Nightsun® XP Searchlight System Kit and Procedure to Incorporate EASA AD 2010-0183 Prescribed Conformance,

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## Nightsun® XP Searchlight System
Kit and Procedure to Incorporate EASA AD

2010-0183 Conformance

SEE DOCUMENT ECR FOR APPROVAL SIGNATURESNightsun® XP Searchlight System Kit and Procedure to Incorporate EASA AD 2010-0183 Prescribed Conformance,

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Page 2 of 22 

### CHANGE RECORD

REV AUTHORIZATION CHANGE DESCRIPTION APPROVAL

NC SAUL VARGAS INITIAL RELEASE F. SANCHEZ 9/28/10Nightsun® XP Searchlight System Kit and Procedure to Incorporate EASA AD 2010-0183 Prescribed Conformance,

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Page 3 of 22 ITEM PART NUMBER QTY DESCRIPTION SOURCE

1 033873 REV. B, OR LATER 1 NUT, FLANGE 3⁄4-16UNF2B THREAD, WITH SAFETY WIRE HOLES SPECTROLAB

2 017603 1 NAME PLATE, (TO REIDENTIFY GIMBAL TO A 033295-3 OR -4 CONFIGURATION) SPECTROLAB

3 034377 AR MS35690-1230, MODIFIED 3⁄4”-16 HEX NUT (SAFETY WIRE HOLES). UNMODIFIED NUT EQUIVALENT TO MCMASTER-CARR 91845A175. SPECTROLAB

4 033732 1 OVERLAY, NAMEPLATE SPECTROLABNightsun® XP Searchlight System Kit and Procedure to Incorporate EASA AD 2010-0183 Prescribed Conformance,

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Page 4 of 22 The design change to the Nightsun® XP Searchlight S ystem incorporated by this kit introduces a seconda ry mechanical positive locking mechanism to the Spectr olab Nightsun® XP 033295 series of gimbals that prevents the gimbal azimuth top nut from loosening and allowing the center shaft from rotating out. B riefly, Loctite® 262 is applied to the nut which is torqued to 120-140 ft-lbs and followed by safety wire.

Once modified per this document, 034374, the Nights un® XP gimbals will be re-identified as either 0332 95-3 or 033295-4, white light and IFCO light, respective ly.

Note that a certain level of expertise in aeronauti cal work practices and knowledge is assumed of the personnel performing the work described below.

Procedural Steps to rework 033295 series gimbals is mandatory and in a timely manner as prescribed by
EASA and the TC/STC Holders.

Implementation of this procedure should be less the n three (3) man-hours.

Reference
1. Nightsun® XP Series Maintenance Manual, 033566-1



# ! Caution

Personnel working with ESD sensitive devices should wear

ESD safe garments.

Procedural Steps to rework 033295 series gimbals.

1. Remove the gimbal and searchlight system from aircr aft.

2. Separation of the gimbal from the searchlight is no t a requirement but instead is left up to each

installer based on their holding fixtures on hand. Refer to the Maintenance Manual for further

instructions.

3. Remove the applicable Dovetail from gimbal

Reference Figures 1 through 3 of the Appendix: Par Avion dovetails are on the Nightsun® XP IFCO

models, 033704 series, and Spectrolab dovetails are on the Nightsun® XP models (white light),

033338 series.Nightsun® XP Searchlight System Kit and Procedure to Incorporate EASA AD 2010-0183 Prescribed Conformance,

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Page 5 of 22 4. Referencing Figures 4 and 5, remove the top shroud, taking note of its position relative to the rest o f

the gimbal. This is done in order to be able to pr operly reposition the shroud and spooler harness

upon reassembly.

a. Remove all screws under the Aircraft Adapter (5/16 th and #10 screws) that attach the Shroud

to the gimbal.

b. Carefully unravel the spooler harness and set aside the gimbal, this harness will not be

disconnected from the gimbal.

5. Remove top nut

An impact wrench maybe used to remove this nut, see Figure 6.

This Kit contains the replacement nut.

a. Note that there are two versions of this nut corres ponding to two (2) different Upper

Adapters (commonly referred to as Dovetail Adapter) :

i. 033293 dovetail adapter (1/4”-20):

1. 3⁄4-16 Hex Nut is to be replaced with a 3⁄4-16 hex nut that has two (2) safety

wire through holes. Item 3 of the Parts List, 0343 77.

ii. 033673 dovetail adapter (5/16”-24):

1. The 033873 Rev. B, or later, Flange Nut has two (2) safety wire through

holes. Item 1 of the Parts List, 033873.

6. Remove and save the washer shims, if any, located b eneath the top nut (applicable to units equipped

with the 1⁄4-20, 033293, dovetail adapter only). The se washer shims must be reinstalled when the

azimuth gearbox is ready to be reassembled.

7. Remove the Dovetail Adapter and Round-off corner ed ge of inner legs (four places)

a. Use a file, grinder, etc. to break edge of legs, se e Figure 7 of the Appendix. The purpose is

to provide a rounded surface for the safety wire to contour around.

8. Reinstall the Dovetail Adapter

a. Reinstall the washer shims previously removed (1/4- 20, 033293 dovetail adapters only).

b. Reinstall nut to hold the dovetail adapter onto the shaft.

c. Apply Loctite® 262 and torque to 120-140 Ft-lbs.

d. Install safety wire per standard practice, referenc e pictures 9 and 10 below.Nightsun® XP Searchlight System Kit and Procedure to Incorporate EASA AD 2010-0183 Prescribed Conformance,

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Page 6 of 22 e. CAUTION, when installing the safety wire, make sure to terminate the wire end away from

any electrical connection and along the inner edge of the Dovetail Adapter legs (corner edge

rounded off above).

