lsm-500-040 rev e cessna caravan boom beam · lopresti aviation 800-859-4757 / 772-562-4757 or fax...

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

210 Airport Drive East, Sebastian, Florida, 32958, U.S.A.

Cessna Caravan Wing Mounted Taxi/Landing Lights

Installation Instructions Model 208, 208A, 208B

LSM-500-040

Rev E 07-29-14



REVISION DESCRIPTION

Rev Date Description IR 08-18-04

1. Initial release. A 08-26-08 1. LSM-SCD-009-1 was LSM-500-200-100.

2. LSM-SCD-004-1 was LSM-500-300-36I. 3. LSM-SCD-006-3 was LSM-500-200-128. 4. LSM-SCD-007-1 was LSM-500-314-3. 5. LSM-SCD-008-12W was LSM-500-331-12B. 6. LSM-501-103-3 was LSM-501-103-1. 7. Weight and balance was +7.9 lbs.

B 04-03-11 1. LSM-500-300-46L was LSM-500-300-46I. 2. Added LSM-500-358-11 tuning plate qty 2. 3. Added LSM-500-358-13 tuning plate qty 2. 4. Added LSM-SCD-019-1 as alternate ballast. 5. CS125-103224CR was KA3A-1CS125103224CR and qty was

4. 6. CB9120V5 was KA5A1-2CB9120V5 and qty was 4. 7. Added CB92 adhesive kit qty 6. 8. Added AN960-8 washer qty 12. 9. Added photo 1 and Figure 2. 10. Deleted Appendix A. 11. Weight and balance was 5.4 pounds. Added 60W ballast kit

installation data. 12. Revised electrical load analysis to add 60W ballast kit

installation data. C 04/15/14 1. Added 85 watt option.

2. Removed 35 watt option D 07/09/14 1. Added ClickBond Stud Installation Instructions E 07/29/14 1. Revised CB92 to be Customer Furnished.

BOOM BEAM

Thank you for your purchase of the LoPresti Speed Merchants BOOM BEAM. We have written this Installation Manual to make your installation as easy and professional as possible. 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.

LSM-500-040-3, 60 watt BoomBeam HID System Nomenclature Part Number Vendor Quantity Lamp/Starter Assy LSM-SCD-009-1 LoPresti Speed Merchants 4

Reflector Lens Assy (Taxi Light)

LSM-SCD-004-1 LoPresti Speed Merchants 2

Reflector Lens Assy (Landing Light)

LSM-500-300-46L LoPresti Speed Merchants 2

Tuning Plate LSM-500-358-11 LoPresti Aviation 2


Ballast to Power Wire


Ballast to Lamp/Starter Wire

LSM-SCD-008-12W LoPresti Speed Merchants 4

60W Ballast 28 Volt LSM-SCD-019-1 LoPresti Speed Merchants 4

Mounting Guide for Ballast

LSM-501-103-3 LoPresti Speed Merchants 4

Abrasion shield LSM-501-103-5 LoPresti Speed Merchants 2

Nuts for Temp Use with Mounting Guide

AN315-3R 12

Strap LSM-500-304-1 LoPresti Speed Merchants 4

Stud CS125-103224CR Click Bond 12

Cable Tie Mount CB9120V5 Click Bond 8

Adhesive Kit CB92 Click Bond (6) Customer Furnished

Spacer NAS43DD3-48FC 12

Washer AN960-8 12

Nut MS21042-3 12

Washer AN960-10 24

Cable Tie Wraps MS3367-1-9 12

Connectors M7928/5-4 8

Shrink Tube M23053/5-106-0 24 inches

LSM-500-040 Rev E Page 3



LSM-500-040-5, 85 watt BoomBeam HID System Nomenclature Part Number Vendor Quantity Lamp/Starter Assy LSM-SCD-009-1 LoPresti Speed Merchants 4

Reflector Lens Assy (Taxi Light)


Reflector Lens Assy (Landing Light)

LSM-500-300-46L LoPresti Speed Merchants 2



Ballast to Power Wire


Ballast to Lamp/Starter Wire

LSM-SCD-008-12W LoPresti Speed Merchants 4

85W Ballast 28 Volt LSM-SCD-019-5 LoPresti Speed Merchants 4

Mounting Guide for Ballast

LSM-501-103-3 LoPresti Speed Merchants 4

Abrasion shield LSM-501-103-5 LoPresti Speed Merchants 2

Nuts for Temp Use with Mounting Guide

AN315-3R 12

Strap LSM-500-304-1 LoPresti Speed Merchants 4

Stud CS125-103224CR Click Bond 12

Cable Tie Mount CB9120V5 Click Bond 8

Adhesive Kit CB92 Click Bond (6) Customer Furnished

Spacer NAS43DD3-48FC 12

Washer AN960-8 12

Nut MS21042-3 12

Washer AN960-10 24

Cable Tie Wraps MS3367-1-9 12

Connectors M7928/5-4 8

Shrink Tube M23053/5-106-0 24 inches




Installation Instructions for both -3 and -5 kits

1. Prior to light installation, aim the landing and taxi lights against a hangar wall and mark the location of the beams. This will be used later to adjust the new lights. 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

2. Remove lens covers from the LH/RH wing landing/taxi lights. Remove stock bezels. Remove stock landing and taxi lights. Retain all hardware for later use.

