Perko 9304 User manual

XR Series
500 WATT MARINE SEARCHLIGHT
Model 9304
Operator’s/Maintenance Manual
(Covers Standard 110 VAC and
Optional 220 VAC Power Supplies)
Manufactured By
We Make it Right, Right Here!!
Miami, FL
9/08
9304-PTD-51F

OPERATOR’S MANUAL
WITH
MAINTENANCE SUPPLEMENT
FOR
MODEL 9304
XR Series 500 WATT MARINE SEARCHLIGHT
(Covers Standard 110 VAC and
Optional 220 VAC Power Supplies)
© COPYRIGHT 1999-2008
BY PERKO, INC.
ALL RIGHTS RESERVED. THIS BOOK OR PARTS THEREOF, MAY NOT BE
REPRODUCED IN ANY FORM WITHOUT PERMISSION OF PERKO, INC.
3

TABLE OF CONTENTS
CHAPTER I INTRODUCTION PAGE
1-1 General 6
1-2 Description 6
CHAPTER II- INSTALLATION
2-1 General 10
2-2 Unpacking 10
2-3 Installation 10
2-4 Post Installation and Checkout 13
CHAPTER III INSTALLATION AND OPERATIONAL CHECKOUT
3-1 Preoperational Checks 15
3-2 Lamp Ignition 15
3-3 Manual-Beam Focus Adjustment 15
CHAPTER IV OPERATING PROCEDURES
4-1 General 17
4-2 Lamp Ignition 17
4-3 Main Operation 17
4-4 Turn-Off 17
CHAPTER V OPERATOR MAINTENANCE
5-1 General 18
5-2 Inspection 18
5-3 Cleaning 18
5-4 Lubrication 18
5-5 Testing 18
5-6 Xenon Lamp Removal 19
5-7 Xenon Lamp Installation 19
CHAPTER VI MAINTENANCE
6-1 General 21
6-2 Detailed Functional Description (110 VAC) 21
6-3 Detailed Functional Description (220 VAC) 22
CHAPTER VII WARRANTY & REGISTRATION
7-1 Warranty Policy 27
7-2 Instructions for Installing Xenon Lamps 28
7-3 18 Month Limited Warranty 31
7-4 Lamp Failure Report 32
7-5 Warranty Registration 33
7-6 Purchase Notification 34
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APPENDIX A
7-1 Optional Heater Package Installation Guide 35
LIST OF ILLUSTRATIONS
2-1 500 Watt Marine Searchlight 14
Interconnect Diagram
9304-1-A 500 Watt Marine Searchlight
Outline Drawing Foldout
9304-2-B 500 Watt Marine Searchlight Foldout
Power Supply Exploded View
9304-3-A 500 Watt Marine Searchlight Foldout
Power Supply Outline Drawing
9304-4-A 500 Watt Marine Searchlight Foldout
Yoke & Base Drawing
9304-5-B 500 Watt Marine Searchlight with 110 VAC Power Supply Foldout
Schematic Drawing
9304-6-B 500 Watt Marine Searchlight with 220 VAC Power Supply Foldout
Schematic Drawing
9304-7-B 500 Watt Marine Searchlight with 220 VAC Power Supply Foldout
Schematic Drawing
LIST OF TABLES
6-1 500 Watt Marine Searchlight Parts List 25
5

