SERVICE MANUAL INSTRUCTIONS FOR CONTINUED
Contents
1. EN PSE GE Teel SW CONT RELAY BH GA Page 6 of 16 206 4000 FLI LITE WITH HYD POWER PACK SKI SERVICE MANUAL 6 3 Gear Selector Switch The gear selector switch is located on the instrument panel in front of the pilot The gear selector is an electrical switch that changes pump direction of the electro power pack for gear up or down The red light on panel indicates the pump has power supplied to it 8 HYDRAULIC PUMP DISASSEMBLY AND SERVICE Pump may be returned to factory for service Electric pump motor may be returned to factory for service The pump is located on the fuselage side just aft of access panel in the baggage compartment The entire pump assembly maybe removed from the aircraft by removing the 2 top and 2 lower bolts securing the pump bracket to the fuselage bracket Remove hydraulic lines and unplug wiring harness Remove assembly from aircraft The screens maybe cleaned by the following without removing pumps from the aircraft 1 Remove return line on lower reservoir and drain oil 2 Remove screw on bottom of reservoir for tank removal 3 After tank removal pick up filters to be pulled off friction fit and cleaned Refer to Figures 8 1 amp 8 2 4 Replace tank reinstall lower hose and fill with clean hydraulic oil Mil H 5606 5 Fill by removing breather and filler stand pipe NOTE ANY PARTS THAT MAYBE REQUIRED TO REPLACE REFER TO WIPAIRE 206 WIPLINE2. PICKUP TUBE HAND PUMP RETURN PORT RESERVOIR ATTACH SCREW Figure 8 1 Hydraulic Pump Page 12 of 16 206 4000 FLI LITE WITH HYD POWER PACK SKI SERVICE MANUAL FILTER UP THERMAL RELIEF VALVE PRESSURE SWITCH DOWN THERMAL RELIEF VALVE DOWN PRESSURE RELIEF VALVE PICK UP TUBE HAND PUMP UP PRESSURE RELIEF VALVE Figure 8 2 Internal View Hydraulic Pump Page 13 of 16 206 4000 FLI LITE WITH HYD POWER PACK SKI SERVICE MANUAL 9 CONTINUED AIRWORTHINESS As coded in the Inspection Time Intervals chart in this section there are items to be checked each 25 50 100 and 200 hours Also there are notes on special items which may require servicing at more frequent intervals e When conducting an inspection at 25 hours all items marked for 25 hours would be accomplished e When conducting an inspection at 50 hours the 25 and 50 hour items would be accomplished e When conducting an inspection at 100 hours the 25 50 and 100 hour items would be accomplished e When conducting an inspection at 200 hours the 25 50 100 and 200 hour items would be accomplished e A complete inspection Annual Inspection would include all 25 50 100 and 200 hour items INSPECTION TIME INTERVALS HOURS 25 50 100 200 Electrical Pump and Indicator Light System Wiring Inspect for chafing broken or loose terminals and general condition Solenoids Inspect wirin
3. 3450 PARTS CATOLOG ON WEB SITE WWW WIPAIRE COM 8 1 Setting Thermal and Pressure Relief Valves 1 These are preset at the factory Thermal relief is set at 1100 100 0 PSI and pressure relief at 800 100 0 PSI 2 If adjusting refer to Figure 8 2 for location of relief valves 3 Loosen jam nut on relief valve to be changed Turn clockwise to increase and C clockwise to lessen 4 Donot exceed factory settings noted above 8 2 Troubleshooting Hydraulic System 1 PROBLEM Power pack does not run after gear selection RED pump light OFF Probable cause a Circuit breaker has tripped b Pressure switch not pulling in at low cut in c Solenoid switch not pulling in Page 7 of 16 206 4000 FLI LITE WITH HYD POWER PACK SKI SERVICE MANUAL 2 3 4 d Motor not properly grounded e Pressure buildup on both sides of up and down lines PROBLEM Power pack does not run after gear selection RED pump light ON Probable cause a Faulty pump motor Verification and Remedy a Reset circuit breaker b Short across pressure switch leads and see if motor runs If motor operates replace pressure switch c Short across solenoid pressure switch leads and see if motor runs If motor operates replace solenoid pressure switch d Ifc above does not produce results and it is verified that voltage was actually applied to motor it can be assumed motor is bad or not properly grounded e Check motor gro
