lsm-500-042 rev v hawker boom beam - amazon s3 · lsm-500-300-46l par 46 reflector was...

LoPresti Aviation 800-859-4757 / 772-562-4757 or fax 772-228-9750

http://www.LoPrestiAviation.com 210 Airport Drive East, Sebastian, Florida, 32958, U.S.A.

Hawker Beechcraft Hawker Wing Mounted Taxi/Landing Lights

Installation Instructions Models 750 / 800 / 800XP / 850XP / 900XP / 1000

STC ST02893AT

LSM-500-042

Rev V 07-03-14



REVISION DESCRIPTION

Rev Date Description

IR

04-16-04 1. Initial release.

A

05-12-04 1. Added paragraph 9 detailing wire harness routing. 2. Added Figure 2 Wire Harness Routing Diagram. 3. Revised old Figure 2 to Figure 3 and changed reference in paragraph

12. 4. Revised old Figure 3 to Figure 4 and changed reference in paragraph

13. 5. Deleted wire routing instructions in paragraph 14. 6. Revised Continuing Airworthiness requirements per AC 21-40,

Appendix 5. 7. Deleted Appendix A CBPS-206 Click Bond Process Specification due

to illegibility.

B

5-21-04 1. Revised Figure 4 Electrical Wiring Diagram to conform to FAA

requirements. 2. Added Appendix A CBPS-206 Click Bond Process Specification.

C

7-08-04 1. Added wing taxi/landing light installation for U-125/U-125A models. 2. LSM-500-345-5 was LSM-500-331-18B. 3. Added STC and AML to document.

D

8-09-04 1. Weight and balance datum STA was -49.19. 2. M7928/5-5 was M81714/12-12D-2 3. M7928/5-3 was M81714/12-20D-2 4. Added M23053/5-106-0 shrink tube

E

8-17-04 1. M7928/5-4 was M7928/5-5 2. Added Electrical Load Analysis 3. Revised note 8 to add optional lamp/starter wire routing for older

model 800 aircraft. 4. Revised note 10 to make NAS43DD3-22FC spacers optional for older

model 800 aircraft.

F

10-29-04 1. Added Model 1000 2. Revised note 17 to add requirement for temporarily attaching lens

covers when aiming lights. 3. LSM-500-346-5 was LSM-500-346-1. 4. LSM-500-344-3 was LSM-500-344-1. 5. Corrected error in Note 11: LSM-500-345-5 was LSM-500-331-18B. 6. Added AN525-832R12 screws for attaching LSM-500-346-5 to LSM-

500-344-3. 7. Revised Figures 4 & 5 to show in-line resistor in LSM-500-346-5

Ballast to Power Wire, Taxi. 8. Revised Boom Beam current draw in Electrical Load Analysis from

1.65 amperes to 1.73 amperes.

G

12-16-04 1. Added Figure 6 to add jumper wire on cockpit overhead panel “CG”

switches “RT” and “RU”. 2. LSM-500-346-1 was LSM-500-346-5 in Parts List and Figures 4 & 5. 3. LSM-500-346-7 was LSM-500-346-3 in Parts List and Figures 4 & 5`.



H

03-09-05 1. Added Figure 7 for S/N 258532, EJA and Netjets squat switch mod

aircraft to allow all wing lights to illuminate during landing light switch selection.

2. LSM-500-358-1 was LSM-500-300-46I. 3. Revised Para. 18: Was “Adjust light position IAW Hawker

800/800XP/1000 Aircraft Maintenance Manual, Landing and Taxi Lamps – Maintenance Practices. Prior to adjusting lights, temporarily install LH/RH lamp bay window assemblies to achieve most accurate results.”

4. M7928/5-4 qty was 2. 5. M7928/5-3 qty was 2. 6. In Para 10 made rotating reflector assy in bezel ring optional. 7. Added LSM-500-359-1 Jumper Wire to parts list, Figure 6 and Figure

7.

I

05-10-05 1. Continuing Airworthiness Requirements inspection interval was

“during an annual or 100 hour inspection interval”. 2. Deleted models U-125 and U-125A. 3. Revised Para. 18 to allow operators to adjust the aiming to meet their

preferences.

