Boeing Spectrolab SX-16 Nightsun Maintenance Manual
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Boeing Spectrolab SX-16 Nightsun Maintenance Manual

Boeing Spectrolab SX-16 Nightsun Maintenance Manual

Searchlight system
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Document 031734-1/Revision A
1.0 OVERVIEW OF THE SX-16 NIGHTSUN
1.1

Description and Features

The SX-16 Nightsun
this point forward in the manual) is a versatile, mobile, high-intensity light source. It can be mounted
on fixed wing aircraft, helicopters, and water craft. When properly installed and operated, it can flood
an area with light from a safe distance.
•
The Searchlight uses an air cooled, high-intensity xenon arc lamp. It emits light that is the
same color as daylight, starts rapidly, and can be operated continuously or started and
stopped to meet operational requirements.
•
The Gimbal assembly that supports the Searchlight enables users to aim the Searchlight
beam at various positions with respect to Azimuth (horizontal directions) andElevation
(vertical directions).
•
The SX-16 Nightsun
1.2
About This Manual
This manual provides the following information: (1) information to help you to set up the SX-16
®
Nightsun
components and (2) information to help you maintain and troubleshoot the SX-16
®
Nightsun
. A separate manual provides information about operation.
1.3
Read, Obey, and Keep Instructions
To ensure the safety of people and equipment, it is important to read and obey all instructions and
safety warnings contained in this document and posted on the equipment before you attempt to
operate, maintain, or troubleshoot the SX-16 Nightsun
1.4
Applicable Documents
032431, SX-16 QUICK CONNECT CABLING DIAGRAM
032436, SX-16 QUICK CONNECT SYSTEM SCHEMATIC
032427, STANDARD SX-16 SEARCHLIGHT AND GIMBAL SYSTEM ENVELOPE DRAWING
032428, LONGER ARM SX-16 SEARCHLIGHT AND GIMBAL SYSTEM ENVELOPE DRAWING
032429, IFCO SX-16 SEARCHLIGHT AND GIMBAL SYSTEM ENVELOPE DRAWING
034187, SX-16 IFCO QUICK CONNECT CABLING DIAGRAM
032436, SX-16 QUICK CONNECT SYSTEM SCHEMATIC
033899, IFCO SPECTROLINK SX-16 QUICK CONNECT SYSTEM SCHEMATIC
034030, IFCO SPECTROLINK SX-16 SEARCHLIGHT AND GIMBAL SYSTEM ENVELOPE
DRAWING
033584, SX-16 IFCO SPECTROLINK QUICK CONNECT CABLING DIAGRAM
032222, STANDARD HARD WIRED SX-16 SEARCHLIGHT AND GIMBAL SYSTEM ENVELOPE
DRAWING
020720, HARD WIRED SX-16 SYSTEM SCHEMATIC
031661, HARD WIRED SX-16 CABLING DIAGRAM
034029, SPECTROLINK SX-16 SEARCHLIGHT AND GIMBAL SYSTEM ENVELOPE DRAWING
032229, HARD WIRED IFCO SX-16 SEARCHLIGHT AND GIMBAL SYSTEM ENVELOPE
DRAWING
Source: Spectrolab, Inc.
The document reference is online, please check the correspondence between the online documentation and the printed version.
®
Searchlight System (called the SX-16 Nightsun
®
responds to directional commands from a hand operated Control Box.
®
SX-16 Nightsun
Maintenance Manual
031734-1 Revision B
®
®
or simply the Searchlight from
®
. Keep this document for reference.
1
Searchlight System
January 27, 2014

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Summary of Contents for Boeing Spectrolab SX-16 Nightsun