500 WATT MARINE SEARCHLIGHT
CHAPTER I
1-1 GENERAL. This manual contains descriptive theory, installation procedures and maintenance
instructions for the XR Series 500 Watt Marine Searchlight, Model 9304, which will hereinafter be referred
to as the 500 Watt Searchlight (figure 1-1).
NOTE
All service and/or installation work on Xenon Searchlights
should be preformed by a Qualified Marine Electrician!!
1-2 DESCRIPTION.The 500 Watt searchlight is comprised of a head assembly, a yoke and base
assembly, a Power Supply unit, a remote control panel, a remote ammeter, and either manual or electric
directional controls.
The head assembly housing, the yoke arms and the base are made of aluminum. All components of the
searchlight which are exposed to the weather are painted with epoxy paint. White is the standard color.
The head assembly is supported at its approximate center of gravity by two stainless steel shoulder bolts
extending through holes with bushings in the yoke arms. These bolts engage threaded holes in bosses on
each side of the housing.
The yoke arms are attached to the yoke support plate. The yoke support plate rotates around the spindle
of the base plate on two tapered bearings. A sliding stop plate, located around the base of the rotating
cover allows approximately 380 degrees of azimuth rotation of the searchlight (approximately 190 degrees
either side of dead ahead). The stop is necessary to prevent the electrical cable in the bottom of the head
assembly housing from being severely stressed by wrapping around the yoke. The yoke support plate is
retained on the base by a nut at the top of the spindle. A rubber boot is provided around the base of the
yoke support plate for weather protection. The base is fastened to the ship’s structure with four bolts
through four holes provided in the base plate.
The major components of the 500 Watt Searchlight are described
individually as follows:
6
Yoke & Base
Searchlight Head
Optical Assembly
Power Supply
Remote Ammeter
Control Panel

a. Head Assembly. The head assembly is comprised of the head, to which is fastened the front window
assembly, rear cover and the rack assembly.
The front window assembly contains a tempered clear glass sealed into a machined aluminum frame with
a rubber gasket. The window assembly is joined to the housing with a floating hinge along the lower edge
of the housing. When closed, the window assembly and a gasket is held tight against the front flange face
of the housing by three over-center clamps. A moisture proof and air tight seal is effected by the clamps.
The rear cover is attached to the housing in the same manner as the front window assembly. A gasket
seal also is provided in the rear cover.
The electrical cable passes through a water tight feed-thru in the searchlight housing wall.
The gasket in the front window assembly and the rear cover, together with the watertight feed-thru for the
electrical cable, provide an effective moisture proof, air tight seal so that the entire housing, when closed,
is protected against the intrusion of water and air.
The support assembly is fastened to the housing with four radial bolts extending inward through the hous-
ing wall and engaging threaded holes in the mounting plate. The support assembly contains the reflector,
blower motor, the lamp and the necessary high voltage electrical components to initiate lamp ignition.
The gear rack assembly attaches to two angle brackets which in turn are fastened to two mounting boss-
es attached to the bottom of the searchlight housing. This mounting arrangement provides for sufficient
positive adjustment of the gear rack so that it can be properly aligned and meshed with the mounting spur
gear which gives the head vertical movement.
b. Yoke and Base Assembly.The yoke and base assembly is comprised of two yoke arms bolted to a
yoke support plate and a base plate having a central spindle. The yoke support plate rotates on two
tapered roller bearings mounted on the base plate spindle. These bearings require lubrication. A different
bearing housing
is centrally positioned on top of the rotating cover and fastened by two machine bolts. The mechanical
directional controls fit into this housing such that the outer tube (azimuth directional control) is clamped to
this housing by a special clamp.
The inner rod (elevation directional control) extends through this housing such that the end of the rod
extends approximately one inch above the center of the gear rack on the bottom of the searchlight hous-
ing. An oil seal located in the bearing housing surrounds the inner rod as it passes through the bearing
housing to prevent water from leaking into the pilot house. A pinion gear fastened to the end of the inner
rod meshes with the gear rack to provide vertical motion of the searchlight head (See Mechanical
Directional Controls).
c. Power Supply.
WARNING
The following equipment contains voltages and current which are hazardous to
human life. Extreme caution must be exercised when performing tests required while power is on.
The XR Series Power Supply, PERKO # 9511-000-110 operates on 120 VAC, 60 Hz. (Standard)
The XR Series Power Supply, PERKO # 9511-000-220 operates on 220VAC, Single Phase 60 Hz.
(Optional)
The Power Supply will accommodate input voltage variations from approximately 115 to 130 VAC or 215
to 250 VAC respectively from the ship’s power generators.
7

