caravan cessna 208b lamp

7/24/2019 caravan cessna 208b lamp

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LoPresti Aviation800-859-4757 / 772-562-4757 or fax 772-228-9750 LoPrestiAviation.com

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

Cessna CaravanWing Mounted Taxi/Landing Lights

Installation InstructionsModel 208, 208A, 208B

LSM-500-040

Rev E07-29-14


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REVISION DESCRIPTION

Rev Date DescriptionIR 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.


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BOOM BEAM

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

possible.Before you start: READ ALL INSTRUCTIONSCall 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 PowerWire


Ballast toLamp/Starter Wire

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

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

Mounting Guide forBallast

LSM-501-103-3 LoPresti Speed Merchants 4

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

Nuts for Temp Usewith 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) CustomerFurnished

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


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LSM-500-040 Rev EPage 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 PowerWire


Ballast toLamp/Starter Wire

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

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

Mounting Guide forBallast

LSM-501-103-3 LoPresti Speed Merchants 4

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

Nuts for Temp Usewith 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) CustomerFurnished

Spacer NAS43DD3-48FC 12

Washer AN960-8 12Nut 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


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Installation Instructions for both -3 and -5 kits

1. Prior to light installation, aim the landing and taxi lights against a hangar wall andmark 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 receivingequipment antennae for the following equipment:

GPSATC TransponderDMETCAS

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 ClickBondCBPS-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 onthe wing spar behind the taxi light cutout to clear existing structure. Follow theinstructions to prepare the adhesive, mount the studs, cure the adhesive andreapply finishes as required.

Use LSM-501-103-5 abrasion shield to protect finish outside of the stud bondingarea, you may trim the shield if required.

Repeat for the landing light cutout. Installation is typical for the LH and RH ofaircraft. See photo 1 and Figures 1 and 2.

Photo #1


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4. Attach the ballasts by sliding AN960-10 washer, NAS43DD3-48FC spacer andAN960-10 washer over the Click Bond studs (3 places). Position the ballast overthe studs. Add AN960-10 washer and MS21042-3 nut on topside of ballast andtighten. 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-500-304-1Strap using (2) of the existing screws/lock washers on each assembly. Connectorshould point down in relation to top of lens. When assembling the landing lightreflectors, install the LSM-500-358-13 tuning plate in the recessed pocket of thereflector over the rubber washer. Install the LSM-500-358-11 tuning plate on themounting 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: fora tighter, more focused landing light beam pattern do not install the tuning platesand flat washers. See photo 2.

Photo #2

6. Connect LSM-SCD-007-1 Ballast to Power wire to ballast. Apply Dow Corning DC4di-electric compound (or equivalent) to both connectors prior to attaching. ConnectLSM-SCD-008-12W Ballast to Lamp/Starter wire to ballast. Apply Dow Corning


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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 usingM7928/5-4 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 CB92adhesive. Secure harnesses using MS3367-1-9 tie wraps per AC43.131B.

9. Landing Light Installation: Install existing bezel ring around LSM-500-300-46L Par46 Assembly. Align lens top with 12:00 position on bezel ring. Install bezel ringhardware 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 adda bead of RTV sealant on the interior side of the light between bezel ring andreflector. Connect the LSM-SCD-008-12W wire connector to the LSM-SCD-009-1starter connector on Par 46 Assembly. Apply Dow Corning DC4 di-electric

compound (or equivalent) to both connectors prior to attaching. Install Par 46Assembly and bezel ring in outboard lamp location using existing mountinghardware. Installation is typical for LH/RH of aircraft.

10. Taxi Light Installation: Install existing bezel ring around LSM-SCD-004-1 Par 36Assembly. Align lens top with 12:00 position on bezel ring. Install bezel ringhardware and tighten. Inspect taxi light/bezel ring assembly for tightness of fit. Ifthe taxi light is loose or can rotate in the bezel ring it will be necessary to add abead of RTV sealant on the interior side of the light between bezel ring andreflector. Connect the LSM-SCD-008-12W wire connector to the LSM-SCD-009-1starter connector on the Par 36 Assy. Apply Dow Corning DC4 di-electriccompound (or equivalent) to both connectors prior to attaching. Install taxi

light/bezel ring assembly in inboard lamp location using existing mountinghardware. Installation is typical for LH and RH of aircraft.

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

12. Reinstall lens covers using existing hardware.

13. Fill out Form 337.


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Maintenance Requirements Instructions for Continued Airworthiness

Modification of an aircraft by this Supplemental Type Certificate obligates the aircraftoperator to include the maintenance information provided by this document in the

operators Aircraft Maintenance Manual and the operators Aircraft Scheduled MaintenanceProgram.

1. Maintenance Manual information for the Boom Beam is contained in LoPresti SpeedMerchants Installation Manual Number LSM-500-040 (this document), and should beplaced into the operators appropriate airplane Maintenance Manual.

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

3. Wiring diagram information contained in this data package should be placed into theaircraft operators appropriate airplane Wiring Diagram Manuals.

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

During an annual or 100-hour inspection interval, inspect the mechanical andelectrical integrity of the BOOM BEAM equipment and components.

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

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

The bulb/starters, ballasts and reflectors must be checked for soundness inmechanical and electrical conditions. Cracked or broken bulb/starter, ballast, orreflector 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.


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Electrical Load AnalysisThe new Boom Beam installation replaces the two existing lamps in each wing with aballast 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 2.4amperes 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 3.0amperes at steady state, after the lamps warm up.


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LoPresti Aviation800-859-4757 / 772-562-4757 or fax 772-228-9750 LoPrestiAviation com

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caravan cessna 208b lamp