Installation Instructions Cessna Citation CJ Series Landing Lights Models 525, 525A, 525B (S/N 525-0001 thru 525-0679, 525A-0001 thru 525A-0416, 525B-0001 thru 525B-0262, 525B-0264 thru 525B-0293) Cessna Citation Model 560XL Landing Lights Excel (S/N 560-5001 thru 560-5372), XLS (S/N 560-5501 thru 560-6000), XLS+ (S/N 560-6001 and Subs) STC ST02893AT LSM-500-099 Rev P 07-29-14
REVISION DESCRIPTION Rev Date Description IR 06-13-11 1. Initial release. 1. CB92 qty was 2. A 10-06-11 2. Deleted frame STA from weight and balance data. 3. Added optional ballast mounting location / orientation for older aircraft. 4. Revised note 7 to allow the use of a lubricant when installing the gasket over the reflector. 1. Added -3 kit for Model 560XL. B 04-09-12 2. Revised weight and balance to add -3 kit. 3. Revised electrical load analysis to add -3 kit. 4. LSM-SCD-008-24W was LSM-SCD-008-18W. 5. Added alternate ballast mounting locations on fwd / aft compartment bulkheads and outboard skin. C 04-25-12 1. Added -5 and -7 kits. 1. Deleted -5 and -7 kits. D 07-25-12 2. LSM-500-417-5 & -6 were LSM-500-417-3 for -3 kit. 3. Added LSM-500-344-13 qty 2 for -3 kit. 4. LSM-SCD-007-1 qty was 2 for -3 kit. 5. LSM-SCD-008-24W qty was 2 for -3 kit. 6. MS3367-1-9 qty was 16 for -3 kit. 7. CB92 qty was 3. 8. Added Figure 2. 9. Revised electrical load analysis and weight and balance for 560XL installation. 1. Deleted LSM-SCD-019-1 qty 2 for -3 kit. E 08-17-12 2. LSM-500-344-15 was LSM-500-344-13 for -3 kit. 3. LSM-SCD-007-17 was LSM-SCD-007-1 for -3 kit. 4. Deleted LSM-SCD-008-24W for -3 kit. 5. Deleted LSM-501-103-3 for -3 kit. 6. Deleted AN315-3R for -3 kit. 7. Deleted MS21042-3 for -3 kit. 8. Deleted AN960-10 for -3 kit. 9. Deleted NAS43DD3-48FC for -3 kit. 10. Deleted CS125-103224CR for -3 kit. 11. MS3367-1-9 qty was 24 for -3 kit. 12. CB92 qty was 6 for -3 kit. 13. Added LSM-500-417-13 qty 8. 14. Added MS35206-247 qty 4. 15. Added AN960-8 qty 4. F 08-22-12 1. LSM-500-415-7 / -8 was LSM-500-415-1 for -1 kit. 2. LSM-500-344-13 was LSM-SCD-019-1 for -1 kit. 3. Deleted LSM-SCD-008-24W, LSM-501-103-3, AN315-3R, MS21042-3, AN960-10, NAS43DD3-48FC and CS125-103224CR from -1 kit. 4. LSM-SCD-007-1 qty was 2. 5. Model 525 weight and balance was +.7 pounds. 6. Model 525 electrical load analysis was 27.3 amperes less than stock system.