J

08-08-05 1. Added MS35207-233 screw, qty 16. 2. Revised note 9 to allow for alternate lamp/starter wire harness routing

through lower outboard lamp bay lightening hole. 3. Revised note 11 to add option of using MS35207-233 screws for

landing light mounting.

K

09-26-05 1. Added note 1. 2. LSM-500-346-3 was LSM-500-346-7. 3. Deleted AN525-832R12. 4. SW8CRV spiral wrap was SWTF12X. 5. Revised Figures 4 and 5 to show deleting resistor and capacitor in

LSM-500-346-3 Ballast to Power Wire, Landing. 6. LSM-500-344-1 was LSM-500-344-3. 7. MS81969/14-11 was MS81969/14-02. 8. Deleted MS21919WDG11.

L

03-07-06 1. Added Model 850XP. 2. 11-12334 spiral wrap was SW8CRV.

M

01-16-07 1. Added LSM-SCD-004-1 PAR 36 Reflector . LSM-500-343-1 PAR 36

Assy is now an alternate. Revised manual text to reflect part number change.

2. LSM-500-300-46L PAR 46 Reflector was LSM-500-358-1 PAR 46 Assy, Landing. Revised manual text to reflect part number change.

3. Added LSM-500-358-11 spacer, qty 2. 4. Added LSM-500-358-13 spacer, qty 2. 5. Added AN960-8 washer, qty 6. Revised para 6 to add washers to the

landing light reflector assembly. 6. Revised LSM-500-344-1 Ballast Assy view in Figure 1. 7. In para 14, MS81969/14-11 was MS81969/14-02.

N 08-22-07

1. Added models 750 and 900XP. 2. Revised “Raytheon” to “Hawker Beechcraft”.

O 03-18-08

1. Revised ICA requirements: ICA was “the lesser of 600 hours or one year.” Revision was accomplished in accordance with HBC ICA requirement changes.



P 08-13-08

1. ICA frequency requirements were 800 hours and 1600 hours. 2. LSM-SCD-009-1 was LSM-500-200-100. 3. LSM-500-345-11 was LSM-500-345-3. 4. LSM-500-345-13 was LSM-500-345-5. 5. LSM-500-346-19 was LSM-500-346-1. 6. LSM-500-346-21 was LSM-500-346-3. 7. LSM-500-344-7 was LSM-500-344-1. 8. Weight and balance: 6.6 lbs was 7.9 lbs.

Q 09-30-10

1. Revised para 15 to exclude Model 1000 from LSM-500-359-1 jumper wire installation.

2. Deleted Appendix A.

R 10-04-10

1. Deleted MS35489-13 grommet. 2. LSM-500-345-7 was LSM-500-345-11. 3. 11-12334 qty was 12”. 4. Revised weight and balance to add 60W ballast installation option. 5. Revised electrical load analysis to add 60W ballast installation option.

S 10-21-10

1. Added Figures 6 and 7 for Model 1000 for LSM-500-359-1 jumper wire installation.

T 10-26-10

1. Revised Figure 7 for Model 1000 with nose gear squat switch installed.

U 02-10-14

1. Added -3 85W light installation kit.

V 07-03-14 1. Added Clickbond Stud Installation Instructions.

LSM-500-042 Rev V Page 4



BOOM BEAM INSTALLATION

Before you start: READ ALL INSTRUCTIONS Call us at 800-859-4757 if you have any questions. Begin by checking the contents of your kit against the list below.

