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A-10031 Service Manual 8_27_2010

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1. 12 Troubleshooting There are a number of troubleshooting instructions given throughout this manual in relevant areas This section is intended to compile these instructions and additionally provide any additional instructions that have become evident since the original writing Table 12 1 Troubleshooting Model 3400 Amphibious Floats Float Hull Assemblies Excluding Amphibian Gear Detected Problem Possible Cause _ Corrective Action Water in floats nstall plug Missing plug l Improperly fastened access panel nstall panel latch locker door _ or locker door nspect seals replace as necessary Replace as necessary Disassemble clean inspect and reinstall Improperly sealed fasteners with sealant Damaged float hull _ Inspect float bays for signs of penetration Excessive drift left or Water Rudder rigging is right during water _ misaligned taxi operations 3 Align the float rudders by re adjusting the _ steering cables and or the balance cable nspect and repair damage l Damage to water rudder blade s ocate and replace damaged pieces Howling noise from Locker door left open Fly the airplane Land Latch the doors one or both floats after take off Aircraft is unstable Broken structural members _ Inspect Struts Tie Rods etc for breaks and during water _ for adjustment operations Rudder Pedal feels Mis aligned st
2. Check battery voltage and condition Refer o aircraft maintenance manual Check voltage at the aircraft buss Check voltage at the terminal block near the draulic pump lt Check gear and hydraulic systems for mechanical damage debris or other _ obstructions Assure normal freedom of movement throughout the Floats Nose and Main Gear Assemblies Mechanical Obstructions Hydraulic Pump stops Mechanical Obstructions lt Check gear and hydraulic systems for working before the mechanical damage debris or other gear reach full _ obstructions Assure normal freedom of position movement throughout the Floats Nose and Main Gear Assemblies l solate the malfunctioned switch and replace as necessary Pressure Switch malfunctioning Slow Gear Operation Mechanical Obstructions _ Check gear and hydraulic systems for mechanical damage debris or other obstructions Assure normal freedom of _ movement throughout the Floats Nose and Main Gear Assemblies EROCET Incorporated HENS 8 12 03 73 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 Table 12 1 Troubleshooting Model 3400 Amphibious Floats Cont d Hydraulic System Detected Problem Possible Cause _ Corrective Action Check all lines for damage such as
3. 3 Float Handling and Jacking In order to service the landing gear parts and to do retraction tests the floats are jacked up and blocked using a floor jack with at least 1 ton capacity Raise only one float at a time chock the opposite float properly and assure proper balance The best lift point is 6 inches ahead of the step on the keel This locates the jack directly under the main bulkhead in the float If space permits use a board in between the jack and the keel After raising the float block the float in a couple of places ahead of the step Use a sawhorse to support the after body of the float to keep the plane from tipping back Locate a sawhorse support under one of the back bulkheads which are located 16 or 45 forward from the stern Jack the other float carefully to a height that will clear the landing gear for retraction tests and repeat supports to this side as well to assure stability before climbing into aircraft and initiating retraction During initial installation or for maintenance and retraction tests if convenient the lifting rings on the top of the fuselage provide the proper points to attach a lifting harness to elevate the complete airplane The hoist should have a capacity of least 2 tons and a proper lifting harness to assure that the pull on the lift rings is vertical must be used The airplane may be lifted with either a launching dolly or large forklift under the spreader bars Care should be taken to lift as c
4. Gear Advisory Audio Detected Problem Possible Cause l Corrective Action Gear Advisory Audio Volume is too low or audio wiring Check Aircraft Audio Panel settings and Warning does not is incorrectly installed ook up activate See A 10037 for Model GC600 compromised does not arm or _ and Pitot systems _ trigger the advisory unit _ Return the advisory unit to Aerocet for repair r K 65 units refer to Section 6 7 of this Manual For GC600 Units Refer to A 10037 CMM Internal components are compromised rigger Speed is not correctly set Audio Warning does Airspeed did not exceed the Arm not activate after a _ speed Go Around _ Increase airspeed during the downwind leg f a Go Around procedure l The Arm speed setting is too For K 65 units refer to Section 6 7 of this high Manual _ For GC600 Units Refer to A 10037 Audio Warnings Incorrect Cancel Button is being Depress the cancel button for the operation continue to activate depressed applies to GC600 e g the upper Cancel Button for cancelling the Gear is UP warning Audio Warnings _ Airspeed is too close to Arm and Maintain slightly higher speeds continually reactivate Trigger speeds while flying inthe i pattern after The Arm and Trigger speed For K 65 units refer to Section 6 7 of this depressing the correct _ Settings a