CAUTION
XR Series power supplies are factory wired for a specific input voltage. Do not connect the ship’s power
to the Power Supply until a qualified technician determines that the ship’s voltage to
be connected to the Power Supply is the same as that for which the Power Supply can
accommodate. It may be necessary to reposition transformer jumpers at the time of
installation to match the Power Supply with the ship’s voltage.
The function of the Power Supply is to convert the ship’s alternating current to direct current required by
the xenon lamp for proper operation. The lamp requires approximately 20 volts at approximately 20 to 25
amperes DC. The Power Supply also provides power to the high voltage and boost circuits necessary to
ignite the xenon lamp and to sustain its operation.
The Power Supply is a 20 VDC, 25 amp Power Supply operated on appropriate ship’s power. The Power
Supply is mounted in a cabinet suitable for bulkhead mounting and with ample access space for cable
connections. The standard (110 VAC) and optional (220 VAC) power supplies cannot be field adjusted to
subsitute for each other and must be operated at their intended ship’s supply voltage.
d. Controls. There are two control systems which perform different functions. The electrical control sys-
tem controls the power to the searchlight while the mechanical directional control system controls the
azimuth (horizontal) and elevation (vertical) movement of the searchlight head. These systems are
described as follows:
(1) Electrical Controls. Remote Control Panel STANDBY/ON/IGNITE Switch (Figure 2-1) - the
“STANDBY” position removes power from the lamp circuit. This is essentially an “OFF” position. The “ON”
position energizes the ignition circuit and automatically starts the lamp operation. In addition, the “ON”
position maintains power to the lamp so that operation is sustained. If this position fails to start the lamp,
position the switch to the “IGNITE” position until the lamp is observed to be operating and then release
pressure on the spring-loaded switch. The remote ammeter will also indicate the lamp is operating by
showing 20 - 25 amperes of current flow. To turn the lamp “OFF”, position switch into the “STANDBY”
position.
NOTE
Should the lamp fail to ignite in the “ON” (or “IGNITE” positions after approximately ten seconds)
or
should it fail to sustain operation after initial ignition, the lamp may be faulty.
Beam Focus Switch - This switch applies power to an electric motor which drives the focus mechanism.
Holding the BEAM switch engaged continuously will cycle the focus mechanism continuously from the
compact mode to the spread mode. The BEAM switch should be held in position until the desired beam
pattern is obtained. Small adjustments may be obtained by momentarily engaging the beam focus switch.
NOTE
The beam pattern size may be changed (within limits) independent of the focus mechanism
by making an adjustment within the searchlight head. This adjustment should be made
ONLY by qualified and trained service personnel. Refer to paragraph 3-3.
A green power indicator light is provided on the control panel to indicate that power is applied to the elec-
trical system.
8

A remote ammeter is provided with the Power Supply. This instrument should be located in the pilot house
at a convenient location so that the pilot on watch can monitor the current being supplied to the lamp. A
current indication which falls within the 20 to 25 ampere range is satisfactory. Should the current indication
fall outside this range.
(2) Mechanical Controls. The mechanical controls provide the azimuth (horizontal) and elevation
(vertical) movement to the searchlight head. These controls are comprised of a handle assembly located
in the pilot house, a hollow tube and solid shaft, both of which extend from the handle assembly upward
through the pilot house ceiling to the base of the searchlight. The hollow tube is clamped to a bearing
housing fastened to the rotating yoke and base assembly. The lower end of this tube is clamped to the
handle assembly. Moving the handle in a horizontal plane moves the searchlight head horizontally. The
solid shaft is located inside the hollow tube. The lower end of this shaft is fastened to a miter gear such
that when the control handle is twisted, the solid shaft rotates within the tube. The upper end of the solid
shaft extends through the bearing housing previously mentioned and to a point approximately one inch
above the gear rack fastened to the bottom of the searchlight head housing. A fiber or nylon spur gear is
fastened to the upper end of the solid shaft, and this gear engages the gear rack. Twisting the control han-
dle provides rotary motion to the spur gear which causes the gear rack to move, thus imparting vertical
rotational movement to the searchlight head.
A ceiling mount is provided to cover the rough opening made in the ceiling to allow the shaft and tube to
pass through. This mount has a friction screw clamp to prevent the light from swinging freely in azimuth or
to lock it in a desired position.
This mechanical directional control assembly (known also optional as a lever gear control) is supported
from the rotating yoke and base assembly. Provision is made to allow additional support by the installation
of a solid rod and base plate extending from the bottom of the handle assembly to the pilot house control
console.
9