-1 60W Light Installation Kit Nomenclature Part Number Vendor Quantity Lamp/Starter Assy LSM-SCD-009-1 LoPresti Speed

Merchants 4

Par 36 Reflector (Taxi Light)

LSM-SCD-004-1

LSM 2

Par 46 Reflector (Landing Light)

LSM-500-300-46L LSM 2

Ballast to Power Wire, Taxi

LSM-500-346-19 LSM 2

Ballast to Power Wire, Landing

LSM-500-346-21 LSM 2

Ballast to Lamp/Starter Wire, Landing

LSM-500-345-7 LSM 2

Ballast to Lamp/Starter Wire, Taxi

LSM-500-345-13 LSM 2

Strap LSM-500-304-1 LSM 4 Ballast Assy, 60W LSM-500-344-11 LSM 2 Spacer LSM-500-358-11 LSM 2 Spacer LSM-500-358-13 LSM 2 Jumper Wire LSM-500-359-1 LSM 2 Adhesive Kit CB92 Click Bond 2 Spacer NAS43DD3-22FC 8 Screw MS35207-233 16 Cable Tie Wraps MS3367-1-9 12 Grommet Edging MS21266-1N 72” Spiral Wrap 11-12334 Aircraft Spruce 20” Pin Extractor, Red/Wht M81969/14-11 1 Pin Extractor, Yellow/Wht

M81969/14-04 1

Butt Splice, Landing M7928/5-4 4 (Model 800) Butt Splice, Taxi M7928/5-3 4 (Model 800) Shrink Tube M23053/5-106-0 12” Washer AN960-8 6




-3 85W Light Installation Kit Nomenclature Part Number Vendor Quantity Lamp/Starter Assy LSM-SCD-009-1 LoPresti Speed

Merchants 4

Par 36 Reflector (Taxi Light)

LSM-SCD-004-1

LSM 2

Par 46 Reflector (Landing Light)

LSM-500-300-46L LSM 2

Ballast to Power Wire, Taxi

LSM-500-346-19 LSM 2

Ballast to Power Wire, Landing

LSM-500-346-21 LSM 2

Ballast to Lamp/Starter Wire, Landing

LSM-500-345-7 LSM 2

Ballast to Lamp/Starter Wire, Taxi

LSM-500-345-13 LSM 2

Strap LSM-500-304-1 LSM 4 Ballast Assy, 85W LSM-500-344-17 LSM 2 Spacer LSM-500-358-11 LSM 2 Spacer LSM-500-358-13 LSM 2 Jumper Wire LSM-500-359-1 LSM 2 Adhesive Kit CB92 Click Bond 2 Spacer NAS43DD3-22FC 8 Screw MS35207-233 16 Cable Tie Wraps MS3367-1-9 12 Grommet Edging MS21266-1N 72” Spiral Wrap 11-12334 Aircraft Spruce 20” Pin Extractor, Red/Wht M81969/14-11 1 Pin Extractor, Yellow/Wht

M81969/14-04 1

Butt Splice, Landing M7928/5-4 4 (Model 800) Butt Splice, Taxi M7928/5-3 4 (Model 800) Shrink Tube M23053/5-106-0 12” Washer AN960-8 6




Installation Instructions

1. Important Note: Prior to installation of this STC kit, determine the model number of the Precise Flight, Inc. Pulselite controller, if installed. For aircraft with model 2401/2401S controllers or with no Pulselite controller installed, proceed with the installation of the Boom Beam as outlined in this installation manual. For aircraft with model 2400 controller installed, it will be necessary to upgrade to model 2401S to have pulse light functionality.

2. Prior to light installation, jack aircraft and level IAW the Aircraft Maintenance Manual. Disconnect the main batteries. Ensure that the Boom Beam reflectors are not in direct visual view of the receiving equipment antennae for the following equipment: GPS ATC Transponder DME TCAS

3. Remove lamp bay window assembly typical LH/RH sides. Remove W438/W338 lower leading edge wing access panel typical LH/RH. Remove old sealant around edges of window assembly, access panel and on recessed wing surfaces. See photos 1 and 2.




Photo #1

Photo #2




4. Mark the 12:00 position on all bezel rings. Remove landing/taxi light bezel ring attach hardware. Disconnect all landing and taxi light electrical power and ground wires. Remove lights. See photo 3. For Model 750, post mod 253563C Model 800, Model 800XP, Model 850XP, Model 900XP and Model 1000 aircraft: Pull wires through access panel opening and disconnect from front module using supplied extraction tools. For pre mod 253563C Model 800 aircraft: Pull wires through the access panel opening. Remove existing terminals from each wire (8 total LH/RH). Crimp one contact (M7928/5-4) on each landing light wire (4 total LH/RH). Crimp one contact (M7928/5-3) on each taxi light wire (4 total LH/RH).

