Wipaire 8750, Service Manual

Page 1: ...SALES AVIONICS INTERIOR MAINTENANCE PAINT REFINISHING Revision B P N 1005723 Doc No W8750 24 01 SERVICE MANUAL and INSTRUCTIONS FOR CONTINUED AIRWORTHINESS for the WIPAIRE MODEL 8750 AMPHIBIOUS SEAPLANE FLOAT ON THE CESSNA MODEL 208 208B CARAVAN ...

Page 2: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B P N 1005723 Doc No W8750 24 01 Page 2 of 104 Revision IR THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 3: ...ew oleo updated photo p25 changes to MLG rigging procedure update to inspection procedures defined water rudder rigging procedures remaining pages repaginated removed p107 5 30 2014 D See List Added Shear Torque chart PR 1440 C Sealant Tef Gel and full contact info Removed Warranty Claim Form Corrected 1200 was 1000 1400 was 1150 and 1900 was 1300 5 26 2015 E See List Added Dow Corning DC4 and Mob...

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Page 5: ...6 IR 42 IR 78 C 7 D 43 F 79 C 8 D 44 IR 80 C 9 IR 45 IR 81 C 10 D 46 F 82 F 11 IR 47 IR 83 E 12 D 48 IR 84 C 13 IR 49 C 85 C 14 D 50 C 86 C 15 IR 51 C 87 C 16 IR 52 C 88 C 17 B 53 C 89 F 18 B 54 C 90 C 19 IR 55 C 91 C 20 IR 56 C 92 C 21 B 57 C 93 C 22 C 58 C 94 D 23 C 59 C 95 C 24 IR 60 C 96 C 25 IR 61 C 97 B 26 C 62 C 98 IR 27 IR 63 C 99 B 28 IR 64 C 100 IR 29 IR 65 C 101 IR 30 IR 66 C 102 B 31 I...

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Page 7: ...E GEAR 33 3 0 NOSE GEAR 34 3 1 ADJUSTMENT TEST 36 3 2 NOSE GEAR BASIC SERVICING 37 3 3 NOSE GEAR DISASSEMBLY 38 3 4 NOSE GEAR ASSEMBLY 39 CHAPTER 4 MAIN LANDING GEAR BRAKES GEAR RETRACTION 42 4 0 GENERAL 43 4 1 MAIN GEAR RETRACTION 47 4 2 MAIN GEAR ASSEMBLY SETUP 54 4 3 ADJUSTING THE GEAR UP POSITION 59 4 4 ADJUST MAIN UP AND DOWN POSITION SWITCHES 60 4 5 EMERGENCY GEAR OPERATION 64 CHAPTER 5 HYDR...

Page 8: ...SSES PRODUCTS AND INSP CHECKLISTS 81 9 0 SERVICING INSTRUCTIONS 82 9 1 CORROSION REMOVAL 84 9 2 MAINTENANCE CHECKLIST 85 9 3 FLOAT REMOVAL AND RE INSTALLATION GUIDE 90 9 4 WEIGHING PROCEDURES FOR CESSNA 208 208B CARAVAN 96 CHAPTER 10 TROUBLESHOOTING 97 CHAPTER 11 INSTALLATION PRINT INFORMATION 101 CHAPTER 12 AIRCRAFT INSTALLED PERFORMANCE ITEMS AND DECRIPTIONS 103 12 1 WING FENCES 104 12 2 VORTEX ...

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Page 10: ...T TERMINOLOGY 19 FIGURE 1 6 MAINTENANCE ACCESS POINTS 20 FIGURE 1 7 HYDRAULIC 22 FIGURE 3 1 NOSE WHEEL BOX 35 FIGURE 3 2 NOSE WHEEL GREASING 37 FIGURE 3 3 NOSE GEAR BOX ITEMS 40 FIGURE 4 1 MINIMUM BRAKE 43 FIGURE 4 2 MAIN GEAR LOWER 46 FIGURE 4 3 MAIN GEAR GREASING POINTS 48 FIGURE 4 4A MAIN GEAR ADJ DOWN 50 FIGURE 4 4B MAIN GEAR ADJ DOWN 51 FIGURE 4 5 MAIN GEAR ADJ UP 52 FIGURE 4 6 MAIN GEAR DOWN...