  • Page 1 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 ® 1.0 OVERVIEW OF THE SX-16 NIGHTSUN Description and Features ® ® The SX-16 Nightsun Searchlight System (called the SX-16 Nightsun or simply the Searchlight from this point forward in the manual) is a versatile, mobile, high-intensity light source.
  • Page 2 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 2.0 SAFETY Product Safety ® SX-16 Nightsun poses the following hazards that can cause fatal or serious personal injury or damage to nearby property, including the aircraft: •...
  • Page 3 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 • During preflight tests on the ground, make sure that the beam is directed away from nearby people and flammable materials. Make sure to tell people not to look at or to walk through the Searchlight beam.
  • Page 4 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 Figure 1 Gimbal ® The SX-16 Nightsun has electrostatic sensitive devices (ESD). Observe precautions for handling ESD components. • When maintaining exposed electrical components, never work alone. •...
  • Page 5 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 Safety Messages Used in this Manual This manual contains important safety messages that are identifiable by their appearance. These safety messages identify hazards and contain information to help you avoid personal injury, and property damage to the Searchlight, aircraft, or other property.
  • Page 6 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 Guidelines for the Installer 3.2.1 General Guidelines ® Spectrolab does not install the SX-16 Nightsun . It is the responsibility of system installers to ensure the integrity and safety of the installation, configuration, and integration with the aircraft/structure.
  • Page 7 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 components, the connectors on each component (J1 on the Junction Box for example), and the cables attached to each connector. ® Figure 2 Overview of SX-16 Nightsun Connections Overview of Cabling ®...
  • Page 8 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 Connect one end of the bulkhead to Gimbal cable to the bulkhead through connector. On the other end, connect the Gimbal portion of the cable to the 4 pin connector on the Gimbal.
  • Page 9 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 4.2.2 Enhanced Gimbal Assembly Description The Enhanced (Unibody) Gimbal (Figure 4) is constructed with high-strength Aluminum Alloy and does provide an unrestricted service life limit as with the other configurations. The Enhanced Gimbal integrates reinforcement features such as a one-piece arm, ribbed bends and a flared design to provide structural integrity.
  • Page 10 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 Figure 5 Example of Enhanced Gimbal with Elevation Stop Blocks Installed for White Light (WHT LT) Configuration Standard (Older, Pre-August 2004) The older standard configuration (Figure 6) has adjustable Azimuth horizontal Roll Pins that are pressed into radiating holes on the bottom of the Gearbox.
  • Page 11 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 A light-weight Aluminum version for slow speed aircraft (up to 168 knots) has a maximum service life of 7 years. • A heavier, high-strength Steel version for high-speed aircraft (up to 271 knots) and has a maximum service life of 10 years •...
  • Page 12 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 • On the non-drive side of the Gimbal Arm, the threaded portion of the Wing Bolt projecting outward from the spacer and arm bearing can be viewed. This portion of the Wing Bolt screws into one of the Searchlight’s mounting bosses and extends through the Arm Bearing.
  • Page 13 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 4.5.2 Inspection Procedure 4.5.2.1 Standard Connector The Spectrolab Gimbal has a circular 4-pin quick-release standard connector that supplies power to the Gimbal motors (the Searchlight has its own connector). The connector is mounted on an aluminum bracket that screws into the Azimuth Gearbox housing with four mounting screws (Figure •...
  • Page 14 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 4.5.4 Cable Ties The motor wires are cut at the factory so that they are long enough to allow a full range of Gimbal motion.
  • Page 15 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 Standard Elevation Stop (018569-1) IFCO Elevation Stop (030535 Rev D and previous) IFCO Elevation Stop (030535 Rev E and later) Figure 9 Various Elevation Stops 4.6.1.1 Replace an Searchlight Elevation Stop Required Tools and Supplies (Not provided by Spectrolab):...
  • Page 16 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 022955-22 019059-111 022955-51 Required Tools and Supplies: Locking Pliers Wrench Hex Hex Wrench Loctite 272 • Remove the Searchlight from the Gimbal Assembly. • With Locking Pliers, compress the Roll Pin then remove by twisting and pulling away from the Gimbal Arm at the same time (Figure 11).
  • Page 17 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 • Stationary precision shoulder bolt that is mounted on the Gimbal arm. Each ¼”-20 precision shoulder bolt should be torque to 78 ±2 inch-pounds. •...
  • Page 18 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 • First try to wiggle the Roll Pin with needle nose pliers. It should have a tight fit in its hole and should be very stiff. •...
  • Page 19 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 A fresh hole can be used on the same adapter ring by rotating it 90, 180, or 270° such that a fresh hole is in the desired location. The ideal solution, however, is to replace the adapter ring.
  • Page 20 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 4.8.1 Standard Gimbal Arm Inspection Need and Schedule The paint or powder-coat finish protects the surface and interior sections of the Gimbal arms from corrosive salt spray or other atmospheric corrosives.
  • Page 21 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 If the Gimbal has not exceeded its service life (Inspection Need and Schedule) If a Gimbal arm is returned to service, follow the installation instructions in the Gimbal Arm Installation Procedure section of this manual WARNING! Cracks or loose rivets in Gimbal arm can cause...
  • Page 22 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 4.9.3 Preparation for Painting After removing any corrosion: • Sand the area lightly with medium grit sandpaper (120 or 220 grit), then wipe the area clean of sanding residue.
  • Page 23 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 Examine the condition of the motor wires and the rubber boots. If the insulation on the wires is cracked or appears to be near the end of its useful service life, replace it. Similarly, the boots should be soft and pliable.
  • Page 24 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 4.13 Gimbal Arm Installation Procedure for Gimbals with Current Azimuth Stop Configuration This procedure applies to the current Azimuth stop configuration, which was introduced in August 2004 on a new (replacement) Gimbal arm: •...
  • Page 25 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 Stake the bearings in place using a center punch to deform the metal at the outer edge of the bearing to retain the bearing. Stake each spacer in four places.
  • Page 26 ® SX-16 Nightsun Searchlight System Maintenance Manual Document 031734-1/Revision A 031734-1 Revision B January 27, 2014 moisture damage or old age. These motors should not be repaired. They should be inspected according to the following schedule: • Daily inspection: Verify motor function Visually inspect the rubber motor boots and wiring •...

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