Photo #3

5. Mount LSM-500-344-11 or LSM-500-344-21 Ballast Assy on the inner surface of the W438/338 leading edge access panel as shown in Figure 1. Position Ballast Assy per Figure 1 and outline three bonding areas for mounting standoffs. Prepare access panel bonding surface and standoff bonding surfaces per the ClickBond CBPS-206 instructions included. Remove excess adhesive from access panel flange surfaces. Allow adhesive to cure for two hours minimum at 75 degrees F. Touch up exposed surfaces using an approved primer.




6. Install (4) starter bulb assemblies LSM-SCD-009-1 onto (2) Par 36 taxi light reflectors (LSM-SCD-004-1) and (2) Par 46 landing light reflectors (LSM-500-300-46L) using supplied ring clip and gasket and secure in place with LSM-500-304-1 Strap using (2) of the existing screws/lock washers on each assembly. Connector should point down in relation to top of lens. When assembling the landing light reflectors, install the LSM-500-358-13 spacer in the recessed pocket of the reflector over the rubber washer. Install the LSM-500-358-11 spacer on the mounting face of the reflector. Install (3) AN960-8 washers over the -11 spacer, then the retainer clip with starter bulb and finally the remaining hardware. See photo 4.

Photo #4

7. Install MS21266-1N grommet edging around (4) lightening holes aft of taxi and landing light mounting locations. Trim to fit as required, typical LH and RH of aircraft. Secure with 3M 1300L adhesive or equivalent.

8. Install 11-12334 spiral wrap over TKS poly anti-icing lines above the leading edge access panel opening, typical LH/RH. Secure using MS3367-1-9 cable tie wraps. See photo 5.




Photo #5

9. Guide the small LSM-500-345-13 ballast to lamp/starter wire connector from the leading edge access panel opening through the upper lightening hole and out the lightening hole aft of the taxi light mount position. On newer aircraft with a larger diameter lightening hole, it is permissible to run the wire harness through the lower lamp bay wall lightening hole. Guide the connector end of the LSM-500-345-7 ballast to lamp/starter wire along the -13 harness and out the lightening hole aft of the landing light mount position. See photos 6 and 7. Install 11-12334 spiral wrap over both harnesses where they pass through the lightening hole and secure both ends with MS3367-1-9 cable tie wraps. Note: On some older model 800 aircraft the lightening hole does not exist. For aircraft with this configuration, route the landing and taxi light lamp/starter wires along the existing wiring conduit from the lamp bays to the access panel opening per the instructions in Para. 10. See photo 8.




Photo #6

Photo #7




Photo #8

10. Route LSM-500-345-7 and LSM-500-345-13 Ballast to Lamp/Starter Wires along existing wire bundle path to access panel opening. Secure to wire bundle using MS3367-1-9 cable tie wraps per AC43-13.1B. Ensure adequate slack in wires for connection to landing and taxi light lamp/starters. See Figure 2-1 for Model 750, post mod 253563C Model 800, Model 800XP, Model 850XP, Model 900XP and Model 1000 aircraft. See Figure 2-2 for pre mod 253563C Model 800 aircraft.




11. Landing Light Installation: Install bezel ring around LSM-500-300-46L Par 46 reflector assembly. Align lens top with 12:00 position mark on bezel ring, then rotate the reflector 45 degrees outboard (as installed on aircraft) to provide clearance for wire harness connector. If clearance is not required this step may be optional. Install bezel ring hardware and tighten. Inspect landing light/bezel ring assembly for tightness of fit. If the landing light is loose or can rotate in the bezel ring it will be necessary to add a bead of RTV sealant on the interior side of the light between bezel ring and reflector. See photo 9. Connect the LSM-500-345-7 wire connector to the LSM-SCD-009-1 starter connector on Par 46 reflector. Apply Dow Corning DC4 di-electric compound (or equivalent) to both connectors prior to attaching. Install Par 46 reflector and bezel ring in inboard lamp location using existing mounting hardware. Install NAS43DD3-22FC spacers over mounting screws to offset Par 46 reflector forward. Verify that there is adequate screw thread




penetration through the fasteners. If not, replace existing mounting screws with MS35207-233 screws. Installation is typical for LH/RH of aircraft. See photo 10. Note: On some older model 800 aircraft with the lamp bay opening configuration shown in photo 11, it is not necessary to use the NAS43DD3-22FC spacers. Use existing mounting hardware to install the Par 46 reflector.