5. WARNING DO NOT OVER TORQUE DECK BOLTS 25FT LBS OR YOU MAY CAUSE DAMAGE TO THE FLOAT STRUCTURES Assure that all float sockets and spreader ends are free of chips and debris Apply a thin film of marine grade grease to the sockets and the spreader ends This amount of grease should be enough to omit adding more through the grease zerks immediately after installation is complete EROCET TSSUE Incorporated eon Date 8 12 03 45 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION 5 6 7 8 9 1 2 3 4 5 REVISION Date 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 WARNING INTRODUCE GREASE VERY SLOWLY AND CAREFULLY WHEN USING THE GREASE FITTING ON THE SPREADER SOCKETS OFTEN INITIAL ASSEMBLY GREASE IS SUFFICIENT FOR YEARS OF SERVICE SO SPARING USE IS ADVISED TO REDUCE RISK OF CAUSING TOO MUCH PRESSURE OR COMPROMISING THE SEAL Carefully insert the spreader ends into one float using a second person to help support the float and or the spreaders Align the pre drilled holes place the deck fittings as shown in the drawings and install the bolts Itis not necessary to tighten the clamp blocks and nuts at this time NOTE ALL PARTS AND HARDWARE THAT PENETRATE FLOAT STRUCTURES ARE INTENDED TO BE SEALED WITH A MARINE GRADE URETHANE ADHESIVE SUCH AS SIKA FLEX 292 OR 3M 5200 DO NOT USE SILICONE With the bolts inserted into the on
6. Any brackets and the submersible sensor may be removed Check all parts for corrosion and I glide bushings for wear Replace as necessary 5 6 Complete Assembly of Main Gear including adjustment of submersible sensor and main gear hydraulic actuator Reference 35A CPL 45000 Sheets 1 7 Reverse procedure in Section 5 5 with the following particulars Any attachment hardware and bolts that pass through the bulkhead should be sealed with a one part urethane adhesive to assure water tightness When installing the main gear hydraulic actuator back into the bulkhead note that there is a Stat O Seal washer on the head side of the bolt and a Thred Seal washer on the thread side of the bolt Aerocet also recommends use of a one part urethane marine grade sealant here as well such as Sika Flex 292 Do not use silicone Install the drag link assuring the placement of the plastic spacer item 11 to protect the extension spring from contacting the drag link during operation After installing the drag link and affixing it to the hydraulic actuator adjust the rod end so that the drag link rests firmly against the stop bracket with the hydraulic actuator fully retracted The system must be powered up to assure that the actuator is fully retracted main gear in down position Be careful when doing this with floats properly jacked up according to Section 3 Add 3 4 turn of thread clockwise motion into the rod end allowing for assurance of
7. Return the GC600 unit to Aerocet for Internal components are deploying compromised repair Gear position _ Hydraulics lines are not correctly Trace the hydraulic lines to the installation activates opposite installed likely reversed on one _ drawing applicable to the Aircraft action for one float float or the other _ Provided with Installation Package from the other one l available from Aerocet Inc or Seaplanes float s gear goes UP _ West Inc for 182 Aircraft See also 35A and the other goes l 60010 DOWN EROCET PAGE 8 12 03 Incorporated 74 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 Table 12 1 Troubleshooting Model 3400 Amphibious Floats Cont d Hydraulic System Detected Problem Possible Cause _ Corrective Action Emergency Hand Selector lever is not positioned Refer to the SAFM Operating Instructions Pump does not move correctly Placard for instruction on the proper the float gear position of the lever Select position and etry With the floats suspended ensure that the Electric Hydraulic Pump reservoir is properly filled Proceed to activate the pump in one direction only re filling the _ reservoir as necessary Repeat for opposite direction until all air is purged from system l Air in the hydrau
8. DATE Figure 5 3 S 1001 SJONVNSALNIVW 0410 ANY AIENASSV Y5dds4 1d 0410 lt HONSYM JA33 1S 0410 O9cSPL VSE lt SOY LNAWSI1WV SNOYdOL amp 99CSVL VSE lt gdW19 AAAd1S AWOYHS 89cSTL VSE Se 04 INAWNDI1V SNOYOL L 99 S01 VSE TOOL YANNVdS ANOYOL L9OGSVL VSE EROCET TSSUE Incorporated aoe DATE 8 12 03 25 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 5 4 Oleo Assembly Reference 35A CPL 45000 Sheets 2 6 7 and 35A CPL 45200 Sheets 1 amp 2 10 11 13 In general reverse disassembly procedures Lube all seals before putting them into place Assure that all Polypak seals face correctly for keeping the pressure in the oleo The lip side of the seals should face to the inside of the oleo Reassemble the top cap to the chrome upper if these were disassembled Lube the threads with grease Holding the chrome upper using the Chrome Sleeve Clamp 35A 45268 in a vise screw the top cap back into place Torque the top cap to the chrome upper using Torque Spanner Tool 35A T45267 and a 2 rod inserted through the I Glide bushings Torque should be 80 foot pounds Set in place the metering insert but do not snap ring in It is easy to fill the oleo with fluid with this removed as described in step 7 Push the top cap and chrome upper throu
