Raytheon Hawker

Nose Mounted HID Lights

Installation Instructions
LSM-500-060
Rev E
12-9-10

Model 1000

WARNING: This product may contain chemicals known to the State of

California to cause cancer and birth defects or other reproductive harm. For more
information, visit www.flywat.com/regulatory
 REVISION DESCRIPTION
Rev Date Description
IR 1. Initial release.
01-20-06
A 1. LSM-SCD-007-1 was LSM-500-314-3.
09-17-10 2. Revised ICA time intervals.
B 1. Revised LSM-500-378-5/-6 installation procedure to match drill three
09-24-10 holes.
2. Added option to run light housing harnesses up RH side of nose cone
using CB9120V5 Click Bond cable tie mounts.
3. Added CB9120V5 cable tie mounts qty 6.
4. Added CB92 adhesive kit qty 2.
C 1. Added LSM-500-377-3 Ballast Assy as alternate.
10-12-10 2. Revised weight and balance to add 60W ballast option.
3. Revised electrical load analysis to add 60W ballast option.
4. Added 60W ballast upgrade installation instructions and kit list.
5. Deleted option to run light housing harnesses up RH side of nose
cone.
6. Deleted CB9120V5 cable tie mounts qty 6 and CB92 adhesive kit qty
2.
D 1. LSM-500-379-3 & -4 were LSM-500-379-1 & -2 for 60W ballast
10-22-10 upgrade kit.
2. Added Figure 3 for 60W ballast upgrade instructions.
3. Weight and balance was Datum STA 7.25 feet.
E 1. Deleted -1 35W or 60W kit dash number.
12-9-10 2. Revised 60W upgrade kit dash number from -3 to -1.
 LSM-500-060 Rev E Page 2

BoomBeam HID

Thank you for your purchase of the BoomBeam HID kit. 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.

Nomenclature Part Number Vendor Quantity

Ballast to Power Wire LSM-SCD-007-1 Whelen Aerospace 2
Technologies
Ballast Assembly, LSM-500-377-1 Whelen Aerospace 1
35W Technologies
Ballast Assembly, LSM-500-377-3 Whelen Aerospace Alternate
60W Technologies
Plate Assembly, LH LSM-500-378-1 Whelen Aerospace 1
Technologies
Plate Assembly, RH LSM-500-378-2 Whelen Aerospace 1
Technologies
Light Housing Assy, LSM-500-379-1 Whelen Aerospace 1
LH Technologies
Light Housing Assy, LSM-500-379-2 Whelen Aerospace 1
RH Technologies
Bolt AN3-5A 4
Washer AN960-10 4
Clamp, Cable MS21919WDG6 2
Clamp, Cable MS21919WDG8 5
Cable Tie Wraps MS3367-1-9 8
Connectors M7928/5-4 4
Shrink Tube M23053/5-106-0 6 inches
-1 60W Ballast Upgrade Kit List
Nomenclature Part Number Vendor Quantity
Ballast to Power Wire LSM-SCD-007-1 Whelen Aerospace 2
Technologies
Ballast, 60W LSM-SCD-019-1 Whelen Aerospace 2
Technologies
Placard, LH LSM-100-298-12 Whelen Aerospace 1
Technologies
Placard, RH LSM-100-298-13 Whelen Aerospace 1
Technologies
Light Housing Assy, LSM-500-379-3 Whelen Aerospace 1
LH Technologies
Light Housing Assy, LSM-500-379-4 Whelen Aerospace 1
RH Technologies
Bolt AN3-34A 3
Washer AN960-10 15
Cable Tie Wraps MS3367-1-9 8
Connectors M7928/5-4 4
 LSM-500-060 Rev E Page 3

Shrink Tube M23053/5-106-0 6 inches

Spacer NAS43DD3-32FC 3
Spacer NAS43DD3-48FC 3
Spacer NAS43DD3-80N 3

Installation Instructions
1. Prior to light installation, ensure that Whelen Aerospace Technologies LSM-500-042 Wing
Mounted Taxi/Landing Light kit conforming to Revision H or later is installed. Jack aircraft
and level IAW the Aircraft Maintenance Manual. Disconnect the main batteries.

2. Using a pencil, outline the edges of the LH & RH light housing mount brackets where they
seat against the aft radome flange.

3. Remove existing stock nose lights and discard. Disconnect existing power and ground
wires from light housings and label (LH PWR/LH GND and RH PWR/RH GND). Remove
existing light mount brackets and discard. Retain bracket mount hardware for later use.

4. Remove cable clamps and attach hardware. Retain attach hardware for later use. Discard
clamps. Temporarily tie off wire harnesses for future use.