CHAPTER II
INSTALLATION
2-1 GENERAL. The following paragraphs contain instructions for unpacking, installing and perform-
ing post installation inspection and checkout of the 500 Watt Searchlight.
2-2 UNPACKING.The searchlight components are packaged according to best commercial practice.
Care should be exercised when unpacking to prevent damage to any of the searchlight components.
Packages should be examined prior to opening for evidence of possible damage in shipment. Any ship-
ping damage should be reported to the freight carrier or its representative. Immediately upon unpacking,
check the contents of the shipping containers against the packing list. Make sure components are not dis-
carded with the packing material. Report any shortages directly to PERKO, Inc.
WARNING
A spare xenon lamp may be shipped with a searchlight. It is not necessary to open this
lamp package. Xenon lamps contain xenon gas under pressure in a quartz tube and,
if mishandled, may explode.
WARNING
The searchlight head and the Power Supply should each be handled by two or more
persons because of the weight and/or bulk of these two components.
2-3 INSTALLATION.
a. Preliminary
Remove the Yoke and Base and Mechanical Control components from their shipping containers and
inspect for damage. If undamaged, place the Yoke and Base, Mechanical Control elevation rod, and
Mechanical Control azimuth tube near the customer-provided (1/2" X 21" dia.) support plate with mounting
studs. Place the remaining Mechanical Control components near the operator's station.
b. Mechanical Installation
WARNING
DO NOT FASTEN the Yoke and Base to the Support Plate until an adequate layer of
moisture sealant has been applied between the base plate and support plate.
(1). At the support plate (ON the Roof), place the Yoke and Base on the support plate, aligning the
four holes in the searchlight base with the studs in the mounting plate such that the Yoke rotates from for-
ward to aft in either port or starboard directions approximately 190 degrees. The rotational stop should be
felt with the Yoke pointed in the 190 degree aft position. Remove the Yoke and Base from the support
plate and apply an adequate layer of moisture sealant. Replace the Yoke and Base on the support plate
and fasten it using four customer-provided nuts with locking washers (or bolts).
(2). Remove the shaft housing from the Yoke and Base by removing the 5/16" mounting bolts.
(3). Align, insert and lower the azimuth tube through the 1.5" diameter hole taking care that it does
not fall through the ceiling above the operator's station.
(4). Support the azimuth tube to prevent it from falling, while placing the shaft housing over the end
of the azimuth tube, and fasten the housing to the tube using the shaft housing clamps provided (see
Detail, Drawing 9304-1).
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(5). Gently lower the azimuth tube through the roof until it is supported on the Yoke and Base by the
shaft housing. Re-install the two 5/16" bolts and fasten the shaft housing to the Yoke and Base.
(6). At the operator's station, determine the desired height for the Mechanical Control. Determine
how long the azimuth tube should be and cut to desired length using a metal hacksaw. Deburr the cut
end of the azimuth tube using a file or coarse emery cloth and slide the ceiling mount over the tube and
upward toward the ceiling. Temporarily tighten the friction clamp knob (if installed).
(7). At the Yoke and Base, lightly lubricate the elevation rod with 30W non-detergent oil, align and
insert the end of the elevation rod with the cross-drilled hole into the shaft housing, and carefully feed the
rod through the oil seal and azimuth tube down through the roof.
(8). At the operator's station, position the elevation rod into the shaft seat of the Mechanical Control
handle assembly and install the roll pin (1/8” X 5/8") provided. "Squeeze" force rather than "hammer"
force is preferable (see Detail, Drawing 9304-1).
(9). Gently push the pinned elevation rod and Mechanical Control handle assembly upward until the
azimuth tube seat properly engages the azimuth tube. Clamp the Mechanical Control handle assembly to
the azimuth tube (see Detail, Drawing 9304-1).
(10). At the Yoke and Base, use a hacksaw and cut off the protruding elevation rod leaving approxi-
mately 3.0" of elevation rod exposed above the top of the shaft housing. Deburr this cut.
(11). Install the spur gear provided on the elevation rod with the gear hub down. DO NOT install the
roll pin at this time.
(12). At the operator's station, TEST and verify that the Yoke and Base rotates smoothly when the
Mechanical Control handle assembly is rotated and that the spur gear/elevation rod rotates freely when
the Mechanical Control handle assembly grip is twisted.
Remove the Searchlight Head components from their shipping containers and inspect for damage. If
undamaged, place these components near the installed Yoke and Base.
(13). At the Yoke and Base, install the bushings provided into the trunnion holes of the arms of the
Yoke and Base. Place the shoulder bolts (3/4-10 X 2.5") into the bushings in preparation for engaging the
Searchlight Head bosses (see Detail, Drawing 9304-1).
(14). Lift the Searchlight Head into position between the arms of the Yoke and Base (window facing
forward), install the optional washers if desired between the Searchlight Head bosses and the arms of the
Yoke and Base, and engage/tighten the mounting bolts such that the Searchlight Head swings smoothly in
the trunnions.
(15). Tilt the Searchlight Head (window up) and install the rack support and rack assembly to the bot-
tom of the Searchlight Head as shown in Drawing 9304-1. Tighten (finger-tight) rack mounting hardware
to allow for final positioning when the rack engages the spur gear.
(16). Tilt the Searchlight Head to engage the spur gear with the rack assembly and adjust the rack
support and spur gear height until the spur gear teeth mesh smoothly and fully with the rack assembly
teeth for all rack positions. Tighten the rack support mounting hardware.
(17). Hold the spur gear at the correct height, drill a 1/8" hole in the elevation rod using the cross-
drilled spur gear hub hole as a pilot, and insert the roll pin (1/8” X 1") provided. "Squeeze" force rather
than "hammer" force is preferable when installing the pin (see Detail, Drawing 9304-1).
11

