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Boeing SPECTROLAB Nightsun SX-16 Maintenance Manual
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Boeing SPECTROLAB Nightsun SX-16 Maintenance Manual

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Document 031734-1/Revision A
5.18.5 Cooling Blower
The Searchlight will rapidly overheat without the blower operating potentially damaging the entire
Searchlight. Operation of the Searchlight without the blower should only be considered in critical
emergency situations. Even then, operation should be limited to 60 seconds at a time within a 10
minute period. Even with this limited duty cycle, the Searchlight probably will suffer internal damage,
which can be very expensive to repair. In a life critical emergency, the choice to operate the
Searchlight is a choice that the operating crew must make.
Reliable operation of the blower is vital to the performance and service life of
the Searchlight. If the blower does not operate, it must be repaired or replaced
immediately.
5.18.5.1
Audible Inspection (Daily)
Conduct daily inspections of the blower while the Searchlight is completely assembled and installed
on the aircraft.
•
The aircraft engine should not be running during the inspection so that you can hear the
blower. Instead, operate the blower using the aircraft battery or a quiet auxiliary power unit
(APU).
•
Place the Start/On/Off switch in the On position to turn on the Searchlight blower.
The blower should start rapidly and run smoothly. It should come up to full speed
o
within 2 seconds and sound smooth and even. Let the fan run for 10 to 15 seconds to
be sure that it runs smoothly.
If the blower takes longer than 2 seconds to run at full speed, either the wiring or the
o
blower itself may be faulty and must be checked.
Any change or unevenness in the tone or pitch of the blower may indicate bad
o
bearings or brushes. If the blower does not operate smoothly, it must be removed
and replaced.
•
Turn the Start/On/Off switch to the Off position. The blower should coast smoothly to a stop in
a few seconds.
5.18.5.2
Removal of the Rear Cover
Place the Searchlight on a workbench during this procedure for ease of blower removal and
replacement.
•
If the Searchlight must remain on the aircraft, place the Searchlight in a horizontal position,
and remove the power cable.
•
If the Searchlight will be on a workbench, clean the top of the workbench, and place a soft
material on top of the bench. Position the Searchlight so that it rests on the window
assembly. The rear cover should be approximately at shoulder height. Remove the power
cable.
Source: Spectrolab, Inc.
The document reference is online, please check the correspondence between the online documentation and the printed version.
SX-16 Nightsun
NOTICE
DANGER!
The arc lamp contains pressurized xenon gas at
approximately 85 to 90 psi at room temperature and
up to 370 psi at full operating temperature.
If the lamp is mishandled, it can explode and send
hot, sharp shards of quartz at high-speed in every
direction. These shards can cause serious bodily
injury.
To reduce the risk of serious injury:
•
Remove power from the Searchlight so it
cannot be turned on during maintenance with
front glass removed.
84
®
Searchlight System
Maintenance Manual
031734-1 Revision B
January 27, 2014

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Summary of Contents for Boeing SPECTROLAB Nightsun SX-16