9. 4X LIGI IS co LIGHTS IS CO AEROCE INSTAL 35A C Ni8U EM12E AN6X2 H1141 SHOWN WITH INSTALLATION HARDWARE AND TARGET IS IN RANGE THREADED MOUNT REQ D YELLOW SENSOR END HTS SHOW GREEN WHEN HOOK UP PLETE AND POWER IS APPLIED SHOW AMBER WHEN HOOK UP PLETE POWER IS SUPPLIED T_35A 45071 LATION HARDWARE PER PL 45000 EROCET Incorporated ERCE 8 12 03 29 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION DATE 8 27 2010 SUBTITLE Model 3400 Amphibious Floats pitas 6 6 Landing Gear Retraction System 6 1 General Description Normal landing gear extension and retraction is accomplished by hydraulic actuators for each gear The hydraulic system is powered by a reversible electrically driven hydraulic pump Hydraulic pump operation is initiated by moving the landing gear switch on the gear advisiory to either the up or down position The landing gear will travel to the position indicated cycling the electrically driven hydraulic pump The pump is shut off by pressure switches When the pressure switch senses a certain amount of pressure in the hydraulic line which the electric pump is forcing fluid through it will send a signal to the motor relay shutting down the pump The pressure increases at the end of operation when all the actuators have traveled to the end of their stroke Eight position indicator lights four gear up and four ge
10. LOCATE MIDDLE HOLE OF BRACKET ASS Y AT THE CENTER OF THE ACCESS COVER PLATE MAKE PIVOT ADJUSTMENTS TO SUIT PILOT VIEW USE THE BRACKET ASS Y HOLES TO LOCATE DRILL LOCATIONS IN THE ACCESS COVER PLATE EROCET 8 12 03 Incorporated ERCE 39 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION DATE 1 REVISION 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 Installation Ref Drawing No 35A 59402 and Figures 6 8 1 amp 6 8 2 a mpg bh Locate an inspection cover on the underside of the wing just inboard or outboard of the wing strut Position the Mirror Bracket so the middle hole is approximately centered in the access cover and temporarily affix the mirror assembly to it Once a good access panel is selected remove it and drill a 11 191 hole in the center This will serve as a pivot point for finalizing the installation Loosely assemble the Mirror Bracket and Inspection Cover with Machine Screw Washer and Nut Do not tighten fully so that it can be rotated to finalize orientation While seated in the Pilot s and or Co Pilot s seats instruct an assistant to pivot and adjust the Mirror Assembly to suit proper viewing of the Nose and Main Gear assemblies It may be necessary to bend the bracket for optimum view Mark bracket hole pattern for remaining two screw holes and remove the cover from the underside of the wing Dri
11. 6 EROCET Appendix TSSUE Incorporated ee DATE 8 12 03 81 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 Installation Drawings for Aerocet Model 3400 Amphibious Floats The following appendices list the specific drawings included for each aircraft model covered by this ICA For current versions applicable to your installation please consult the STC s AML for revision level of the Master Drawing List The appendices are bound separately Appendix A Cessna 180 or Cessna 185 Per STC SA01257SE Aerocet Document A 18 Part Application Listing Weight Affidavit for Cessna 180 or 185 Seaplanes on Aerocet Model 3400 Amphibious Floats 35 24001 TSO Rudder Assembly also in CPL 35A 46010 TSO Float Wiring Schematic 35A 3 1000 Master Drawing List 35 11050 Tie Rod Assembly Rear 35 11051 Tie Rod Assembly Forward 35 24010 Water Rudder Retract Handle Assembly 35A 59000 General Installation Cessna 180 185 Aerocet Amphib Floats 35A 59030 Amphibious Model 3400 180 185 Installation Ventral Fin 35A 59100 Strut Tie Rod amp Step Installation Cessna 180 185 Aerocet 3400 Amphib Floats 35A 59200 Spreader Bar and Deck Fitting Installation Cessna 180 185 Aerocet 3400 Amphib Floats 35A 59300 Water Rudder Retract Installation Water Rudder Rigging Cessna 180 185 Aerocet 3400
12. Bleeder Assembly 35A T45201 provides an easier leveraged way to facilitate this and keep alignment 8 Using the Oleo Sleeve Wrench 35A T45260 remove the bottom cap from the oleo Locate the service wrench in a vise Position the oleo bottom facets into the wrench Place a 1 2 steel rod through the bottom cap bushings and unscrew the bottom cap from the oleo bottom in a counter clockwise motion Drain residual fluid into the bucket Check fluid for contamination 9 Remove the high pressure charging valve 10 Push the top cap and chrome upper down through the oleo bottom 11 Service all available seals as necessary 12 Further disassembly may be accomplished by removing the internal snap ring and metering insert 13 The top cap may be removed from the chrome upper by clamping the chrome using Chrome Sleeve Clamp 35A 45268 in a vise Unscrew the top cap counter clockwise using the 1 2 rod Make sure the clamp tools surfaces are perfectly clean before use 14 Top cap seals may be serviced at this time 15 The metering rod should be examined for damage and if removed should be safety wired back upon replacement 16 Examine I Glide bushings and replace as necessary 24 of 82 REVISION Incorporated rA ry fe O a oO U S oO p S d O z 2 oO U d gt Q oO op Model 3400 Amphibious Floats SUBTITLE 8 12 03 8 27 2010 ISSUE DATE REVISION