G 09-14-12 1. LSM-500-344-15 was LSM-500-344-13 for -1 kit. 2. Added MS35206-247 to -1 kit. 3. Added LSM-SCD-019-1 qty 2 for -3 kit. 4. LSM-500-417-5 qty was 1 for -3 kit. 5. Deleted LSM-500-417-6 for -3 kit. 6. Deleted LSM-500-417-13 for -3 kit. 7. Added LSM-SCD-019-1 for -3 kit. 8. Deleted MS35206-247 from -3 kit. 9. Deleted AN960-8 from -3 kit. 10. CB92 qty was 4 for -3 kit. H 10-15-12 1. -1 kit was Model 525 S/N 0001 thru 0679. 2. Added -5 kit for Model 525 S/N 0001 thru 0175. I 10-29-12 1. Added AN315-3R qty 6 for -3 kit. 2. Added MS21042-3 qty 6 for -3 kit. 3. Added AN960-10 qty 12 for -3 kit. 4. Added CS125-103210CR qty 6 for -3 kit. 5. Added LSM-501-103-3 qty 2 for -3 kit. 6. Added Figure 1. J 12-03-12 1. Deleted LSM-500-415-7, -8 & -15 for -1 kit. 2. Added LSM-500-415-27 qty 2 for -1 kit. 3. Added LSM-500-415-29 qty 2 for -1 kit. 4. Added LSM-500-415-31 qty 2 for -1 kit. 5. LSM-500-415-9 qty was 2 for -5 kit. 6. Added LSM-500-415-10 qty 1 for -5 kit. 7. Revised Figures 2 and 4. K 03-27-13 1. Added CS125-103224CR qty 6 as alternate for -3 kit. 2. Added NAS43DD3-48FC qty 6 to -3 kit. 3. AN960-10 qty was 12 for -3 kit. 4. Added Figure 2 for ballast mounting option. L 06-26-13 1. Added photo 3. 2. Revised Figure 5 to show connectors pointing outboard. 3. Revised ballast mounting for -5 kit to outboard of opening. M 02-05-14 1. Added -7, -9, -11 kits. 2. Revised electrical load analysis. N 07-10-14 1. Added ClickBond Stud Installation Instructions. P 07-29-14 1. Revised CB92 Adhesive Kit to Customer Furnished
LSM-500-099 Rev P Page 1 of 38 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. -1 60W Wing Fairing Light Installation Kit Models 525, 525A, 525B (S/N 525-0176 thru 525-0679, 525A-0001 thru 525A-0416, 525B-0001 thru 525B-0262, 525B-0264 thru 525B-0293) Nomenclature Part Number Vendor Quantity Light Array Assy LSM-500-415-31 2 Fwd Retainer LSM-500-415-27 2 Aft Retainer LSM-500-415-29 2 Ballast Assy, 60W LSM-500-344-15 2 Ballast to Power Wire LSM-SCD-007-1 4 Harness Screw MS35206-247 4 Cable Tie Wraps MS3367-1-9 16 Splice M81824-1-3 4 Shrink Tube M23053/5-106-0 6 inches Adhesive CB92 Click Bond (3) Customer Furnished
LSM-500-099 Rev P Page 2 of 38-3 60W Wing Fairing Light Installation Kit Cessna Citation Model 560XL Landing Lights Excel (S/N 560-5001 thru 560-5372), XLS (S/N 560-5501 thru 560-6000), XLS+ (S/N 560-6001 and Subs) Nomenclature Part Number Vendor Quantity Light Array Assy LSM-500-417-5 2 Ballast Assy, 60W LSM-500-344-15 2 Ballast Mounting LSM-501-103-3 2 Guide Ballast, 60W LSM-SCD-019-1 2 Ballast to Power LSM-SCD-007-17 2 Wire Harness Nut AN315-3R 6 Stud CS125-103210CR Click Bond 6 Stud CS125-103224CR Click Bond 6 (Alternate) Washer AN960-10 24 Nut MS21042-3 6 Spacer NAS43DD3-48FC 6 Cable Tie Wraps MS3367-1-9 12 Splice M81824-1-3 4 Shrink Tube M23053/5-106-0 6 inches Adhesive CB92 Click Bond (6) Customer Furnished
LSM-500-099 Rev P Page 3 of 38-5 60W Wing Fairing Light Installation Kit Model 525 (S/N 0001 thru 0175) Nomenclature Part Number Vendor Quantity Light Array Assy, LH LSM-500-415-9 1 Light Array Assy, RH LSM-500-415-10 1 Ballast Assy, 60W LSM-500-344-15 2 Ballast to Power Wire LSM-SCD-007-1 4 Harness Cable Tie Wraps MS3367-1-9 8 Splice M81824-1-3 4 Shrink Tube M23053/5-106-0 6 inches Adhesive CB92 Click Bond (3) Customer Furnsihed
LSM-500-099 Rev P Page 4 of 38-7 85W Wing Fairing Light Installation Kit Models 525, 525A, 525B (S/N 525-0176 thru 525-0679, 525A-0001 thru 525A-0416, 525B-0001 thru 525B-0262, 525B-0264 thru 525B-0293) Nomenclature Part Number Vendor Quantity Light Array Assy LSM-500-415-31 2 Fwd Retainer LSM-500-415-27 2 Aft Retainer LSM-500-415-29 2 Ballast Assy, 85W LSM-500-344-19 2 Ballast to Power Wire LSM-SCD-007-1 4 Harness Screw MS35206-247 4 Cable Tie Wraps MS3367-1-9 16 Splice M81824-1-3 4 Shrink Tube M23053/5-106-0 6 inches Adhesive CB92 Click Bond (3) Customer Furnished