Photo #9




Photo #10

Photo #11




12. Taxi Light Installation: Install bezel ring around LSM-SCD-004-1 Par 36 reflector assembly. Align lens top with 12:00 position mark on bezel ring. Install bezel ring hardware and tighten. Inspect taxi light/bezel ring assembly for tightness of fit. If the taxi light is loose or can rotate in the bezel ring it will be necessary to add a bead of RTV sealant on the interior side of the light between bezel ring and reflector. See photo 9. Connect the LSM-500-345-13 wire connector to the LSM-SCD-009-1 starter connector on the Par 36 reflector. Apply Dow Corning DC4 di-electric compound (or equivalent) to both connectors prior to attaching. Install taxi light/bezel ring assembly in outboard lamp location using existing mounting hardware. Installation is typical for LH and RH of aircraft. See photo 12.

Photo #12




13. Install LSM-500-346-19 Ballast to Power Wire Assy, Taxi and LSM-500-346-21 Ballast to Power Wire Assy, Landing per Figure 3 and Figure 4. For Model 750, post mod 253563C Model 800, Model 800XP, Model 900XP and Model 1000 aircraft use M81969/14-11 and M81969/14-04 pin installation/removal tools to insert pins in front spar terminal module per Figure 3. For pre mod 253563C Model 800 aircraft remove pins from wire assemblies and use M7928/5-3 and M7928/5-4 butt splice connectors to join wires per Figure 4. Cover splices with M23053/5-106-0 shrink tube. Installation is typical for LH/RH of aircraft.




14. Supporting the leading edge access panel with the ballast assembly facing up, attach LSM-500-345-13 ballast end connector and LSM-500-346-19 ballast end connector to the top ballast. Attach LSM-500-345-7 ballast end connector and LSM-500-346-21 ballast end connector to bottom ballast. Apply Dow Corning DC4 di-electric compound (or equivalent) to all connectors prior to attaching. Install leading edge access panel on wing using existing attach hardware. Installation is typical for LH/RH of aircraft.

15. For all aircraft except for Model 1000 without the EJA/Netjets squat switch mod installed, install LSM-500-359-1 jumper wires on LH/RH Landing/Taxi Light switches “RT” and “RU” in cockpit overhead panel “CG” per Figure 5. For Model 1000 without the EJA/Netjets squat switch mod installed, install LSM-500-359-1 jumper wires on LH/RH Landing/Taxi Light switches “RT” and “RU” in cockpit overhead panel “CG” per Figures 6 or 7. For aircraft with the EJA/Netjets squat switch mod installed, install LSM-500-359-1 jumper wires on LH/RH Landing/Taxi Light switches “RT” and “RU” in cockpit overhead panel “CG” and cap and stow wires as shown in Figure 8. It is permissible to retain the existing squat switch mod configuration as installed.




16. Reconnect aircraft batteries.

17. Perform functional test of all lights by applying aircraft power and cycling through taxi/landing light switch positions.

18. Prior to adjusting lights, temporarily install LH/RH lamp bay window assemblies to achieve the most accurate results.

Light Aiming Instructions:

Aim lights per the AMM except as follows: For aircraft on jacks Dimension “C” = X minus 16.0 Inches and Dimension “D” = X minus 6.0 Inches. For aircraft on ground Dimension “C” = X minus 20.0 Inches and Dimension “D” = X minus 10.0 Inches. Note: It may be helpful in checking the location of the beam center to move the target boards closer to the lights before moving the boards out to Dimension “B”. Do not tape over or cover the reflector without leaving air passage for cooling or reflector damage may occur.