13. damage pressure X Oleo Strut ISSUE DATE 8 12 03 TITLE REVISION DATE 8 27 2010 INSPECTION TIME INTERVALS SUBTITLE EROCET Incorporated Service amp Maintenance Manual Model 3400 Amphibious Floats 6 PAGE 63 of 82 FILE NO A 10031 REVISION HOURS MONTHS Whichever occurs first Retraction System Fluid Perform Retraction Test Hydraulic Fluid Level Inspect travel also perform emergency gear extension amp retraction test Check sight glass fill to within 1 of top of sight glass with gear down 100 200 25 50 12 24 Retraction System Fluid Cont d Retraction System Electric Hydraulic Fluid Screen Contaminates Clean and inspect screen Check for moisture amp debris Hydraulic Lines amp Fittings Inspect for leaks dents corrosion contact with airframe cables struts Hydraulic Actuators Pump Solenoids Pressure Switches Inspect for leakage fittings seals rod straightness corrosion Inspect wiring mounting loose terminals general condition Position sensors in floats Inspect wiring mounting general condition Pump and Indicator Wiring to Gear Advisory Water Rudders amp Tiller Posts Inspect wiring mounting terminal blocks in floats general condition Inspect for damage and freedom of movement check right after a take off
14. float 8 12 03 REVISION DATE 8 27 2010 TITLE SUBTITLE EROCET Incorporated Service amp Maintenance Manual Model 3400 Amphibious Floats This page intentionally left blank except this line PAGE 42 of 82 FILE NO A 10031 REVISION 6 EROCET Incorporated ERCE 8 12 03 43 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 8 Float Installation and Removal to Aircraft The appendices are intended to provide aircraft specific installation drawings or instructions necessary to install Aerocet Model 3400 Amphibious Floats Some approvals by way of Supplemental STC or via field approval Form 337 are not the property of Aerocet and may require other documentation Supplemental Airplane Flight Manuals SAFM s or Airplane Flight Manual Supplements AFMS s STC documentation or other necessary information is not included in this section It is the responsibility of the Installer and the Owner s and the Pilot to ensure that the modification is accomplished and documented in a correct manner Float service and maintenance is dealt with in previous sections of this manual supplemented by the Customer Parts List CPL 3400 CPL 8 1 Installation Instructions For Cessna 180 185 Installation 35A 59000 For Cessna 206 Installa
15. 27 2010 10 INSPECTION TIME INTERVALS SUBTITLE EROCET Incorporated Service amp Maintenance Model 3400 Amphibious TABLE 1 PAGE 61 of 82 FILE NO Manual A 10031 REVISION Floats 6 Recommended Service Schedule General Practices and Product Listings for Service HOURS MONTHS Whichever occurs first Nose Landing Gear Nose Gear Tracks Inspect clean and re lube daily note 1 100 200 25 50 12 24 Nose Gear Bottom Block Lubricate Do not lubricate without reading warning note 2 Nose Wheel Bearings Inspect re lube bearings amp seals prior to assembly Nose Wheel Seals Spray lubricant LPS 2 on seals where they contact the tensioner bushings Nose Wheel Fiberglass Spring Inspect for cracks delamination paint Nose Gear Aluminum Parts Inspect for corrosion damage Internal Protection of Nose Gear Box Apply corrosion spray to box inside front float compartment note 3 Bolts Hardware Inspect for corrosion apply corrosion protection note 4 Nose Gear Lock amp Slide Bushings Inspect for wear apply light amount of grease to slide pins through holes in lock Seal Around the Nose Gear Box Inspect for gaps and reseal between box and float front Centering Device Check Assure side to side travel at the axle is within limits and vertical travel is also within
16. 35A 60015 Float Wiring Schematic 35A 62000 Walkwire Plate Installation 36 15010 Installation Aerocet Model 3400 Floats Cessna 206 Series Aircraft 36 15011 Spreader and Deck Fitting Installation Cessna 206 Aerocet 3400 Floats 36 15100 Strut amp Flying Wire Installation Cessna 206 Aircraft 36 15200 Water Rudder Rigging Installation 36 15300 Boarding Step Installation 36 15400 Hydraulic Pump Installation 36 15410 Electrical Installation 36 15460 Emergency Hand Pump Installation 36 15480 Terminal Block Assembly 36 15490 Hydraulic Pump Mounting 36 15500 Aileron Fence Installation 36 15600 Placards Aerocet Model 3400 Floats Cessna 206 Installation End of Cessna 206 3400 Installation Listings
