DIAMETER. USE A SMALL FLAT-BLADE SCREWDRIVER
FOR THIS. LIFT GOOSENECK FROM POLE WHILE PULLING
SECONDARY WIRES OUT OF GOOSENECK.
J3. REMOVE SLEEVE INSERT PN440065
UNSCREW FASTENER PN106119-3 FROM THE LOWER END OF THE
GOOSENECK CONNECTOR AND PULL THE SLEEVE INSERT OFF.
J4. REASSEMBLE GOOSENECK ASSEMBLY (DO NOT CONNECT GOOSENECK
TO POLE IF LS100 WILL BE PACKED FOR SHIPPING)
REPLACE O-RINGS PN106108-7 AND PN482038 ON GOOSENECK
AND SLEEVE INSERT. TO MAKE IT EASIER TO FEED THE LAMP
IRES THROUGH THE REPLACEMENT GOOSENECK, STRAIGHTEN THE
GOOSENECK AND INSERT A LENGTH OF COAT-HANGER WIRE OR
OTHER SMALL DIAMETER WIRE THROUGH THE GOOSENECK SO THAT
IT EXTENDS BEYOND BOTH ENDS. ATTACH THE LAMP WIRES TO
THIS STIFF WIRE AND PULL THE LAMP WIRES THROUGH THE
OOSENECK. (IN CIRCUMSTANCES WHERE ONLY THE WIRES MUST
BE REPLACED, SIMPLY ATTACH A LONG STRING TO THE LAMP
WIRES BEFORE PULLING OUT THE OLD WIRES. LEAVE THE
STRING HANGING OUT BOTH ENDS. TIE ON THE REPLACEMENT
WIRES IE: NEW TRANSFORMER SECONDARY WIRES, AND USE THE
STRING TO PULL THEM THROUGH THE POLE AND GOOSENECK
ASSEMBLY.) ASSEMBLE IN REVERSE ORDER OF DISASSEMBLY.
USE LOCKTITE 262-21 (PN M30328) ON SOCKET-HEAD CAP
SCREW APPLY DOW 111 (PN M11379) GREASE ON LOWER
GOOSENECK ROTATION STOP (NOT MOLYCOAT 33 AS USED ON
UPPER GOOSENECK ROTATION STOP). THE DOW 111 THAT YOU
WILL USE ON THE LOWER ROTATION STOP ASSEMBLY WILL
PROVIDE SLIGHTLY MORE RESISTANCE TO ROTATION THAN THE
MOLYCOAT 33 REQUIRED.THIS GREATER RESISTANCE IS
DESIRABLE.
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GOOSENECK ASSEMBLY (R & R) CONTINUED
J4. CONTINUED
INSPECT THAT THERE IS A WIRE PROTECTOR PN440059 AROUND
THE WIRES AT THE TOP OF THE POLE. REFER TO SET-UP
INSTRUCTION IN OWNERS MANUAL. BEND TWO PRONGS LOCATED
AT THE UPPER END OF THE POLE INWARD APPROXIMATELY 10
DEGREES TO ENABLE THEM TO RETAIN GOOSENECK WHEN
INSERTED INTO THE POLE. ALIGN THE TWO FLAT RECESSED
AREAS OF THE INSERT WITH THE PRONGS OF THE POLE AND
INSERT SECURELY. INSERT WIRES UP AND THROUGH GOOSENECK
ASSEMBLY AND ATTACH NEW CRIMP CONNECTORS PN483308.
REFER TO WIRING DIAGRAM IN APPENDIX BB.
J5. VERIFY REPAIR
ILLUMINATE LS100. FLEX GOOSENECK. CHECK FOR ROTATION
STOP WITH NO SQUEAKING SOUND AND SMOOTH OPERATION.
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KBASE POLE PN440033 (R & R)
K1. REMOVE BASE MOUNT PLATE ASSEMBLY
PRIOR PROCEDURE 'C' STEP 1.
K2. CUT TRANSFORMER SECONDARY WIRES
CUT BOTH TRANSFORMER SECONDARY WIRES MIDWAY BETWEEN THE
POLE GROMMET AND THE TRANSFORMER COVER GROMMET. THIS
WILLPROVIDE ENOUGH LENGTH TO ADEQUATELY STRIP, AND
REATTACH POLE WIRES TO TRANSFORMER. CUTTING THEM TOO
CLOSE TO THE TRANSFORMER WILL RENDER THE TRANSFORMER
USELESS. CUTTING THEM TOO CLOSE TO THE POLE GROMMET
WILL NECESSITATE REMOVING LIGHT HOUSING AND FEEDING
MORE WIRE TO THE BASE. THIS REQUIRES UNTYING THE KNOT
AT THE LIGHT HOUSING, FEEDING MORE WIRE DOWN THE POLE,
AND RE-TYING THE KNOT.
K3. REMOVE GOOSENECK FROM POLE
PRIOR PROCEDURE 'J' STEPS 1 & 2
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BASE POLE (R & R) CONTINUED
K4. REMOVE POLE FROM BASE.
TRANSFER THE LARGE 'O' RING AT THE BOTTOM OF THE POLE
TO THE REPLACEMENT POLE. THE FUNCTION OF THIS IS TO
CONCEAL THE CONNECTION BETWEEN THE POLE AND THE BASE.
K5. REMOVE GROMMET FROM POLE.
SAVE GROMMET FOR REASSEMBLY IF IT IS IN GOOD CONDITION.
K6. REASSEMBLE (DO NOT CONNECT GOOSENECK TO POLE IF THE
LS100 MUST BE PACKED FOR SHIPPING BACK TO THE CUSTOMER)
PUT GROMMET OVER SECONDARY WIRES AND INSERT IT INTO THE
WIRE HOLE IN THE POLE. DO THIS BEFORE CONNECTING THEM
TO THE TRANSFORMER. ELECTRICALLY CONNECT AND RESTORE
THE TRANSFORMER SECONDARY WIRES TO THE LAMP WIRING FROM
THE POLE USING CLOSED END CRIMP CONNECTORS PN711036.
DO NOT MAKE A DIRECT CONNECTION (SHORT CIRCUIT) BETWEEN
THE TWO TRANSFORMER SECONDARY WIRES. REFER TO WIRING
DIAGRAM IN APPENDIX BB. STRIP, CRIMP, TO MAKE TIGHT
CONNECTIONS WITH NO EXPOSED CONDUCTORS.
K7. VERIFY REPAIR
CONNECT LS100 TO APPROPRIATE A.C. POWER OUTLET AND
ILLUMINATE LAMP. CHECK FOR QUIET AND SMOOTH OPERATION
AS IN PREVIOUS STEP. CHECK ROTATION STOP. PERFORM
APPROPRIATE TEST, A02476 OR A02477.
T E C H N I C I A N N O T E S:
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