These aiming instructions are intended as a starting point. It is permissible to adjust beam aiming to account for individual pilot/operator preferences.

19. Install lamp bay window assembly using existing attach hardware. Seal edges of window assembly and leading edge access panel per the AMM. Installation is typical LH/RH of aircraft.

20. Fill out Form 337.




21. Maintenance Requirements –

Instructions for Continued Airworthiness

“Modification of an aircraft by this Supplemental Type Certificate obligates the aircraft operator to include the maintenance information provided by this document in the operator’s Aircraft Maintenance Manual and the operator’s Aircraft Scheduled Maintenance Program.”

1. Maintenance Manual information for the Boom Beam is contained in LoPresti Speed Merchants Installation Manual Number LSM-500-042 (this document), and should be placed into the operators appropriate airplane Maintenance Manual.

2. Line Replaceable Unit (LRU) part numbers and other necessary part numbers contained in the installation data package should be placed into the aircraft operators appropriate airplane Illustrated Parts Catalog (IPC).

3. Wiring diagram information contained in this data package should be placed into the aircraft operator’s appropriate airplane Wiring Diagram Manuals.

4. Scheduled Maintenance Program tasks to be added to the aircraft operators appropriate airplane maintenance program are as follows:

During an inspection interval of the lesser of 900 hours (+40 hours) or one year (+one month), inspect the mechanical and electrical integrity of the BOOM BEAM equipment and components as follows:

Physically inspect the ballast assembly mounting hardware.

Visually inspect ballast electrical harnesses for frayed or damaged insulation, broken wires or loose connectors.

Visually inspect the landing and taxi light reflectors. Visually inspect the mounting bracket and lamp/starter mounting hardware for structural integrity.

Visually inspect the lamp/starter electrical harnesses for frayed or damaged insulation, broken wires or loose connectors.

During an inspection interval of the lesser of 1800 hours (+50 hours) or two years (+2 months), inspect the mechanical and electrical integrity of the BOOM BEAM equipment and components as follows:


Physically inspect all electrical harnesses for frayed or damaged insulation, broken wires or loose connectors.

Physically inspect the landing and taxi light reflectors for damage. Physically inspect the mounting bracket and lamp/starter mounting hardware.




During subsequent inspection intervals of the lesser of 1800 hours (+50 hours) or two years (+2 months) thereafter, inspect the mechanical and electrical integrity of the BOOM BEAM equipment and components as follows:


Physically inspect all electrical harnesses for frayed or damaged insulation, broken wires or loose connectors.

Physically inspect the landing and taxi light reflectors for damage. Physically inspect the mounting bracket and lamp/starter mounting hardware.




Weight and Balance Information

35W Ballast Assy Installation:

Weight and balance change of +6.6 pounds at Datum STA -1.45 feet.

60W and 85W Ballast Assy Installation:

Weight and balance change of +7.6 pounds at Datum STA -1.45 feet.

Electrical Load Analysis The existing Landing/Taxi light system installed in each wing of the aircraft includes one taxi light and one landing light. The taxi light is rated at 100 watts and draws a maximum of 3.85 amperes at 26 VDC. The landing light is rated at 450 watts and draws a maximum of 17.3 amperes at 26 VDC. The maximum current draws, at 28 VDC, are 3.6 and 16.1 amperes, respectively. Steady state values will be lower, as the lamps warm up. The new Boom Beam installation replaces the two existing lamps in each wing with a ballast and lamp assembly; a total of four assemblies. Each 35W ballast assembly draws a maximum of 4.1 amperes at startup and then draws 1.73 amperes at steady state, after the lamps warm up. Each 60W ballast assembly draws a maximum of 5.9 amperes at startup and then draws 2.4 amperes at steady state, after the lamps warm up. Each 85W ballast draws a maximum of 8.4 amperes at startup and then draws 3.0 amperes at steady state, after the lamps warm up. The total current required to operate the Boom Beam Lighting system is less than the existing system and therefore places no burden on the aircraft generating and distribution system.

lsm-500-042 rev v hawker boom beam - amazon s3 · lsm-500-300-46l par 46 reflector was...

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