17. CMM A 10037 See illustration for comparison between the K 65 and GC600 units The newer GC600 is designed to be a direct replacement for the K 65 Both fit the same panel opening and accept the same wiring connector and hook up The K 65 will not be readily available after 11 09 K 66 Auxiliary Advisory optional is no longer used with the GC600 Figure 6 7 GC600 GEAR ADVISORY PUMP RUNNING INDICATOR TWO CANCEL SWITCHES xy CANCEL AND TEST SWITCHES ARE FLUSH ON DISPLAY FACE TEST AND CANCEL TOGGLE SWITCH PUMP RUNNING INDICATOR K 65 GEAR ADVISORY The landing gear handle is an electrical switch mounted within the Gear Advisory Unit on the instrument panel and has two positions UP for gear up and DOWN for gear down which give a mechanical indication of the gear position selected From either position the handle must be pulled out to clear a detent before it can be repositioned Moving the handle to UP or DOWN will start the reversible electrically driven hydraulic pump in the selected direction of gear travel Operation of the landing gear system will not begin until repositioning of the handle is complete The following information may be applied to K 65 units only Eight indicator lights are mounted on the Landing Gear Advisory Unit adjacent to the landing gear handle The four blue indicator lights labeled WATER positioned respective to their location on the float i e top left front le
18. airplane is lowered to the struts Apply corrosion inhibiting compound such as Puralketone to all metal fasteners during and after installation Tie Rods should be generously lubricated with a high quality anti seize compound to all threads to avoid galling of stainless components Tighten them evenly assuring the craft s alignment to like datum points on each wing and each float Anti chafing material such as leather vinyl or nylon may be affixed where tie rods pass closely If this is not a first installation thoroughly inspect the tie rods for corrosion pits dents or other damage before using them Apply a coat of wax or oil to prevent corrosion 8 1 5 Water Rudder Rigging Installation For Cessna 180 185 Installation 35A 59300 For Cessna 206 Installation 36 15200 1 2 3 4 5 Aerocet floats are supplied with stainless 3 32 Wire Rope per MIL DTL 83420 Type I Composition B which is to say non jacketed stainless steel Aerocet supplies stainless 7 X 7 but allows steel 7 X 7 as well 7 X 19 is acceptable if preferred Start cable installation with the water rudder inter connect or balance cable having someone hold the water rudders aligned to one another Install the turnbuckle to one side typically near the left float with clearance to the float structure at full water rudder deflection Do not install the turnbuckle in the middle as it will allow greater movement in the cable possibly agai
19. cotter pins and safety wire 7 Ensure that the aircraft and the floats have been closely squared to one another See Strut and Tie Rod Installation Adjust Tie Rods as necessary 8 Check all exposed hardware for application of anti corrosion compounds 9 Check all grounds and electrical routing 10 Check aircraft battery condition Insufficient power or reserve will produce unpredictable results during gear checks EROCET Incorporated ERCE 8 12 03 50 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 11 Check the fluid level in the Electric Hydraulic Pump should have no less than 1 inch of fluid in the sight glass but may be fully filled at initial start as the system will use some of that 12 Check wheel assemblies for lubricant 13 Bleed or purge all air from brake lines Pedal fade after much bleeding may indicate a leak or a worn master cylinder 14 Re connect aircraft battery according to Cessna Service Manual 8 1 12 System Activation 1 With the aircraft and floats securely hoisted or lifted and all precautions taken to prevent an engine start 2 Note the position of the float gear and place the Gear Position switch to match 3 Activate the Master Switch 4 Note any audio enunciations Push TEST button on gear advisory to verify audio enunciation Announc
20. from putting too much pressure on the internal components Grease guns can develop incredible force EROCET Incorporated ERCE 8 12 03 21 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 5 Main Gear 5 1 General Description The main landing gear utilizes a trailing arm link design using a 6 00 X 6 tire and a oleo shock strut The main gear is retracted and held in the up position by a hydraulic actuator There are no up locks to fail and the geometric design allows the actuator to hold the gear in the up position under high G forces with low hydraulic pressures In the down position the oleo and drag link travel into an over center position against the stop bracket When the gear is in the down position this position is maintained even without hydraulic pressure with two springs assisting the over center position Proximity sensors are used to give gear position information to the landing gear advisory 5 2 Main Wheel Removal amp Assembly Reference 35A CPL 45700 Consult Parker Cleveland Maintenance Manual and Parts Catalog or Aerocet Component Maintenance Manual A 10036 for wheel and brake maintenance and repair 1 Make sure gear is in the down position and hydraulic gear motor circuit breaker is pulled 2 Block and jack the airplane according to Section 3 3 Remove brake pads and slid