4. Wipaire Inc 1700 Henry Avenue South St Paul MN 55075 Phone 651 451 1205 Fax 651 451 1786 CESSNA MODEL 206 ON FLI LITE 4000 WITH HYDRAULIC POWER PACK SERVICE MANUAL AND INSTRUCTIONS FOR CONTINUED AIRWORTHINESS ISSUED OCTOBER 20 2004 CONTACT WIPAIRE SERVICE DEPARTMENT OR CHECK OUR WEBSITE AT WWW WIPAIRE COM FOR LATEST REVISIONS 206 4000 FLI LITE WITH HYD POWER PACK SKI SERVICE MANUAL LOG OF REVISION REV NO PAGES DESCRIPTION DATE ORIG ALL OCT 20 2004 Page 2 of 16 206 4000 FLI LITE WITH HYD POWER PACK SKI SERVICE MANUAL INTRODUCTION This manual describes the general servicing and maintenance for the Model 4000 FLI LITE ski hydraulic power pack installation For services and repairs not covered by this manual contact the factory The service products referred to throughout this manual are described by their trade name and may be purchased from the factory Parts Department To contact Wipaire for service assistance or parts sales call or write Wipaire Inc Telephone 651 451 1205 Fax 651 451 1786 Page 3 of 16 206 4000 FLI LITE WITH HYD POWER PACK SKI SERVICE MANUAL 5 RETRACT SYSTEM OPERATION AND MAINTENANCE 5 1 Description and Operation Retraction and extension of the main and nose skis is affected by a hydraulic actuation system shown schematically in Figure 5 1 Figure 5 2 shows the ele
5. ctrical schematic The gear system is hydraulically actuated and driven by one reversible electric pump A pressure of between 500 psi and 700 psi in the down and 500 psi and 700 psi in the up position is maintained in the supply line When the pressure falls below 500 psi in the down position and 500 psi in the up position the pressure switch activates the pump solenoid providing power to the pump When the pressure reaches 700 psi in the down position and 700 psi 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 oil back to the pump reservoir when the line pressure exceeds 800 100 0 psi The system also has an internal relief valve to protect against thermal expansion when line pressure exceeds 1100 100 0 psi See Section 8 for disassembly service and troubleshooting The system requires hydraulic oil Mil H 5606 Red To check the fluid level fill the reservoir with hydraulic oil and cycle the gear If the reservoir empties i e fluid disappears in sight glass stop the cycle by pulling the circuit breaker on the control panel 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 up and down positions If the fluid level continues to decline duri
6. g x mounting and general condition Pressure Switches X Inspect wiring mounting and general condition Pump Motors Inspect wiring mounting and X X general condition Landing Gear Pivot Inspect for Gear condition lubrication Systems corrosion and paint Nose and Main Wheel Bearing Grease zerk fittings Hydraulic Fluid Level gt lt gt lt Wheels and Tires Inspect for wear pressure condition Brake Assemblies Inspect x for wear corrosion leakage Page 14 of 16 206 4000 FLI LITE WITH HYD POWER PACK SKI SERVICE MANUAL INSPECTION TIME INTERVALS HOURS 25 50 100 200 Hydraulic Fluid Screen Clean and inspect Note floats sit for extended periods of time i e if removed during winter months screen should be cleaned before putting floats back into service Hydraulic fluid in reservoir should be checked for moisture or other contaminates and changed if necessary Main and Nose Gear x Actuator Assemblies Inspect for condition lubrication leakage corrosion and cleanliness Hydraulic lines Inspect for X leaks condition and security Perform Retraction Test Main Gear Inspect up and X down for proper engagement Perform emergency gear X Extension hand pump Nose and Main Wheel X Bearings Disassemble and inspect As general inspection g
7. ng gear cycles check for external leaks If pump cycles on and off during gear cycle it may be necessary to select hand pump to UP Cycle gear UP with electric pump then select gear DOWN on hand pump and cycle gear DOWN with electric pump Repeat if necessary This manually bleeds system NOTE Fluid level in reservoir in UP position is full DOWN position reservoir is half full Don t over fill in DOWN position A cockpit mounted switch accomplishes the selection of gear up or gear down Page 4 of 16 206 4000 FLI LITE WITH HYD POWER PACK SKI SERVICE MANUAL HYDRAULIC PUMP ASSY EMERGENCY HAND PUMP SKI FITTING Figure 5 1 Schematic Hydraulic System CESSNA 206 Page 5 of 16 206 4000 FLI LITE WITH HYD POWER PACK GEAR SWITCH ee eb ON SKI SERVICE MANUAL 382 1177 4A11000 011 WIRING HARNESS REF OR 382 1203 4 11000 012 WIRING HARNESS REF PLIMP ON o uwa gt a WHICH HARNESS DEPENDS ON MODEL REF AC 4004 DIODE 3 Figure 5 2 Schematic Electrical CESSNA 206 9 EE 8 DC BUSS Me 5 DC BUSS AOA 12V 25 240 POWER RELAY wT 87a 30 phi 191 GE lt an a GE PR SW SW RELAY gs 87 30 a7 GA T x GRN 86 F