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Page 12: ...hipping Address Phone Number Fax Number Purchasing Contact Phone Number E Mail Fax Number Accounts Payable Contact Phone Number E Mail Fax Number Type s of Aircraft Owned or Maintained Model s of Floats and Skis Owned or Maintained FedEx and or UPS account number if applicable Please return to Wipaire Customer Service Fax 651 306 0666 Phone 651 306 0459 CustomerService wipaire com ...

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Page 14: ...e department is available for your questions 24 hours a day 7 days a week where ever you are in the world Parts Sales and Technical Support Dept Wipaire Inc 1700 Henry Avenue Fleming Field South St Paul MN 55075 Telephone 651 306 0459 Fax 651 306 0666 Website www wipaire com Email CustomerService wipaire com In this service manual we have worked hard to include many repair scenarios in addition to...

Page 15: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B Revision IR Page 15 of 104 P N 1005723 Doc No W8750 24 01 FIGURE 1 1 FRONT VIEW CESSNA 208 CARAVAN ...

Page 16: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B P N 1005723 Doc No W8750 24 01 Page 16 of 104 Revision IR FIGURE 1 2 TOP SIDE VIEWS CESSNA 208 CARAVAN ...

Page 17: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B Revision B Page 17 of 104 P N 1005723 Doc No W8750 24 0 FIGURE 1 3 FRONT VIEW CESSNA 208B CARAVAN ...

Page 18: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B P N 1005723 Doc No W8750 24 01 Page 18 of 104 Revision B FIGURE 1 4 TOP SIDE VIEWS CESSNA 208B CARAVAN ...

Page 19: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B Revision IR Page 19 of 104 P N 1005723 Doc No W8750 24 01 FIGURE 1 5 FLOAT TERMINOLOGY ...

Page 20: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B P N 1005723 Doc No W8750 24 01 Page 20 of 104 Revision IR FIGURE 1 6 MAINTENANCE ACCESS POINTS ...

Page 21: ...he wheel well Figures 1 1 and 1 2 show three view drawings of the Cessna 208 as installed on Wipline model 8750 amphibious floats Figures 1 3 and 1 4 show three view drawings of the Cessna 208B as installed on Wipline model 8750 amphibious floats As a part of the float installation the following additional changes are made to the landplane 1 The hydraulic landing gear retraction system components ...

Page 22: ...ead The hydraulic actuators are located adjacent to each gear Hydraulic system fluid level should be checked at 25 hour intervals and should be serviced to levels in accordance with the installed placard using MIL H 5606 red hydraulic fluid The fluid level placard Figure 1 7 is installed on the forward hydraulic Reservoir FIGURE 1 7 HYDRAULIC FLUID LEVEL PLACARD The nose wheels are fully castoring...

Page 23: ... to the aircraft The strut package is comprised of the forward struts main pylons rear cross wires and front cross wires or flying wires The streamlined struts are made from extruded aluminum alloys The main pylon is built from machined aluminum trusses internal ribs and skinned with aluminum sheet WATER RUDDERS The floats are equipped with water rudders attached at the rear of the float structure...

Page 24: ...nterior should be flushed out especially if salt water or polluted water gets inside the compartments If the floats are being stored inside a building either installed on the aircraft or not it is strongly recommended to remove the inspection covers so the interior of the floats can dry out Even without direct contact with saltwater this hydraulic pump in the aircraft fuselage has severely corrode...

Page 25: ...is faster Most aircraft and most floats are made out of aluminum due to its strength to weight ratio and its ability to withstand fatigue and remain field repairable Steel is used for strength in hardware and landing gear parts and these are often areas where these dissimilar metals cause corrosion Areas where moisture and dirt mix and stay wet against metal are common sites of oxidation Float str...