LSM-500-099 Rev P Page 5 of 38-9 85W Wing Fairing Light Installation Kit Cessna Citation Model 560XL Landing Lights Excel (S/N 560-5001 thru 560-5372), XLS (S/N 560-5501 thru 560-6000), XLS+ (S/N 560-6001 and Subs) Nomenclature Part Number Vendor Quantity Light Array Assy LSM-500-417-5 2 Ballast Assy, 85W LSM-500-344-19 2 Ballast Mounting LSM-501-103-3 2 Guide Ballast, 85W LSM-SCD-019-5 2 Ballast to Power LSM-SCD-007-17 2 Wire Harness Nut AN315-3R 6 Stud CS125-103210CR Click Bond 6 Stud CS125-103224CR Click Bond 6 (Alternate) Washer AN960-10 24 Nut MS21042-3 6 Spacer NAS43DD3-48FC 6 Cable Tie Wraps MS3367-1-9 12 Splice M81824-1-3 4 Shrink Tube M23053/5-106-0 6 inches Adhesive CB92 Click Bond (6) Customer Furnished
LSM-500-099 Rev P Page 6 of 38-11 85W Wing Fairing Light Installation Kit Model 525 (S/N 0001 thru 0175) Nomenclature Part Number Vendor Quantity Light Array Assy, LH LSM-500-415-9 1 Light Array Assy, RH LSM-500-415-10 1 Ballast Assy, 85W LSM-500-344-19 2 Ballast to Power Wire LSM-SCD-007-1 4 Harness Cable Tie Wraps MS3367-1-9 8 Splice M81824-1-3 4 Shrink Tube M23053/5-106-0 6 inches Adhesive CB92 Click Bond (3) Customer Furnished
LSM-500-099 Rev P Page 7 of 38 Installation Instructions 1. All instructions are typical for LH and RH of aircraft. Instructions are applicable to all aircraft models listed except where noted. 2. Remove the existing landing light assemblies. Detach the electrical leads, determine polarity and identify as power and ground. Remove the hardware securing the lanyards. Retain all hardware for later use. See photos 1 and 2. Photo #1 Model 525 View Looking Aft on LH Side
LSM-500-099 Rev P Page 8 of 38 Ballast Mounting Location on Aircraft Skin Alternate Ballast Mounting Location on Fwd / Aft Compartment Bulkheads Photo #2 Model 525 View Looking Aft on LH Side 3. Remove the existing lamp and rubber gasket from the bracket. Retain the bracket attach hardware for later use. 4. For -1 / -5 and -7 / -11 Kit Installations: For the -1 and -7 kits, the LSM-500-344- 15 or LSM-500-344-19 Ballast Assy will be mounted inboard of the LH & RH light access openings on the aircraft skin using ClickBond CB92 adhesive per ClickBond CBPS-206 instructions included. For the -5 and -11 kits, it is recommended that the Ballast Assy be mounted outboard of the light access openings. Position the ballasts to provide the optimum harness connector / ballast connector orientation prior to bonding. On older aircraft with the skin configuration shown in photos 3, 4 and 5, it is preferrable to mount the ballasts on the skin outboard of the landing lights. See photos 3, 4, 5 and 6. For -3 and -9 Kit Installation: The LSM-500-344-15 or LSM-500-344-19 Ballast Assy and LSM-SCD-019-1 or LSM-SCD-019-5 Ballast will be mounted inboard of the LH & RH light access openings on the aircraft skin using Click Bond CB92 adhesive per ClickBond CBPS-206 instructions included. An alternate mounting location is on the aft side of the bulkhead (FS 253.2) as shown in photos 8 and 9. It is suggested that the ballast assemblies be positioned to provide the optimum harness connector / ballast connector orientation prior to bonding. Attach the LSM-501-103-3 Ballast Mounting Guide to the CS125-103210CR or CS125-103224CR studs using AN315-3 nuts prior to applying adhesive to the studs. See photo 6 and Figures 1 and 2.