5. The LSM-500-377-1 or LSM-500-377-3 Ballast Assembly will be mounted on the forward

side of the static inverter mount brackets. See photos 1, 2 and 3. Remove the inverter
mounting hardware and discard. Remove the nutplates on the mount brackets and apply
alodine to the holes. Position the Ballast Assembly on the forward side of the mount
brackets and reattach the inverter to the mount brackets/Ballast Assembly using (4) AN3-
5A bolts and (4) AN960-10 washers from the aft side.
 LSM-500-060 Rev E Page 4

Photo #1 View Lkg Aft

Photo #2 View Lkg Aft at Inverter Mount Brackets

 LSM-500-060 Rev E Page 5

Photo #3 View Lkg Forward at Static Inverter

6. Install the LSM-500-378-1 LH Plate Assembly and LSM-500-378-2 RH Plate Assembly on

the radome flange using the existing attach hardware in the single hole. Position the plates
using the pencil lines and clamp. Transfer drill 3 each .194 diameter holes to the plates.
Countersink the aft facing plate surfaces 100 degrees x .360 diameter.

7. Attach the LSM-500-379-1 LH Light Housing Assembly to the LH Plate Assembly using the
provided hardware. Hand-tighten the hardware to allow for light aiming later. Attach the
LSM-500-379-2 RH Light Housing Assembly to the RH Plate Assembly using the same
procedures.

8. Route Ballast to Lamp/Starter Wires from LSM-500-379-1/-2 Housing Assys along previous
nose light wire bundle path and secure in place using (2) MS21919WDG6 cable clamps on
lower radome flange and (5) MS21919WDG8 cable clamps on LH radome flange. Secure
using existing clamp attach hardware. It is permissible to route the harnesses along the RH
radome flange. Install CB9120V5 cable tie mounts per the included instructions and secure
the harnesses using MS3367-1-9 cable ties.

9. Route Ballast to Lamp/Starter Wires to ballast connectors. Attach LSM-500-379-2 wire

connector to RH ballast connector. Attach LSM-500-379-1 wire connector to LH ballast
connector. Apply Dow Corning DC4 di-electric compound (or equivalent) to all connectors
prior to attaching. Secure both harnesses together and to existing wire harnesses and
cable clamps using MS3367-1-9 cable tie wraps per AC43-13.1B. See Figure 3 for wiring
diagram.

10. Attach two LSM-SCD-007-1 Ballast to Power Wire connectors to LH and RH ballast
connectors. Apply Dow Corning DC4 di-electric compound (or equivalent) to all connectors
prior to attaching. Identify existing aircraft LH light power and ground wires and cut to a
length suitable for splicing to the LH ballast power wire harness. Splice wires using
M7928/5-4 connectors and cover splice with M23053/5-106-0 shrink tubing. Repeat
process for RH light wire harness and RH ballast power wire harness. Secure both
harnesses together and to existing wire harnesses and cable clamps using MS3367-1-9
cable tie wraps per AC43-13.1B. See Figure 3 for wiring diagram.

11. Reconnect aircraft batteries. Perform functional test of nose lights by applying aircraft
power and cycling through switch positions.

12. Light Aiming Instructions:

Set up a target board using the “B” dimension in the AMM lamp adjustment instructions and
center along the centerline of the aircraft. Aim each light through the center of the radome
light cutout to achieve inboard/outboard aiming. Determine dimension “X” per the AMM.
For vertical light aiming, center the beams at X minus 8.5” for aircraft on jacks and X minus
12.5” for aircraft on ground. Tighten all mounting bracket adjustment hardware to 85 in-lbs.
These aiming instructions are intended as a starting point. It is permissible to adjust beam
aiming to account for individual pilot/operator preferences.

13. Fill out Form 337.

 LSM-500-060 Rev E Page 6

60W Ballast Upgrade Installation Instructions

1. Prior to light installation, ensure that Whelen Aerospace Technologies LSM-500-060 Nose
Taxi Light kit is installed. Jack aircraft and level IAW the Aircraft Maintenance Manual.
Disconnect the main batteries.

2. Disconnect all ballast connectors. Identify the aircraft power and ground leads connected
to the existing ballast power harnesses and remove the harnesses. Remove the existing
light housing harnesses back to the light housings. Retain all clamps and clamp mounting
hardware for later use. Remove the light housings. Retain the light housing mounting
hardware for later use.

3. Remove the ballast assembly from the aircraft. Retain the bracket mounting hardware.
Disassemble the ballasts and discard the hardware. Reassemble the LSM-SCD-019-1
ballasts per Figure 1. Reinstall the new ballast / bracket assembly using existing hardware.
 LSM-500-060 Rev E Page 7

4. Install the LSM-500-379-3 / -4 Light Housing assemblies using existing hardware as shown
in Figure 2. Route Ballast to Lamp/Starter Wires to ballast connectors. Attach LSM-500-
379-2 wire connector to RH ballast connector. Attach LSM-500-379-1 wire connector to LH
ballast connector. Apply Dow Corning DC4 di-electric compound (or equivalent) to all
connectors prior to attaching. Secure both harnesses together and to existing wire
 LSM-500-060 Rev E Page 8

harnesses and cable clamps using MS3367-1-9 cable tie wraps per AC43-13.1B. See
Figure 4 for wiring diagram.