Page 26: ...xposed Removal of corrosion is detailed more fully in Chapter 9 but there are a few things an owner can do to stop the spread of corrosion and minimize the damage Aside from the already detailed cleaning and inspection procedures an anti corrosion spray like Corrosion X or its equivalent should be used liberally Because it has the ability to displace moisture and contaminants it can be used when t...

Page 27: ... block up the keel in several places and lower the jack Raise only one float at a time with the opposite float wheels chocked Position a sawhorse under main and after body keel to keep aircraft from tipping fore and aft TOWING When towing the amphibian aircraft two lugs are provided on the lower forward side of the nose spring A rigid V frame can be fabricated to attach to these lugs for towing th...

Page 28: ...vers and propeller anchor assembly 7 Attach a static ground cable to one of the aircraft tie down eyelets and the ground anchor point For water operations the floats are equipped with two deck cleats on each float one forward near the pilot copilot doors and one aft near the cargo door Mooring Procedure on Water at Dock 1 Position the aircraft near the dock and point into the wind as much as able ...

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Page 30: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B P N 1005723 Doc No W8750 24 01 Page 30 of 104 Revision IR CHAPTER 2 AIRWORTHINESS LIMITATIONS ...

Page 31: ... FAA approved and specifies maintenance required under paragraphs 43 16 and 91 403 c of the Federal Aviation Regulations unless an alternative program has been FAA approved The aircraft Airworthiness Limitations are unchanged as a result of installation of the amphibious floats and the associated systems addressed by this STC FAA APPROVED_________________________ DATE_________________________ ...

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Page 33: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B Revision IR Page 33 of 104 P N 1005723 Doc No W8750 24 01 CHAPTER 3 NOSE GEAR ...

Page 34: ... containing magnetic material has reached either end of its travel Refer to Figure 3 1 for visual reference The nose gear has single 5 00 x 5 10 ply tire All tires must be approved to TSO C62 type III NOSE WHEEL AND TIRE REMOVAL To remove each nose wheel 1 Jack the aircraft completely lifting both hulls It is not recommended to jack only one hull 2 Cut cotter pin and remove axle nut 3 Remove the A...

Page 35: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B Revision IR Page 35 of 104 P N 1005723 Doc No W8750 24 01 FIGURE 3 1 NOSE WHEEL BOX ...

Page 36: ...ng flange The up stops nests in the up stop pins Nose gear proximity switches are located on clips that are mounted on the outer cylinder body one on each end The most forward switch is for the gear down lights and most aft is for the gear up position lights Set the proximity switch mounting clip along outer cylinder body to a position such that the light goes out when the over center track is abo...

Page 37: ...ery 25 hours or more frequently whenever in water for an extended period of time especially saltwater Tracks and blocks should be cleaned and left dry or alternately cleaned and wiped with a rag with dry silicone spray on it The nose wheels contain grease nipples for the wheel bearings They should be greased every 25 hours Nose tires are standard 5 00 x 5 10 ply inflated to 60 5 psi All tires must...

Page 38: ...p wrench or other suitable non marring tool unthread the Ram Item 6 from the Nose Ram Rod End Do not attempt to remove the ram piston top brass from the ram shaft stainless steel They are assembled as a unit and permanently secured 6 Remove Ram Assembly Item 3 if desired to replace the T seals Item 10 felt wiper Item 7 and plastic wiper Item 8 7 Replace T seals on the Nose Ram Item 9 and Ram Assem...

Page 39: ...x track 4 Thread the Ram Assembly Item 6 onto the Rod End Item 5 until the ram piston contacts the Flange Assembly Item 7 while at the same time the rollers are seated in the down lock pocket Both the piston and the rollers need to bottom out against their respective mating parts at the same time 5 Tighten the AN316 10R jam nut against the rod end 6 Install the Nose Ram Item 2 onto the Flange Asse...