21. gear is in the down position and hydraulic gear motor circuit breaker is pulled 2 Jack up the airplane according to Section 3 3 Unbolt the bottom block from the composite nose spring 4 Second option pull the centering pin and two lock pins P N 35A 42129 on later model or retro fitted floats from the bottom block and dropping out the lower nose fork assembly 4 3 Nose Gear Full Removal of the Nose Gear apart from the gear box and riveted on slide brackets Reference 35A CPL 42000 Sheets 1 amp 2 35A CPL 42100 Sheets 1 3 and 35A CPL 42300 Sheet 1 Remove bumper by unscrewing the four screws that hold it on Remove the composite nose spring Retract the nose gear cylinder Disconnect and plug the hydraulic lines from the hydraulic piston ap e NS Pull the box cap of the gear box by removing the 10 AN3 fasteners The box cap is sealed into place using single part urethane adhesive Care must be taken to break the seal yet not damage the mating parts 6 Be careful of the wiring for the position sensors Note the position of the up position sensor for reassembly They don t need to be disconnected if the hydraulic piston is pulled back only a short distance 7 Slide the box aft along with the hydraulic piston revealing the lock bushings and slide bushings 8 Clean and Inspect the gear box tracks for wear 9 Inspect and replace slide pins as necessary 10 Inspect and replace lock bushings and slide bushi
22. hole no more than turn is necessary 12 Install cotter pin through the axle nut 13 Install brake mount and brake Figure 5 2 10 ALIGN THESE FACES EROCET Incorporated ERCE 8 12 03 23 of 82 3 FILE NO TITLE Service amp Maintenance Manual A 10031 ee 8 27 2010 SUBTITLE Model 3400 Amphibious Floats REVISION P 5 3 Oleo Removal and Disassembly Reference 35A CPL 45000 Sheets 2 6 7 and 35A CPL 45200 Sheets 1 amp 2 Oleo Bleeder Assembly 35A T45200 may be available from Aerocet upon request See Figure 5 3 Make sure gear is in the down position and hydraulic gear motor circuit breaker is pulled Block and jack the airplane according to Section 3 Remove the oleo by pulling shear pins Keep oleo upright on the bench E a le Hook a length of 4 clear plastic tubing to the charge valve and locate the other end in a clean bucket 6 Release the oleo pressure while keeping the base of the charge valve from turning out from the top cap using a 34 wrench and slowly release the oleo pressure by undoing the valve lock nut counter clockwise 7 Compress the strut to discharge all the fluid from the cylinder This is done by using a 1 2 steel rod positioned through the top cap bushings and pressing down on the cylinder Protect the bottom cap from damage by placing it on a piece of wood or rubber Bench service tool Oleo
23. incorporates a ceramic magnet to trigger the nose gear sensors This is located on the piston nose behind the retaining washer 4 Inspect and replace all seals and any damaged parts for service 5 Pre lube all seals and mating surfaces with a lithium grease 6 Upon reassembly assure that the ports in the piston caps line up with the holes in the cylinder Applicable to 35A 42400 amp 35A 45300 assemblies only 7 For 35A 45400 Main Gear Actuator similar procedures may be followed by referencing illustrations in 35A CPL 45400 Hydraulic fitting on the top end must be removed before removing end cap or damage may occur 6 4 Electrical Diagrams Reference 35A 46010 and or 35A 60015 as applicable Drawing included in back of Service Manual 6 5 Electric Hydraulic Pump Reference 108 Series Power Unit Drawings included in back of Service Manual 1 Remove return line on lower reservoir and drain oil 2 Remove reservoir tank by loosening screw on bottom of tank 3 Note the cleanliness of the pick up filters these are friction fit into place clean as needed 4 The thermal relief is set at 1100 100 100 psi and the pressure relief is set at 800 100 100 psi from the factory Reference the Power Unit Drawings for adjustment if necessary Note These settings are very fine and Aerocet does not recommend making adjustments unless it is necessary 5 It should be noted that the Pressure switches electrical which tur
24. limits EROCET TSSUE DATE 8 12 03 Incorporated 62 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 eee 8 27 2010 SUBTITLE Model 3400 Amphibious Floats REVISION INSPECTION TIME HOURS MONTHS INTERVALS Whichever occurs first 100 200 25 50 12 24 Nose Landing Inspect travel amp extra side Gear Cont d play in deployed position also perform emergency gear extension amp retraction test Perform Retraction Test Gear Main Gear Inspect for corrosion Aluminum Parts i damage X Main Wheel Inspect re lube bearings Bearings amp seals prior to assembly X Spray lubricant LPS 2 on Main Wheel Seals seals where they contact the tensioner bushings X Inspect for wear leakage corrosion X Keep debris from building up especially on the drag Brake Assemblies Cleanliness brace stop to assure overcenter operation amp rock deflector X Axle Seals Inspect O rings on tensioner bushings X Inspect for corrosion Bolts Hardware _ apply corrosion protection note 4 X Inspect for signs of leakage through bolts that Water tightness fasten brackets on amp seals on main gear actuator attach X Inspect for wear pigs Paeniige obliqueness cracks etc X l Assure they are in place Extension Springs Without breake xX Composite Gear Inspect for cracks Box damage X Inspect for leakage