(18). Readjust the position of the rack assembly so that the Searchlight Head elevation is smoothly
and positively controlled (no binding with minimum backlash) by twisting the Mechanical Control handle
assembly grip.
(19). Manually position the Yoke and Base and Searchlight Head until the glass window faces forward.
(20). At the operator's station, loosen the bolts clamping the Manual Control handle assembly to the
azimuth tube and rotate the Manual Control handle to the desired neutral or forward position. Tighten the
clamping bolts onto the azimuth tube (see Detail, Drawing 9304-1).
(21). TEST the operation of the Manual Control and readjust rack assembly/handle assembly as
required.
(22). Position the ceiling mount against the ceiling and fasten in place.
(23). If a console mount is desired, it should be installed as shown in Drawing 9304-1.
Mechanical Installation is COMPLETE. If the above procedures are not satisfactorily completed, phone
Technical Support, PERKO, INC.
c. Power Supply and General Electrical Installation.
WARNING
The Power Supply and optical assembly contain very high voltage and current which
are hazardous to human life. Extreme caution must be exercised when
servicing the XR Series 500 watt marine searchlight. Prior to performing any service
on this part, turn circuit breaker off. Open access door and wait a minimum
of 30 seconds before attempting service.
WARNING
The Power Supply unit is heavy and should be handled and installed
by two or more persons.
(1) The Power Supply for the XR Series Model 9304 500 Watt xenon searchlight is supplied in a
NEMA electrical enclosure measuring 20-1/4 inches high by 16-1/4 inches wide by 9-1/4 inches deep.
Three inches minimum should be allowed around the two ends and the back for adequate ventilation. 30
inches should be allowed in front of the Power Supply to allow service personnel adequate access to the
interior components and necessary service.
(2) The Power Supply should be mounted in a location protected from weather, approximately 24
to 36 inches above the floor. In any event, it should be mounted no nearer than 6 inches to the floor. The
Power Supply should be attached to its mounting surface with four 3/8 inch bolts through the four corner
holes provided in the Power Supply cabinet.
(3) Figure 2-1 shows the 115 VAC Power Supply connection requirements. Install a disconnect near
the Power Supply to disconnect the ship’s power from the searchlight Power Supply. This is a safety
requirement since power to the Power Supply is not disconnected when the Power Supply door is opened.
Prepare and install a 3 conductor power cable from the customer supplied disconnect to the Power
Supply (hot to Terminal 1 of TB3. neutral to Terminal 2 of TB3, and ground to the enclosure”.
12