Page 40: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B P N 1005723 Doc No W8750 24 01 Page 40 of 104 Revision IR FIGURE 3 3 NOSE GEAR BOX ITEMS ...

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Page 42: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B P N 1005723 Doc No W8750 24 01 Page 42 of 104 Revision IR CHAPTER 4 MAIN LANDING GEAR BRAKES GEAR RETRACTION ...

Page 43: ... deeper than 0 015 or thickness below 0 327 is cause for replacement MAIN WHEEL AND TIRE REMOVAL AND INSPECTION To remove each main wheel 1 Remove brake caliper 2 Drain oil from the axle by removing the plug in the hub cap of the inboard wheel 3 After oil drains remove snap ring and hub cap 4 Cut cotter pin and remove axle nut 5 Pull wheel off of axle Each main wheel is a split type rim To remove ...

Page 44: ...t tighten the aft wires in a similar fashion measuring between the face of the clevises and loosening then tightening the wires until they are of equal Secure with jamb nuts BLEEDING BRAKE SYSTEM Whenever the hydraulic brake lines are disconnected and reattached the brake system should be bled To bleed the brake system 1 Check that all lines are properly attached between the brake calipers and bra...

Page 45: ...ck Bleeding To bleed the brakes system using this alternate method 1 Connect pressurize brake bleeding system to outboard caliper CAUTION WHEN PERFORMING CROSS BLEEDING IT MAY BE NECESSARY TO REMOVE RESIDUAL FLUID FROM BRAKE RESEVERIOR TO PREVENT OVERFLOW 2 Open inboard and outboard bleeders on main gear and pump fluid between calipers till all air has been purged from calipers 3 Tighten inboard c...

Page 46: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B P N 1005723 Doc No W8750 24 01 Page 46 of 104 Revision F FIGURE 4 2 MAIN GEAR LOWER ...

Page 47: ... pull on the Main Gear Top Arm Assembly causing it to pivot around a fixed point Also attached to the actuators drive shaft is a visual gear position indicator This indicator consists of colored bands that rotate with the drive shaft allowing the pilot to visually determine the position of the main landing gear by looking at a placard on the deck of the float Since the actuator rotates through app...

Page 48: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B P N 1005723 Doc No W8750 24 01 Page 48 of 104 Revision F FIGURE 4 3 MAIN GEAR GREASING POINTS ...

Page 49: ... on each main gear unit One for sensing gear up position and the other for gear down position These are easily replaceable and can essentially be adjusted during maintenance see figure 4 4A and 4 5 The proximity sensors have a built in LED to indicate when they are sensing the gear position This feature greatly aids in the setup and servicing of the sensors There are several service points on the ...

Page 50: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B P N 1005723 Doc No W8750 24 01 Page 50 of 104 Revision C FIGURE 4 4A MAIN GEAR ADJ DOWN ...

Page 51: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B Revision C Page 51 of 104 P N 1005723 Doc No W8750 24 01 FIGURE 4 4B MAIN GEAR ADJ DOWN INSERT TEST PAPER ...

Page 52: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B P N 1005723 Doc No W8750 24 01 Page 52 of 104 Revision C FIGURE 4 5 MAIN GEAR ADJ UP ...

Page 53: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B Revision C Page 53 of 104 P N 1005723 Doc No W8750 24 01 FIGURE 4 6 MAIN GEAR DOWN STOP ADJ ...

Page 54: ...m 1 This will allow the retraction mechanism to be repositioned by hand without having to move the weight of the tires oleo and drag link assembly Place a rag between the drag link and the bulkhead as the gear will rotate and make contact with bulkhead possibly scratching the finish 3 Remove the 4 nuts connecting the rod linkages Item 3 to the actuator arms Item 5 Remove the rod linkages from the ...