25. necessary 4 7 Nose Wheel Installation Reference 35A CPL 42100 Sheets 2 amp 3 1 Reverse procedures in Section 4 2 2 Be sure to thoroughly clean and re pack wheel bearings bearing seals and coat the axle bolt with marine grade waterproof grease Note Apply spray film to these seals every 25 hours after placed in service Also some greases are not compatible with one another thoroughly clean all old grease lubricant from the wheel cavity and bearing cones before re packing Observe all manufacturer s instructions 3 Assure that the AN8 50A bolt has its head on the left side looking forward and engaged in the fork notch to keep from rotation 4 The Stat O Seals are used to keep water from entering along the bolt and bypassing the wheel seals 5 Tighten the castellated nut enough to ensure that the tensioner bushings don t rotate when the wheel spins yet not bind up the bearings 6 Install cotter pin 7 Check the pressure in the 10 X 3 50 4 tire Pressure should be 70 psi 4 8 Nose Centering Pin and Nose Pivot Pin Service Reference 35A CPL 42100 Sheets 1 amp 3 1 Remove centering pin according to exploded view 2 Check wear on pin This is done by noting that the tire will want to center in the trail position There should be no more than 3 16 free travel side to side at the axle There should be no more than 1 16 063 vertical movement of the nose block Replace as necessary 3 The heat tre
26. opens l _ corrosion damaged insulation or improper _ hook up Ref 35A 60015 schematic lectric Hydraulic Pump motor is failing Replace pump assembly as necessary EROCET Incorporated ERCE 8 12 03 76 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 eee 8 27 2010 SUBTITLE Model 3400 Amphibious Floats REVISION P Table 12 1 Troubleshooting Model 3400 Amphibious Floats Cont d Gear Advisory Includes K 65 Models See A 10037 for additional details applicable to GC600 p Models Gear Advisory Indicator Lights Detected Problem Possible Cause _ Corrective Action Hydraulic Pump light DB 25 connector is not fully Check the DB 25 Connection and firmly re does not illuminate connected install as necessary when the Electric Diodes near the Electric Hydraulic Ensure correct orientation of diodes Hydraulic Pump is Pump are installed backwards checking connections per 35A 60015 activated chematic Diodes are correctly installed but solate the malfunctioned diode s and _have malfunctioned ace as NECESAN ununes _ Faulty wiring Check for faults with installation wiring to _ the Electric Hydraulic Pump This includes corrosion damaged insulation or improper hook up f E A OOT N T e 1 Amp fuse is blown lt Check condition of the fuse Replace as necessary Continue investiga
27. proceed to disconnect aircraft battery according to Cessna Service Manual 6 The electric hydraulic pump is mounted in the back of the aircraft aft of any baggage area For the 180 185 installation refer to 35A 60000 for details For the 206 installation refer to 36 15490 7 The hand pump used in cases of electrical failure is mounted between the pilot and copilot For the 180 185 installation refer to 35A 64000 for details For the 206 installation refer to 36 15460 EROCET Incorporated ERCE 8 12 03 48 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 8 Hydraulic line installation and routing is routed from the electric hydraulic pump forward to the hand pump and down to the floats For the 180 185 installation refer to 35A 60000 For the 206 installation refer to 36 15400 9 Itis good practice to identify gear up retraction lines gear down deployment lines and return reservoir lines to avoid confusion while working on them If a line is improperly connected then the system will not function properly It may run without building pressure in one direction for instance 10 Electrical hook up is done to schematic 35A 60015 and detailed in 35A 60000 for the 180 185 or 36 15410 for the 206 11 Gear Advisory is to be installed in a standard 3 25 instrument hole using 6 32 machine screws It
28. touch the end of their travel in the slide brackets Tighten the jam nut to the rod end to secure position Use tool 35A T42400 to help facilitate this It should be noted that the gear down position sensor should be adjusted as far forward as possible with full contact on the hydraulic cylinder part 35A 42436 This will cause indication when the lock bracket comes into a roughly vertical position The lock bushings and lock bracket travel beyond this point however when positioned properly The gear up position sensor should be located on the hydraulic cylinder to activate when the gear is in the fully retracted position It should be noted that if the position sensor is too far forward it may not indicate when the gear is fully up because the magnetic ring passes by the sensor A single tie wrap on the aft or forward side of the bulkhead along with sealant is adequate to hold the sensor in position The two AN4 47A bolts position the width of the slide brackets parts 35A 42022 L amp R These should be tightened to allow 1 8 movement of the nose spring part 35A 42130 where the bottom block part 35A 42126 attaches Too tight is binding and too loose allows wear and shimmy possibilities Removal of the Complete Nose Box and Gear from the front of the float Reference 35A CPL 42000 Sheets 1 amp 2 35A CPL 42100 Sheets 1 3 and 35A CPL 42300 Sheet 1 Remove bumper by unscrewing the four screws that hold it on Disconnect and plug the