5. Attach two LSM-SCD-007-1 Ballast to Power Wire connectors to LH and RH ballast

connectors. Apply Dow Corning DC4 di-electric compound (or equivalent) to all connectors
prior to attaching. Identify existing aircraft LH light power and ground wires and cut to a
length suitable for splicing to the LH ballast power wire harness. Splice wires using
M7928/5-4 connectors and cover splice with M23053/5-106-0 shrink tubing. Repeat
process for RH light wire harness and RH ballast power wire harness. Secure both
 LSM-500-060 Rev E Page 9

harnesses together and to existing wire harnesses and cable clamps using MS3367-1-9
cable tie wraps per AC43-13.1B. See Figure 4 for wiring diagram.

6. Reconnect aircraft batteries. Perform functional test of nose lights by applying aircraft
power and cycling through switch positions.

7. Light Aiming Instructions:

Set up a target board using the “B” dimension in the AMM lamp adjustment instructions and
center along the centerline of the aircraft. Aim each light through the center of the radome
light cutout to achieve inboard/outboard aiming. Determine dimension “X” per the AMM.
For vertical light aiming, center the beams at X minus 8.5” for aircraft on jacks and X minus
12.5” for aircraft on ground. Tighten all mounting bracket adjustment hardware to 85 in-lbs.
These aiming instructions are intended as a starting point. It is permissible to adjust beam
aiming to account for individual pilot/operator preferences.

8. Fill out Form 337.

LSM-500-060 Rev E Page 10
LSM-500-060 Rev E Page 11
 LSM-500-060 Rev E Page 12

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 BoomBeam HID is contained in Whelen

Aerospace Technologies Installation Manual Number LSM-500-060 (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 operators 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 inspection interval of the lesser of 900 hours (+40 hours) or one year
(+one month), inspect the mechanical and electrical integrity of the BoomBeam HID
equipment and components as follows:
• Physically inspect the ballast assembly mounting hardware.
• Visually inspect ballast electrical harnesses for frayed or damaged insulation,
broken wires or loose connectors.
• Visually inspect the landing and taxi light reflectors. Visually inspect the
mounting bracket and lamp/starter mounting hardware for structural integrity.
• Visually inspect the lamp/starter electrical harnesses for frayed or damaged
insulation, broken wires or loose connectors.

• During an inspection interval of the lesser of 1800 hours (+50 hours) or two years
(+2 months), inspect the mechanical and electrical integrity of the BoomBeam HID
equipment and components as follows:
• Physically inspect the ballast assembly mounting hardware.
• Physically inspect all electrical harnesses for frayed or damaged insulation,
broken wires or loose connectors.
• Physically inspect the landing and taxi light reflectors for damage. Physically
inspect the mounting bracket and lamp/starter mounting hardware.

• During subsequent inspection intervals of the lesser of 1800 hours (+50 hours) or
two years (+2 months) thereafter, inspect the mechanical and electrical integrity of
the BoomBeam HID equipment and components as follows:
• Physically inspect the ballast assembly mounting hardware.
 LSM-500-060 Rev E Page 13

• Physically inspect all electrical harnesses for frayed or damaged insulation,

broken wires or loose connectors.
• Physically inspect the landing and taxi light reflectors for damage. Physically
inspect the mounting bracket and lamp/starter mounting hardware.

Weight and Balance Information

35W Ballast Installation Option: Weight and balance change of +2.9 pounds at Datum STA
-23.75 feet.

60W Ballast Installation Option: Weight and balance change of +3.4 pounds at Datum STA
-23.75 feet.

Electrical Load Analysis

The existing nose light system installed in the nose cone of the aircraft includes two lights.
Each light is rated at 250 watts and draws a maximum of 8.9 amperes at 28 VDC. The
total current draw from both lights is 17.8 amperes. Steady state values will be lower, as
the lamps warm up.

The new BoomBeam installation replaces the two existing lights in the nose cone with a
ballast and lamp assembly. Each 35W ballast assembly draws a maximum of 4.1 amperes
at startup and then draws 1.65 amperes at steady state, after the lamps warm up. Each
60W 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.

The total current required to operate the BoomBeam Nose Taxi Lighting system is 13.0 to
14.5 amperes less than the existing system and therefore places no burden on the aircraft
generating and distribution system.