Page 55: ... actuator needs adjustment It may be necessary to use one of the actuator arms removed in step 5 to help rotate the actuator 11 To adjust the DOWN position loosen the DOWN adjustment screw jamb nut Item 9 and back off the adjustment screw 12 Align the keyway on the actuator shaft Item 4 with the keyway on Wipaire Tool 1004800 Insert the parallel key removed in step 5 into the aligned keyways 13 Th...

Page 56: ...gle will be verified Lay the protractor across the bottom of the lower two screw holes in the actuator arm Note Older float models may not have flat spot shown use the same location as shown Zero the protractor See Figure 4 4B Then place the protractor on the top or bottom of the rod linkage The measured angle should be 4 1 Repeat for the other actuator arm and rod linkage by zeroing the protracto...

Page 57: ...he Top Arm Assembly Item 2 to ensure it is locked over center The Top Arm Assembly needs to be contacting the Top Mount Item 7 when the gear is extended to properly transfer the landing loads Ensure Top Arm and Top Mount are making contact by sliding a 3 inch wide piece of paper in See Figure 4 4B and photo on this page then moving gear to down and locked position If paper is tight gear is rigged ...

Page 58: ...rotation point on the Top Arm Assembly Thus one could effectively remove the entire gear actuator and the geometry of the Oleo and the Top Arm alone would force the contact faces of the top arm and top mount together and lock it over center There are also two over center locks when the gear is in the retracted UP position The first is a spring installed on the actuating arm that prevents motion of...

Page 59: ...the rotary actuator and pull the gear down by hand the rod linkage and the actuator arms have not moved past TDC Re check the position of the UP stop using Wipaire Tool 1004800 If the UP position is found to be correct look for signs of damage in the floats as something is out of position preventing the stop setting using Tool 1004800 from being correct Call Wipaire s Customer Service Department f...

Page 60: ... the Top Arm Assembly in until the LED light built into the proximity switch initially illuminates with the gear arm in the full down over center locked position then thread the set screw in an additional half turn 5 Reposition the gear to the UP position 6 Loosen the jam nuts on the gear up proximity sensor 7 Adjust the gear up proximity sensor switch to have between a 0 030 0 060 gap between the...

Page 61: ...Revision C Page 61 of 104 P N 1005723 Doc No W8750 24 01 12 Check for proper light illumination on the gear selector in the cockpit in both the up and down position 13 If necessary reattach the oleo shock strut to the Top Arm Assembly 14 Remove aircraft from jack stands ...

Page 62: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B P N 1005723 Doc No W8750 24 01 Page 62 of 104 Revision C FIGURE 4 7 ROTARY ACTUATOR ...

Page 63: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B Revision C Page 63 of 104 P N 1005723 Doc No W8750 24 01 FIGURE 4 8 MAIN SHOCK STRUT ...

Page 64: ...aulic power pack reservoir The hydraulic power pack electric pumps have fluid pickup tubes that do not reach the bottom of the hydraulic fluid reservoir This prevents the electric pump from being able to pump all the fluid out of the system The remaining small reserve quantity of fluid below the electric pump pickup tube is then reserved exclusively for the emergency hand pump The quantity of rese...

Page 65: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B Revision C Page 65 of 104 P N 1005723 Doc No W8750 24 01 CHAPTER 5 HYDRAULICS ...

Page 66: ...th the model 8000 installation pressure and return lines at the fuselage exits are connected to pressure and return lines at the strut pylon attach points The only electrical difference between the standard and retrofit hydraulic system is the addition of a port and starboard low power wire that runs to the powered proximity switch that commands main gear position indication See drawing number 100...

Page 67: ... DOWN position and 1200 in the UP position the pressure switch deactivates the solenoid and the pump motor stops A check valve on the output side of the pump retains pressure in the system while the pump is off The pump has an interval relief valve that directs fluid back to the un pressurized pump reservoirs when the line pressure exceeds 1400 psi The system also has an internal relief valve to p...