13
(4) In the pilot house, determine the desired location for the remote ammeter and the electrical con-
trol panel.
(5) Cut a 2 inch by 3 inch opening in the pilot house console for the electrical remote control panel.
A minimum of 3 inches clearance is needed behind the console opening.
(6) Using the remote control panel face plate as a template, drill four mounting holes, one in each
corner.
(7) Insert the remote control panel assembly into the console opening and secure it in place with
four screws through the face plate.
(8) The procedure for installing the remote ammeter is the same as the procedure for installing the
control panel, or it may remain in the bakelite case and placed on the console in an appropriate position.
NOTE
The remote ammeter is provided with a 30 ft. calibrated cable. Do not change the length
of this cable. Excess length should be coiled and stored under the console or near the Power
Supply.
(9) On top of the pilot house, install a weatherproof junction box (customer furnished) immediately
aft of the center of the searchlight base. With the searchlight components in place, the searchlight is now
ready for final interconnecting wiring as shown in Figure 2-1.
(10). Prepare and install a cable assembly from the Power Supply terminal block TB1 to the water-
proof junction box consisting of 2 conductors of No. 8 AWG and 7 conductors of No. 16 AWG (50 ft. maxi-
mum Length).
(11). Prepare and install a cable assembly from the Power Supply terminal block TB2 to the pigtail
leads attached to the control panel, consisting of 6 conductors of No. 16 AWG.
2-4 POST-INSTALLATION AND CHECKOUT.After the equipment is installed and all electrical inter-
connections are made, perform the following inspection and checkout procedures:
(1) Check for loose parts, connections and misplaced tools.
(2) Check for proper routing and interconnection of cables.
(3) Check that all equipment is properly secured and adjusted.

14
Standard 110 VAC 60hz Optional 220 VAC 60hz Ship’s Power
WARNING:
The standard and
optional power supplies
must be operated at
their intended ship’s
supply voltage and are
NOT interchangeable

CHAPTER III
INSTALLATION AND OPERATIONAL CHECKOUT
NOTE
The following checkout procedures are to be performed by competent technicians.
3-1 PRE-OPERATIONAL CHECKS.Prior to applying power to the searchlight, all cabling should
be rechecked for proper connections. Ship’s power should be off. The Power Supply circuit breaker should
be in the OFF position and the remote control panel STANDBY/ON/IGNITE switch A3S1 should be in the
STANDBY position.
3-2 LAMP IGNITION.Place the 500 Watt searchlight in operation by performing the following
steps:
(1) Connect the ship’s power to the searchlight Power Supply by closing the disconnect located
near the Power Supply.
(2) Position Power Supply single-phase circuit breaker A1CB1 to ON.
(3) Position remote control panel STANDBY/ON/IGNITE switch A3S1 to ON or IGNITE.
NOTE
As the xenon lamp accrues hours, it may take longer to ignite in the ON or IGNITE position.
Momentarily move remote control panel STANDBY/ON/IGNITE switch A3S1 to the IGNITE
position and when the lamp ignites, release switch A3S1 immediately.
(4) Position remote control panel STANDBY/ON/IGNITE switch A3S1 to ON or IGNITE position. If
lamp does not ignite after several attempts.
(5) Check remote ammeter A4 near remote control panel A3 when xenon lamp ignites. The initial
current indication should rise to 20 - 25 amperes and remain relatively steady.
CAUTION
Wait 15 minutes before positioning circuit breaker and ship’s power to OFF.
Position remote control panel STANDBY/ON/IGNITE switch
to STANDBY and allow blower fans to cool searchlight.
(6) If current in remote ammeter is above 25 amperes:
(a) Position ship’s power to OFF and Power Supply circuit breaker to OFF.
3-3 MANUAL-BEAM FOCUS ADJUSTMENT.Beam limits can be set for a desired pattern by per-
forming the following steps:
(1) Open searchlight head rear cover.
(2) Remove screw and lock washer from spherical link.
15