LSM-500-099 Rev P Page 9 of 38 Photo #3 Early Model 525 RH Side Alternate Ballast Mounting Location Photo #4 Model 525 (LSM-500-344-15 Not Shown)
LSM-500-099 Rev P Page 10 of 38 Photo #5 Model 525 (LSM-500-344-15 Not Shown) Photo #6 Models 525, 525A, 525B (LSM-500-344-15 Not Shown)
LSM-500-099 Rev P Page 11 of 38 Photo #7 Model 560XL (LSM-500-344-15 Not Shown) Photo #8 Model 560XL (LSM-SCD-019-1 Shown)
LSM-500-099 Rev P Page 12 of 38 Photo #9 Model 560XL (LSM-500-344-15 Shown)
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LSM-500-099 Rev P Page 14 of 38 5. When mounting the ballast assemblies, the adhesive will be applied directly to the studs and the entire assembly will be placed on the aircraft skin per ClickBond CBPS-206 instructions included. Prior to bonding, prepare the surface in accordance with the instructions included with the CB92 adhesive kit. Note: when installing ClickBond studs on metal, all surface finish must be removed prior to applying adhesive. Reapply finish as required after the adhesive has cured. Prepare the adhesive and apply to the bottom of the stud flanges. Position the studs to clear existing structure and fasteners and place firmly on the surface. The gap between the studs and the surface should be such that the adhesive outflows to form a fillet around the stud flange. Allow two hours at room temp for the adhesive to cure. Cured adhesive will be green in color. 6. For -1 / -7 Kit Installation: Remove the silicone cuffs from the stock landing lights and install on the LSM-500-415-31 light array assemblies. Insert these units into the stock light housing. A small amount of moisture will help seat the cuff into the housing. Install the LSM-500-415-27 forward retainer and the LSM-500-415-29 aft retainer over the unit and secure using existing hardware. See Figure 3. 7. For -3 / -9 Kit Installation: Remove the cable ties securing the lamp/starter harness to the mounting plate and attach the LSM-500-417-5 light array assemblies to the LH & RH light support brackets using existing hardware. See Figure 4. 8. For -5 / -11 Kit Installation: Remove the cuffs from the stock landing lights and install on the LSM-500-415-9 & -10 light array assemblies. Install the cuff / light array assemblies into the stock holding fixtures with the lamp/starter connectors pointing outboard. Tighten the holding clamp hardware to secure the light array assemblies. See Figure 5.
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LSM-500-099 Rev P Page 17 of 38 9. For -1 / -7 and -5 / -11 Kit Installations: Attach the LSM-SCD-007-1 Power Harnesses to the ballast connectors. Apply Dow Corning DC-4 (or other di-electric compound) to both connectors prior to attaching. Trim existing power and ground leads and harness leads to a length suitable for joining to the LSM-SCD-007-1 Power Harness. Join two red leads to aircraft positive power and two black leads to aircraft ground wire using M81824-1-3 splices and cover using M23053/5-106-0 shrink tubing. See photos 10 and 11.
LSM-500-099 Rev P Page 18 of 38 Photo #10 Photo #11 10. For -3 / -9 Kit Installation: Attach the LSM-SCD-007-17 Power Harness to the ballast connectors. Apply Dow Corning DC-4 (or other di-electric compound) to all
LSM-500-099 Rev P Page 19 of 38 connectors prior to attaching. Trim existing power and ground leads to a length suitable for joining to the LSM-SCD-007-17 Power Harness leads. Join red soldered lead to aircraft positive power and black soldered lead to aircraft ground wire using M81824-1-3 splices and cover using M23053/5-106-0 shrink tubing. Typical for LH and RH of aircraft. 11. Attach the lamp/starter harnesses to the ballast connectors. 12. Secure all harnesses using MS3367-1-9 cable tie wraps per AC43-13.1B. 13. Do a power on test of the lighting system. Cycle power through the landing, taxi and recognition switch positions. 14. Reinstall the light assembly using existing hardware. Reseal the panel per the AMM instructions. 15. Fill out FAA Form 337.
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LSM-500-099 Rev P Page 22 of 38 Maintenance Requirements Instructions for Continued Airworthiness 1. Maintenance Manual information for the Boom Beam is contained in LoPresti Speed Merchants Installation Manual Number LSM-500-099 (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: 5. During an inspection interval of the lesser of 600 hours or one year, 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. Check for cracking in the reflector housing clamp flanges and for safety wire integrity (if existing). Damaged clamp or broken safety wire must be replaced.
LSM-500-099 Rev P Page 23 of 38-1 Kit Installation: Change of +1.7 pounds. -3 Kit Installation: Change of +3.0 pounds. -5 Kit Installation: Change of +1.5 pounds. Weight and Balance Information Electrical Load Analysis For 60W Kit Installation: The new Boom Beam installation replaces the existing lights with a ballast and lamp assembly; a total of two assemblies. 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. -1 and -5 Kit Installations: The total current required to operate the Boom Beam Lighting system is 22.5 amperes less than the existing system and therefore places no burden on the aircraft generating and distribution system. -3 Kit Installation: The total current required to operate the Boom Beam Lighting system is 28.5 amperes less than the existing system and therefore places no burden on the aircraft generating and distribution system. For 85W Kit Installation: The new Boom Beam installation replaces the existing lights with a ballast and lamp assembly; a total of two assemblies. 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. -7 and -11 Kit Installations: The total current required to operate the Boom Beam Lighting system is 20.1 amperes less than the existing system and therefore places no burden on the aircraft generating and distribution system. -9 Kit Installation: The total current required to operate the Boom Beam Lighting system is 24.9 amperes less than the existing system and therefore places no burden on the aircraft generating and distribution system.
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