Page 68: ...DIRECTION PUMP INTERNAL SHUTTLE VALVE WITH 1150 RELIEF 150 PSI 1400 PSI THERMAL RELIEF UP AND DOWN PREASURE SWITCHES FOR EACH PUMP UP 500 1000 PSI DOWN 500 700 PSI AFT FUSELAGE MOUNTED POWER PACK WITH PUMPS PREASURE SWITHCES AND CHECK VALVES CROSS FITTINGS LOWER FUSELAGE EMERGENCY HAND PUMP IN CABIN A RET DN NOSE GEAR RAMS W POSITION SWITCHES UP DOWN UP DOWN DOWN UP DOWN UP MAIN GEAR RAMS W PROXIM...

Page 69: ...ower pack assembly with MIL H 5606 hydraulic oil and cycle the gear If the reservoir empties stop the cycle by pulling the pump motor circuit breakers Fill the reservoir again and complete the cycle Continue this procedure until the fluid level in the reservoir stabilizes it will vary in level between gear up and down positions If the fluid level continues to decline during gear cycles check for e...

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Page 71: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B Revision C Page 71 of 104 P N 1005723 Doc No W8750 24 01 CHAPTER 6 WATER RUDDER ...

Page 72: ...der moves with the air rudder WATER RUDDER RIGGING All cables in the water rudder steering system should be rigged to 30 5 lbs Retraction cables should be rigged such that the top of the rudder blade is approx 1 inch from the rudder stop on the rudder post in the up position and that the cables are just slack in the down position Water rudders should be centered when the air rudder is centered by ...

Page 73: ...50 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B Revision C Page 73 of 104 P N 1005723 Doc No W8750 24 01 SEE INSTALL DRAWING 1006006 REV A OR LATER APPROVED REVISION FIGURE 6 2 WATER RUDDER STEERING CABLE ROUTING MODEL 208 ...

Page 74: ...50 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B P N 1005723 Doc No W8750 24 01 Page 74 of 104 Revision C SEE INSTALL DRAWING 1006015 REV A OR LATER APPROVED REVISION FIGURE 6 3 WATER RUDDER STEERING CABLE ROUTING MODEL 208B ...

Page 75: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B Revision C Page 75 of 104 P N 1005723 Doc No W8750 24 01 CHAPTER 7 ELECTRICAL ...

Page 76: ...aulic system is the same as with the model 8000 installation pressure and return lines at the fuselage exits are connected to pressure and return lines at the strut pylon attach points The only electrical difference between the legacy 8000 and retrofit 8750 system is the addition of a port and starboard low power wire that runs to the powered proximity switch that commands main gear position indic...

Page 77: ...ufficient hydraulic pressure is obtained in the gear system Gear swings should take less than 45 seconds with both pumps operating If the gear cycle time is greater than 45 seconds it is likely that one pump is not pumping efficiently and or not operating correctly This can be verified by pulling each pump breaker to see if the system functions on one pump but not the other GEAR SELECTOR HEAD The ...

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Page 79: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B Revision C Page 79 of 104 P N 1005723 Doc No W8750 24 01 CHAPTER 8 TKS SYSEM EQUIPPED AIRCRAFT REQUIREMENTS ...

Page 80: ...ding gear free of ice TKS SYTEM MODIFICATION WHEN FLOATS INSTALLED For requirements and guidance on modifying the TKS Icing System on Cessna 208 208B Caravan when 8750 series floats are installed refer to Wipaire installation drawing 1004806 revision A or later approved revision The TKS fluid pod must be removed and connections capped and covered For additional control surface movement changes see...

Page 81: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B Revision C Page 81 of 104 P N 1005723 Doc No W8750 24 01 CHAPTER 9 RECOMMENDED PROCESSES PRODUCTS AND INSP CHECKLISTS ...

Page 82: ...ished A complete inspection Annual Inspection would include all 25 50 100 200 hour items Below is a list of recommended lubricants and protection products when servicing float hull and other amphibious components This lists products used by Wipaire during assembly of the floats There may be equivalent products just as satisfactory for protection However it is recommended if trying different produc...