9. Reinstall the shroud and spooler harness.

a. Rewind the spooler harness and place it over the gi mbal in the same orientation as noted

when removed.

b. Test/verify proper alignment and winding direction of the spooler harness.

i. Reference Figures 11 through 16 of the Appendix.

ii. Rotate shroud in one direction and then in the othe r direction. The spooler is

installed correctly if the shroud freely travels ap proximately 170 degrees in both

directions. If not, remove shroud to verify that t he shroud was wound in the correct

direction and that the windings are correct, repeat step 9.a.

10. Reinstall dovetail and apply a sealing bead of RTV 103 around the perimeter of the dovetail to the

shroud. Safety-wire, loop
end on short side of Dovetail adapter leg,
as shownNightsun® XP Searchlight System Kit and Procedure to Incorporate EASA AD 2010-0183 Prescribed Conformance,

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Page 7 of 22 11. Verify proper operation of the gimbal/searchlight s ystem per standard practice.

12. Reinstall the Gimbal/Searchlight System on to the a ircraft and verify proper operation per standard

practice.

13. Remove existing overlay and label for the gimbal, 0 33295-X series, and replace with new nameplate

and overlay identifying the gimbal as either 033295 -3 or 033295-4.

a. Peel off the overlay and nameplate

b. Clean area with Isopropyl Alcohol (IPA)

c. Apply the new Nameplate and overlay to the gimbal i n the same vicinity as the previously

removed. Apply the overlay symmetrically over the Nameplate.Nightsun® XP Searchlight System Kit and Procedure to Incorporate EASA AD 2010-0183 Prescribed Conformance,

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Page 8 of 22 

## Appendix: Photos of Process Steps

Figure 1: Aircraft Adapter (dovetail)Nightsun® XP Searchlight System Kit and Procedure to Incorporate EASA AD 2010-0183 Prescribed Conformance,

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Page 9 of 22 Figure 2: Loosening of Aircraft Adapter

Figure 3: Removal of Aircraft Adapter from Gimbal ( Dovetail)Nightsun® XP Searchlight System Kit and Procedure to Incorporate EASA AD 2010-0183 Prescribed Conformance,

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Page 10 of 22 Figure 4: Lift Shroud from GimbalNightsun® XP Searchlight System Kit and Procedure to Incorporate EASA AD 2010-0183 Prescribed Conformance,

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Page 11 of 22 Figure 5: Note Winding Orientation of Spooler Harne ss

Figure 6: Remove Nut Holding AdapterNightsun® XP Searchlight System Kit and Procedure to Incorporate EASA AD 2010-0183 Prescribed Conformance,

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Page 12 of 22 Figure 7: Break EdgesNightsun® XP Searchlight System Kit and Procedure to Incorporate EASA AD 2010-0183 Prescribed Conformance,

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Page 13 of 22 Figure 8: Two Styles of Nuts with Safety Wire Holes

Figure 9: Flange Nut with Loctite® 262, Torque and Safety WiredNightsun® XP Searchlight System Kit and Procedure to Incorporate EASA AD 2010-0183 Prescribed Conformance,

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Page 14 of 22Nightsun® XP Searchlight System Kit and Procedure to Incorporate EASA AD 2010-0183 Prescribed Conformance,

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Page 15 of 22 Figure 10: 033292 Adapter with 3⁄4-16UNF-2B nut and s afety wireNightsun® XP Searchlight System Kit and Procedure to Incorporate EASA AD 2010-0183 Prescribed Conformance,

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Page 16 of 22 Figure 11: Re-align Spooler Harness

Figure 12: Placing Gimbal Shroud on Chassis ELECTRICAL SIDE CONNECTOR INTERFACE BOXNightsun® XP Searchlight System Kit and Procedure to Incorporate EASA AD 2010-0183 Prescribed Conformance,

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Page 17 of 22 Figure 13: Positioning Gimbal ShroudNightsun® XP Searchlight System Kit and Procedure to Incorporate EASA AD 2010-0183 Prescribed Conformance,

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Page 18 of 22 • Figure 14: Rotate Gimbal shroud clockwise to veri fy the spooler harness has enough travel without damaging connection terminati ons. The limit of rotation will be approached as the spooler harness gets tighter. The shroud should be able to reach the position illustrated wi th the dashed line after rotating through the external connector(s) housing.Nightsun® XP Searchlight System Kit and Procedure to Incorporate EASA AD 2010-0183 Prescribed Conformance,

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Page 19 of 22 • Figure 15: Rotate the Gimbal shroud counter-clock wise to verify the spooler harness has enough travel without damaging connecti on terminations.

• Figure 16: Rotate the Gimbal shroud back to cente r position so the Gimbal is in the bore sight looking position. Align the s hroud holes with the threaded #8 screw holes and fasten the shroud using the #8 s crews.Nightsun® XP Searchlight System Kit and Procedure to Incorporate EASA AD 2010-0183 Prescribed Conformance,

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Page 20 of 22Nightsun® XP Searchlight System Kit and Procedure to Incorporate EASA AD 2010-0183 Prescribed Conformance,

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Page 21 of 22 Figure 17: Installation of Shroud onto Gimbal and V erification of Proper TravelNightsun® XP Searchlight System Kit and Procedure to Incorporate EASA AD 2010-0183 Prescribed Conformance,

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Page 22 of 22 Figure 18: Reinstall Dovetail; screws attaching shr oud to gimbal and the Dovetail using the 5/16-24 sc rews