  • Page 1 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 5.18.5 Cooling Blower The Searchlight will rapidly overheat without the blower operating potentially damaging the entire Searchlight. Operation of the Searchlight without the blower should only be considered in critical emergency situations.
  • Page 2 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 • Only trained personnel should remove window assembly. • Wear full protective gear that includes safety glasses or full face mask, long-sleeve jacket, and sturdy gloves. •...
  • Page 3 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 Figure 41 Rear Cover Assembly Internal Components Figure 42 Enhanced Rear Cover 5.18.5.3 Detailed Inspection (24 Months) NOTICE Disassembly of the blower is delicate work and should only be performed by personnel experienced in small electric motor repair work.
  • Page 4 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 Every 24 months or 1,200 flight hours or 500 operating hours, conduct a detailed inspection of the blower. • Loosen and remove the two screws that hold the blower end cover in place (Figure 41). Remove the sheet metal cover from the end of the blower motor and feed it gently over the power wires that lead to the bracket with the Diode and terminal posts.
  • Page 5 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 • Place the Start/On/Off switch in the On position to turn on the Searchlight blower. Verify that the fan operates smoothly and rotates in the proper direction (in the direction of the arrow on the motor housing).
  • Page 6 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 • Keep all flammable objects away from the light beam. During close up inspection and cleaning activities, the Searchlight must not be turned on. Remove the Control Box or its cable, or disconnect the Searchlight cable so the light cannot be turned on accidentally during the inspection.
  • Page 7 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 • Position the rear cover so that the fan filter cover is toward the top of the Searchlight (the rear cover only fits onto the Searchlight housing one way). Slip the trim ring (if there is one) over the cover.
  • Page 8 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 5.19.1.3 Boss to Housing External Weld Exam (3 Months) This visual examination of the boss to housing external welds is conducted while the Searchlight is installed on the aircraft.
  • Page 9 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 Observe the pins or screw heads that act as mechanical stops (limits) for the elevation stop plate as they make contact at the limit of travel. The screw head or pin that limits motion as the Searchlight moves upward is called the upper stop.
  • Page 10 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 • May be made of non-magnetic stainless steel, have variable or stepped thickness, and be thinner than 0.125” thick. • Some have magnets, limit switches, or optical sensors attached. 5.19.1.9 Internal Square Drive Hole The internal square hole in the elevation stop measures 0.437”...
  • Page 11 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 5.20 Searchlight Chassis The Searchlight chassis includes the structural and electronic components inside the rear part of the Searchlight housing. It includes the reflector and all of the interior components between the reflector and the rear cover (Figure 43).
  • Page 12 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 5.21 Detailed Inspection with Chassis Removed DANGER! The arc lamp contains pressurized xenon gas at approximately 85 to 90 psi at room temperature and up to 370 psi at full operating temperature.
  • Page 13 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 5.21.1 Ground Wire Inspection The insulated ground wire is connected to the outer end of the lower left front spider leg (Figure 44). • Examine the connection point between the insulated ground wire and spider leg for signs of overheating, corrosion, and broken conductors.
  • Page 14 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 • Examine the light shield to verify the inside is coated with black paint. Also, verify a 1-inch area the lamp makes contact with is free of paint. 5.21.3 Starter Board Inspection The starter board assembly (Figure 45) serves as the mounting location for the electrical components that start the lamp, and it also serves as a structural support for the other interior components.
  • Page 15 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 Look for evidence of arcing, which appears in the form of carbon tracks. Once arcing has taken place, the components usually must be replaced to eliminate the carbon tracks. Routine cleaning can be conducted with oil-free compressed air and/or alcohol.
  • Page 16 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 • The holes in the bushings should maintain a close fit with the reflector rods, but there should be little friction. If the holes in the bushings become enlarged, the reflector will vibrate or shift off-center.
  • Page 17 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 5.21.5.1 T1 Transformer Mounting Feet Inspection The T1 (combined) transformer has mounting feet consisting of formed sheet metal (Figure 45). If these feet crack from vibration fatigue, the transformer core and windings can come loose inside the housing and cause substantial internal damage to the Searchlight.
  • Page 18 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 • Each wire has one or two crimped-on ring lugs. Examine these lugs and crimps for tightness, freedom from corrosion, and signs of heating generated by a bad connection. Repair or replace any poor crimps and lugs.
  • Page 19 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 • If the sockets are tarnished, they can be cleaned with an oil-free solvent such as alcohol. This also can be used to remove any residue left behind from cleaning the sockets with sandpaper or steel wool.
  • Page 20 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 • The operation of the reflector differed between the old and new rod configuration (and cam configuration). The old mechanism (in conjunction with the old focus cam) enabled the reflector to move only during half of the focus cam’s rotation.

  • Page 21: Safety Cables

    ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 Push the rear spider into place. The reflector and the rod assembly should move forward smoothly. As pressure is slowly released on the reflector, it should move to the rear in a smooth motion.
  • Page 22 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 • Lock wire Fillister screw and safety lanyard bolt per NASM 33540. Figure 50 Searchlight Safety Cable Figure 51 Searchlight Safety Cable Attached to Azimuth Gearbox Shaft Gearbox Safety Cable The Gearbox safety cable (Figure 52) connects the Azimuth Gearbox housing to the aircraft mounting bracket (or hard point) to retain the Gimbal to the aircraft in the event of failing mounting bolts or...

  • Page 23: System Wiring

    ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 Inspection All safety cables and lanyards should be inspected during each preflight inspection and every 3 months or 100 flight hours or 50 operational hours. •...
  • Page 24 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 • The exterior split Searchlight/Gimbal cable (this includes those cables that connect the Junction Box and Searchlight/Gimbal but do not have a break for a bulkhead connector, where they pass through the aircraft skin [that is, if there is only a single cable without a break];...
  • Page 25 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 Repairs and Cable Life 7.3.1 Change to 6 AWG Wire In February 2007, the following wiring change was made to all components of the Searchlight system: all 8 AWG wire was changed to 6 AWG wire.
  • Page 26 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 7.4.1.2 Repairs CAUTION! Heat source can cause a fire. If a repair to a cable jacket is made with heat-shrink tubing, some heat sources used to shrink tubing may start a fire inside the aircraft.
  • Page 27 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 7.4.1.3 Functional Tests WARNING! Xenon arc Searchlights produce a high-intensity light beam during operation. If the beam is directed into the eyes at close range, it can cause permanent eye damage in a fraction of a second.
  • Page 28 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 • If you have examined all connectors and found them to be cool or only warm, you may end the test. Restore the Searchlight to flight-worthy condition. Figure 53 Block Diagram of Typical Searchlight System Components and Cables Source: Spectrolab, Inc.

  • Page 29: Control Box

    ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 Figure 54 Diagram of Searchlight with Alternate Controls and Cables for Aftermarket Systems 8.0 CONTROL BOX The Searchlight responds to position commands from a handheld Control Box. The Control Box is versatile size so that it can be attached anywhere in the aircraft.