Page 83: ...Pro Seal Company PR 1440 C PPG Aerospace RTV Silicones General Electric SIKAFLEX 201 or 252 Sika Manufacturing Teflon Spray 6P 730A Comet Industries Hydraulic Fluid Mil H 5606 Electrical Insulating Compound Dow Corning 4 DC4 Dow Corning Corporation Bolt Torque Bolts in Critical Areas For common correct torque when installed or when visual inspection indicates a need for a torque check Tension Nut ...

Page 84: ...on and other factors Pylon before repair Pylon Fully Repaired After removing the corrosion restore the area to the original finish like prime and enamel or coat the metal with a waterproof grease CORROSION X or equivalent should also be applied to stop corrosion and repel moisture and contaminants Corrosion Limits Area Allowable Thickness loss Bottom skins 30 Side Skins fwd of Step 30 Side Skins a...

Page 85: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B Revision C Page 85 of 104 P N 1005723 Doc No W8750 24 01 9 2 MAINTENANCE CHECKLIST ...

Page 86: ...osion or deformation Inspect all attaching hardware for security damage and corrosion Apply ACF 50 to Pylon Float Deck attach point hardware prior to reinstallation Spreader Bars inspect for loose screws and cracks On the aircraft and floats re coat exposed hardware with suitable coating for corrosion per section 9 0 Servicing Instructions of this manual Closely inspect for wrinkled metal cracked ...

Page 87: ... clean and dry or clean and wipe with silicone spray Check side play 3 32 to 1 8 max tolerance General Water rudder blades inspect condition Water rudder steering and retract systems inspect the following cables for broken wire fittings for cable slippage cracks and distortion cable pulleys for freedom of rotation and cable guard pins for presence rigging Remove clean inspect and grease the Aux fi...

Page 88: ...wheel well Hydraulic fluid level MIL H 5606 Wheels and tires inspect for wear pressure and condition Brake assemblies inspect for wear corrosion and leakage Hydraulic fluid in reservoir should be checked for moisture or other contaminates and changed if necessary Main and Nose gear actuators Assemblies inspect for condition lubrication leakage corrosion and cleanliness Nose gear springs scotch ply...

Page 89: ...sure The oleo should be fully serviced replaced or overhauled as required at annual inspection Perform retraction tests as follows 1 Hoist aircraft and place on stands 2 Turn on Aircraft Master switch 3 Select Gear UP position using selector 4 Verify gear lights indicate gear positions correctly while gear is in transit and at the end of travel 5 Select Gear DOWN position using selector 6 Verify g...

Page 90: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B P N 1005723 Doc No W8750 24 01 Page 90 of 104 Revision C 9 3 FLOAT REMOVAL AND RE INSTALLATION GUIDE ...

Page 91: ...keep aircraft level while lifting 5 Lower aircraft so wheels just touch and relieve hydraulic pressure before Pulling pump circuit breakers Install tie wrap to shank for safety 6 Remove the following items from aircraft Nose gear cover plate Lower nose cowlings Steering bungee from nose gear attach point Front flying wire fitting Strut fairings and belly plate Tail hatch cover tail cone if needed ...

Page 92: ...n gear if needed 8 Install nose gear and attach steering bungee 9 Assemble support crew minimum six 6 crew members 10 With wheels just touching the ground remove the 4 main gear saddles and upper front attach bolts 11 Lift aircraft and remove floats 12 Lower aircraft positioning main gear assembly for installation 13 Torque main gear saddle bolts to 75 ft lbs 14 Connect brake lines and bleed for a...

Page 93: ...ENDED AS A GENERAL GUIDE EACH INSTALLATION MAY HAVE SUBTLE DIFFERENCES ALWAYS USE THE INSTALLATION DRAWINGS AS THE FINAL REFERENCE ALL WORK SHOULD BE DONE BY CERTIFIED AIRCRAFT TECHNCIANS Remove the following items from aircraft continued 25 Remove aircraft from hoist and add air to tires as required 26 Install wing root fairings 27 Check all placards to conform to landplane category 28 Make logbo...