8. r cycle 6 7 Probable Cause a Binding in retraction unit b Pressure switch cut off limit too low Remedy a Investigate for free operation Check gear that retracts last b Replace pressure switch PROBLEM Slow gear operation cycle considerably longer than 30 seconds Probable Cause a Plugged oil screen b Poor electrical connection to motor Check ground c Poor motor d Worn pump gears Remedy Clean intake screen located inside reservoir tank Connect motor direct to 12 24 volt source and note operation poor motor needs overhaul Covered in b above Replace pump of PROBLEM Circuit breaker pops during cycle Probable Cause a Wire connections bad or corroded b Bad motor brushes c Bad circuit breaker Page 10 of 16 206 4000 FLI LITE WITH HYD POWER PACK SKI SERVICE MANUAL Remedy a Clean and protect terminal with grease b Overhaul motor c Replace circuit breaker 8 PROBLEM Power pack does not cycle up or down Probable Cause a Pressure build up in both sides of up and down lines Remedy a Select hand pump to up and down position to relieve pressure Return to center and select gear Page 11 of 16 206 4000 FLI LITE WITH HYD POWER PACK SKI SERVICE MANUAL PUMP MOTOR BREATHER Ps Tenere P sf RING MOTOR TO BASE FILLER TUBE JAM NUT ADJUSTING SCREW EXTENSION TUBES RESERVOIR SEAL
9. uidelines each of the following areas should be inspected for their own unique attributes Movable Parts For lubrication servicing security of attachment binding excessive wear safetying proper operation proper adjustment correct travel cracked fittings security of hinges defective bearings cleanliness corrosion deformation Fluid Lines and Hoses For leaks cracks dents kinks chafing security corrosion and deterioration Metal Parts For security of attachment cracks metal distortion broken welds corrosion condition of paint and any other apparent damage Wiring For security chafing burning defective insulation loose or broken terminals corroded terminals Bolts in Critical Areas For corrosion correct torque when installed or when visual inspection indicates a need for a torque check Page 15 of 16 206 4000 FLI LITE WITH HYD POWER PACK SKI SERVICE MANUAL 10 AIRWORTHINESS LIMITATIONS No time limitations for this installation The Airworthiness Limitations section is FAA approved and specifies maintenance required under 43 16 and 91 403 of the Federal Aviation Regulations unless an alternate program has been FAA approved Page 16 of 16
10. und Select hand pump to up and down position to relieve pressure Return to center and select gear Th PROBLEM Power pack does not shut off after gear reaches position a Faulty pressure switch b Faulty or dirty pressure relief valve allowing insufficient pressure buildup Remedy a Replace pressure switch b Clean and check relief valve PROBLEM Power pack shuts off before gear reaches position Probable Cause a Binding jammed or frozen gear retractor which causes pressure to build up and stay up and pressure switch shuts off power pack Remedy a Repair retractor PROBLEM Power pack cycles on and off after gear is in position Probable Cause Page 8 of 16 206 4000 FLI LITE WITH HYD POWER PACK SKI SERVICE MANUAL a Internal hydraulic leak b External hydraulic leak Page 9 of 16 206 4000 FLI LITE WITH HYD POWER PACK SKI SERVICE MANUAL Remedy a Verify leak is not external by checking fluid level in reservoir and looking at couplings for oil leaks If no external leaks are found disconnect and off the hydraulic actuators one at a time and find the leaky one by process of elimination b If isolating entire system still indicates internal leak power pack check valve located in pressure port of pump is bad and needs replacement or reseating c Visually inspect lines cylinders and hoses and replace as necessary 5 PROBLEM Power pack cycles on and off during gea
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