3. The ballasts will be mounted on the wing spar behind the landing/taxi light mount location using Click Bond studs. Click Bond studs shall be installed per ClickBond CBPS-206 instructions included. Temporarily attach 3 Click Bond studs to the LSM-501-103-3 mounting guide using AN315-3R nuts. Position the mounting guide on the wing spar behind the taxi light cutout to clear existing structure. Follow the instructions to prepare the adhesive, mount the studs, cure the adhesive and reapply finishes as required. Use LSM-501-103-5 abrasion shield to protect finish outside of the stud bonding area, you may trim the shield if required. Repeat for the landing light cutout. Installation is typical for the LH and RH of aircraft. See photo 1 and Figures 1 and 2.

Photo #1




4. Attach the ballasts by sliding AN960-10 washer, NAS43DD3-48FC spacer and AN960-10 washer over the Click Bond studs (3 places). Position the ballast over the studs. Add AN960-10 washer and MS21042-3 nut on topside of ballast and tighten. Complete the same operation for all ballasts (4 total).

5. 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 tuning plate in the recessed pocket of the reflector over the rubber washer. Install the LSM-500-358-11 tuning plate 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. Note: for a tighter, more focused landing light beam pattern do not install the tuning plates and flat washers. See photo 2.

Photo #2

6. Connect LSM-SCD-007-1 Ballast to Power wire to ballast. Apply Dow Corning DC4 di-electric compound (or equivalent) to both connectors prior to attaching. Connect LSM-SCD-008-12W Ballast to Lamp/Starter wire to ballast. Apply Dow Corning




DC4 di-electric compound (or equivalent) to both connectors prior to attaching. Repeat for all four ballasts.

7. Remove ring terminals from existing landing/taxi light ground and power wires. Attach power and ground wires to LSM-SCD-007-1 Ballast to Power wires using M7928/5-4 connectors per Figure 3 Typical Wiring Diagram. Cover splices with M23053/5-106-0 shrink tube. Repeat for all ballasts.

8. Install CB9120V5 cable tie mounts as required to secure all harnesses using CB92 adhesive. Secure harnesses using MS3367-1-9 tie wraps per AC43.131B.

9. Landing Light Installation: Install existing bezel ring around LSM-500-300-46L Par 46 Assembly. Align lens top with 12:00 position on bezel ring. 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. Connect the LSM-SCD-008-12W wire connector to the LSM-SCD-009-1 starter connector on Par 46 Assembly. Apply Dow Corning DC4 di-electric compound (or equivalent) to both connectors prior to attaching. Install Par 46 Assembly and bezel ring in outboard lamp location using existing mounting hardware. Installation is typical for LH/RH of aircraft.

10. Taxi Light Installation: Install existing bezel ring around LSM-SCD-004-1 Par 36 Assembly. Align lens top with 12:00 position 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. Connect the LSM-SCD-008-12W wire connector to the LSM-SCD-009-1 starter connector on the Par 36 Assy. Apply Dow Corning DC4 di-electric compound (or equivalent) to both connectors prior to attaching. Install taxi light/bezel ring assembly in inboard lamp location using existing mounting hardware. Installation is typical for LH and RH of aircraft.

11. Perform functional test of all lights by applying aircraft power and cycling through taxi/landing switch positions. Adjust landing and taxi light beam pattern to conform to original configuration. Due to the characteristics of the Boom Beam it is recommended that the lights be aimed several degrees higher than the stock lights.

12. Reinstall lens covers using existing hardware.

13. Fill out Form 337.




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-500-040 (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 annual or 100-hour inspection interval, inspect the mechanical and electrical integrity of the BOOM BEAM equipment and components.

All fasteners must be checked for tightness and all cable ties must be checked for the security of the wiring harnesses. Loose or broken fasteners or cable ties must be tightened or replaced.

The wiring harnesses must be checked for frayed or damaged insulation, broken wires or connectors. Replace if damaged.

The bulb/starters, ballasts and reflectors must be checked for soundness in mechanical and electrical conditions. Cracked or broken bulb/starter, ballast, or reflector must be replaced.

Weight and Balance Information

-3, 60W and -5 85W Ballast Kit Installation:

Model 208/208A: Weight and balance change of +4.0 pounds at Datum STA 166. Model 208B: Weight and balance change of +4.0 pounds at Datum STA 186.




Electrical Load Analysis The new Boom Beam installation replaces the two existing lamps in each wing with a ballast and lamp assembly; a total of four assemblies.

-3, 60W Ballast Kit Installation: Each 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.

-5, 85W Ballast Kit Installation: Each ballast assembly draws a maximum of 8.4 amperes at startup and then draws 3.0 amperes at steady state, after the lamps warm up.

lsm-500-040 rev e cessna caravan boom beam · lopresti aviation 800-859-4757 / 772-562-4757 or fax...

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