(3) Ignite the searchlight and direct the beam toward a relatively flat, vertical surface approximate-
ly 100 feet away.
(4) Swing spherical link downward away from the motion transfer arm. Physically move the motion
transfer arm to obtain the desired beam pattern. Adjust the position of the spherical link until
the retaining screw passes through the link and into the motion transfer arm without changing
the position of the motion transfer arm.
NOTE
Several trial adjustments of the spherical link may be necessary to obtain the desired
narrow-to-wide beam spread pattern.
16

17
CHAPTER IV
OPERATING PROCEDURES
4-1 GENERAL.The following procedures provide the necessary information for lamp ignition, opera-
tion and turn-off of the 500 Watt Searchlight.
4-2 LAMP IGNITION. Perform the following procedure in the sequence written:
(1) Close the disconnect switch located near the ship’s Power Supply to apply power to the
searchlight Power Supply.
(2) Place the Power Supply circuit breaker switch A1CB1 to ON position.
NOTE
As the lamp accrues hours, it may take a few seconds longer to start in the ON or IGNITE
position. The IGNITE position on the remote control panel STANDBY/ON/IGNITE switch
A3S1 can be held for longer periods of time. However, once the lamp ignites,
release the switch immediately.
(3) Position remote control panel STANDBY/ON/IGNITE switch A3S1 to ON. The xenon lamp
should light within one to two seconds. If lamp does not ignite in ON position, set remote con-
trol panel STANDBY/ON/IGNITE switch A3S1 to IGNITE position. Release switch A3S1 when
lamp lights and switch will return to ON position. If lamp does not light in IGNITE position, try
again. If lamp does not ignite after several attempts, refer to service technician.
(4) Check remote ammeter A4 when xenon lamp ignites A2DS1. The initial current indication may
surge above 25 amperes, but after 5 minutes it should stabilize to 20-25 amperes range.
4-3 MAIN OPERATION.
(1) Position BEAM switch A3S2 up or down to adjust beam width. Release BEAM switch when
desired beam width is obtained.
NOTE
The BEAM switch A3S2 adjusts the lamp focus. If the BEAM switch is held up or down,
beam width will cycle from narrow to wide and wide to narrow.
(2) Rotate the lever gear control handle in a horizontal plane around the center shaft to rotate the
searchlight in azimuth.
(3) To change searchlight head elevation, twist lever gear handle in a CW or CCW direction.
4-4 TURN-OFF. Turn-off is accomplished by setting the remote control panel STANDBY/ON/IGNITE
switch A3S1 to the STANDBY position. The blower fans will continue to operate to prevent overheating of
the blower fan motor and xenon lamp. Wait at least 15 minutes before positioning circuit breaker A1CB1 or
ship’s power to OFF.