Page 94: ...t brake lines and cap 9 Cut Tie wrap from pump circuit breakers 10 Tie ropes from tie down rings Connect lifting bar to hoist and inspect aircraft lifting rings for proper assembly before connecting to aircraft Use ballast from tie down to ensure level lifting 11 Raise aircraft until wheels are just touching the ground and assemble 12 Assemble support crew minimum six 6 crew members 13 Remove sadd...

Page 95: ...Hand pump the gear down and up and check for leakage 24 Install springs for steering cables in the tail of the aircraft 25 Route and rig the steering cables and water rudder retract cables with 30lbs 5lbs 26 Install step struts 27 Install brake lines and bleed for air bubbles See Chapter 5 section 5 1 this manual 28 Install elevator down spring 29 Install belly plate and fairings for main gear 30 ...

Page 96: ...e firewall This is station 100 00 Measure 100 00 inches forward of this point this is the datum 0 0 Draw another line between the nose wheel centers and a 4th line between the main wheel centers Measure the distance from 0 0 to the nose wheel line This is X1 and X2 Measure the distance from 0 0 to the main wheel line This is Y1 and Y2 If the floats are seaplane floats the scales go under the step ...

Page 97: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B Revision B Page 97 of 104 P N 1005723 Doc No W8750 24 01 CHAPTER 10 TROUBLESHOOTING ...

Page 98: ...ce pump a Correct wiring and protect terminals with grease b Replace pump motor c Replace circuit breaker a Reset circuit breaker b Replace annunciator test switch Potential Cause s a Circuit breaker is open triggered b Pressure switch is not actuating at the low pressure trip point c Solenoid switch not actuating d Faulty ground on pump e Faulty pump motor a Faulty pressure switch b Faulty or dir...

Page 99: ...ster cylinder c Re rig parking brake control d Remove restriction form lines flush system and reservoir with clean hydraulic fluid e Replace disc and linings f Clean or replace components as required Potential Cause s a Defective bulb a Gear out of position and not contacting gear position switch b Defective gear position switch a Fuel has migrated from one wing to the other causing a fuel imbalan...

Page 100: ...er up stops a Replace defective water rudder cable b Rig water rudder cable system Potential Cause s a Improper brake hydraulic fluid level b Worn brake linings c Defective O ring in master or brake cylinder d Internal damage due to incorrect type of brake fluid In system a Air in brake system b Swollen or defective hoses c Improper brake hydraulic fluid level a Water rudder cable system out of ri...

Page 101: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B Revision IR Page 101 of 104 P N 1005723 Doc No W8750 24 01 CHAPTER 11 INSTALLATION PRINT INFORMATION ...

Page 102: ... 8750 floats A copy of this drawing and all drawings listed thereon can be obtained from Wipaire Inc These drawings are necessary to properly maintain the aircraft WIPAIRE DRAWINGS REQUIRED FOR 8750 FLOAT INSTALLATION CESSNA 208B CARAVAN See Wipaire drawing 1006001 revision A or latest approved revision for a complete list of drawings pertaining to the installation and removal of the 8750 floats A...

Page 103: ...SERVICE MANUAL ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B Revision B Page 103 of 104 P N 1005723 Doc No W8750 24 01 CHAPTER 12 AIRCRAFT INSTALLED PERFORMANCE ITEMS AND DECRIPTIONS ...

Page 104: ... aircraft previously equipped with a TKS fairing have roughly 34 Vortex Generators installed With the addition of the Vortex Generators the aircraft will have improved controllability and safety at low speeds No more than two non adjacent vortex generators per wing can be missing at any one time If a Vortex Generator is missing replace as soon as possible Refer to Cessna 208 models Configuration D...