CHAPTER V
OPERATOR MAINTENANCE
5-1 GENERAL.This chapter contains preventive maintenance instructions essential for maintaining
the components of the searchlight. The instructions include inspection, cleaning and lubrication; opera-
tional testing of controls and 500 Watt xenon lamp and removal/replacement.
WARNING
High voltages exist in the searchlight electronics. Allow searchlight to cool off 15 minutes
before positioning Power Supply circuit breaker A1CB1 or ship’s power to OFF.
WARNING
The xenon gas in lamp is under pressure. It is recommended that a face mask
and gloves be worn when handling a lamp. Do not touch glass area of lamp.
Finger acid or dirt may cause lamp to break when ignited.
5-2 INSPECTION. Periodic inspections of certain critical points of the 500 Watt Searchlight are nec-
essary to detect potential trouble before a malfunction occurs.
(1) Visual Inspection. At designated intervals, check for corrosion on electrical contacts, missing or
broken parts and other evidence of damage.
(2) Mechanical Inspection. Check for proper installation and tightness of head and yoke assem-
blies.
(3) Electrical Inspection. Check power cables and wiring for cracks, breaks and loose connections.
Inspect switches to ensure proper operation.
5-3 CLEANING.Using non-abrasive liquid window cleaner, clean window and dry with lint-free cloth.
If reflector needs cleaning, remove xenon lamp and wipe reflector with lint-free cloth dampened with liquid
window cleaner (See Para. 5-6 for lamp removal procedures).
5-4 LUBRICATION.
(1) Lubricate the following areas with non-detergent oil every three months: Around the eleva-
tion rod oil seal in the bearing housing.
(2) Once every six months (three months in salt water environment).
(a) Apply a heavy coating of marine grade bearing grease to the searchlight head pivot
bolts. Bolts should be removed to accomplish this.
(b) Also, remove the yoke from the base and apply a heavy coating of marine bearing
grease to the tapered roller bearings, bearing housings, surrounding internal areas,
under the lip of the rubber “BOOT” sliding seal and to the sliding stop.
5-5 TESTING. Perform the following operations:
(1) Ignite xenon lamp and check that ignition occurs within 5 seconds. (See Chapter IV for operat-
ing procedures). If lamp fails to ignite within 1-3 seconds, refer to troubleshooting procedures,
Chapter VI.
(2) Adjust beam width (Chapter III) and perform check operation (Chapter IV).
(3) Check lever gear directional control to determine that the searchlight responds with proper move-
ment.
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5-6 XENON LAMP REMOVAL. Perform the following steps in the following sequence:
(a) Position STANDBY/ON/IGNITE switch A3S1 to STANDBY.
(b) Allow searchlight to cool approximately 15 minutes until cooling fans stop running.
(c) Position searchlight Power Supply circuit breaker A1CB1 to OFF and disconnect ship’s
power.
(d) Open searchlight window by unclamping three clamps and lowering window.
WARNING
Avoid unnecessary torque on xenon lamp by using two wrenches, one to engage the flats
on the anode to prevent the lamp from turning and the other to remove the
terminal hold-down nut. Excessive torque on lamp could cause it to break.
(e) Remove hold-down nut from stud on front of lamp using two wrenches.
(f) Remove wire lead from stud.
(g) Loosen screws on lamp plate and remove lamp plate from support assembly.
(h) Carefully pull lamp plate from lamp.
(i) Insert empty lamp extractor through opening in bipod assembly and slide inward until it
engages bayonet base of lamp in lamp holder slots.
(j) Remove the lamp from the extractor and wrap old lamp in its plastic wrapper. Tie lamp at both
ends, wrap in foam rubber and store in its original shipping carton for future disposition.
5-7 XENON LAMP INSTALLATION.Perform the following steps in the following sequence:
(a) Remove new lamp from corrugated box. The lamp is packed in clear plastic with ties at both
ends, then wrapped in foam packing material.
(b) Place lamp wrapped in foam on flat, stable surface.
CAUTION
Do not touch glass area of lamp. Finger acid or dirt may cause
lamp to break when ignited.
(c) Remove foam material.
(d) Untie and remove plastic wrap.
(e) Insert lamp into extractor.
(f) Insert extractor into opening in lamp support and slide forward until lamp cathode stud terminal
engages threaded hole in rear lamp retainer.
(g) Screw lamp in by turning extractor in CW direction until lamp seats firmly.
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(h) Remove the extractor.
(i) Reinstall lamp plate.
(j) Replace wire lead on anode end of lamp and tighten, again using two wrenches.
(k) Close and clamp searchlight window.
(l) Perform operational test on lamp. Refer to Paragraph 5-5 for test procedures.
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