29. wear strips should be observed on preflight when on land or if you suspect damage They should never be allowed to wear through to the gel coat surface on the float Replace as necessary All float access panels are to be removed upon annual inspection to view for hidden damage and to comply with the hydraulic maintenance section and water rudder section During this time assure that all the pump out tubes are not cracked especially around the fitting to the pump out cup that they pass through their respective locators to keep them in the low spots and have no blockage If a pump out tube is cracked it will not pull the water out of its respective compartment resulting in extra weight and CG problems Replace as necessary Any penetration to the float structure delamination of the layers of cloth or gel coat wearing through must be repaired according to hull repair section 8 Significant damage warrants consultation from Aerocet Inc Winter storage where temperatures may drop below freezing is addressed by adding a quart of RV antifreeze through each of the pump out cups Taping over the pump out holes will minimize the amount of moisture that will enter each of the six compartments Do not use masking tape Float locker latches and seals are to be maintained as needed The locker latches are adjusted by adding washers beneath the black catch ramp the correct distance to maintain an indent as the locker latches the white dots to the outsid
30. 0 185 3400 Float installation 651 180 185 44 1 42 8 including all installed 663 206 equipment New Empty Weight Total Total Arm divide moment by weight M W EROCET ISSUE Incorporated eee DATE 8 12 03 53 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 eee 8 27 2010 SUBTITLE Model 3400 Amphibious Floats REVISION A 8 3 1 Weights for components left installed For temporary float removals such as for winter flight on skis it may be desirable to leave certain float equipment on board such as hydraulic lines and fittings float gear wiring and hydraulic pumps The following table shows weight and balance data for typical equipment Equipment not listed must be weighed separately Item Weight Weight Cessna 180 or Cessna 206 185 206 185 Location Location Electric Hydraulic 10 0 Ibs 9 0 167 50 163 0 Pump w hardware Hand Pump 3 2 2 64 31 38 30 63 w hardware incl hyd Fittgs To floor 36 15434 1 N A 125 N A 31 18 w rivets 36 15434 2 N A 125 N A 39 10 w rivets 35 24010 60 N A 22 26 N A 35 24011 N A 50 N A 41 30 Excl rivnuts or nutplates Hyd Lines to pump 2 5 2 5 95 97 5 Ventral fin 2 4 5 214 GC600 Gear 1 70 1 70 14 5 15 9 Advisory 8 12 03 REVISION DATE 8 27 2010 TITLE SUBTITLE EROCET Incorporated Service amp Maintenance
31. 03 52 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 8 3 Weight and Balance The most accurate means to determine the weight and balance of a modified aircraft is by physical measurement CAUTION Aerocet highly recommends that the aircraft be weighed to determine the weight and balance of the 3400 modified aircraft An inaccurate CG may lead to exceeding the CG range resulting in inadequate control Modify the equipment list to include the 3400 float installation and verify the remaining items On level scales with each wheel on the scales aircraft empty no fuel Scale Measured Weight 180 185 Arm 206 Arm Moment W Arm Front Left scale 60 8 60 2 Front Right Scale 60 8 60 2 Rear Left Scale 61 4 62 4 Rear Right Scale 61 4 62 4 Tare weights chocks Tare weights chocks Total Weight amp Moment Total Arm divide moment by weight M W If weighing the aircraft is not practical use the following data Item Weight 180 185 206 Arm Moment alb Arm W Arm Certified Empty Weight as currently equipped verify the equipment list Main gear 121 206 18 0 63 1 800 x6 Cleveland Typical 120 180 185 Nose gear or 41 206 260 0 68 Tail gear 8 less stinger 10 18
32. ADED PRIMARILY IN SHEAR TORQUE LIMITS Thread Size Tension type nuts Shear type nuts MS20364 Nuts MS20365 and Nuts MS20364 and MS20365 and AN310 and AN320 24 000 psi in AN310 90 000 psi in AN320 54 000 psi in 40 000 psi in bolts bolts bolts bolts FINE THREAD SERIES 12 15 7 9 20 12 20 25 12 15 50 70 30 40 100 140 60 85 160 190 95 110 450 500 270 300 480 690 290 410 800 1000 480 600 1100 1300 600 780 2300 2500 1300 1500 2500 3000 1500 1800 3700 5500 2200 3300 5000 7000 3000 4200 9000 11 000 5400 6600 Figure 2 2 1 Recommended Torque Values inch pounds From AC43 13 1B Table 7 1 FINETHREADSERIES ____ FINE THREAD SERIES Self Locking Nuts MINIMUM PREVAILING THREAD SIZE TORQUE 7 16 20 Self locking nuts when re used must 1 2 20 10 inch pounds 9 16 18 13 inch pounds have at least the minimum prevailing 5 8 18 18 inch pounds 3 4 16 27 inch pounds torque listed in figure to the left Nuts that 7 8 14 40 inch pounds 55 Inen pounds are smaller than those listed in the table 1 1 8 12 73 inch pounds 1 1 4 12 94 inch pounds COARSE THREAD SERIES shall not be used if they can be run up by THREAD SIZE MINIMUM PREVAILING TORQUE hand EROCET PAGE 8 12 03 Incorporated 12 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats REVISION P Figure 2 2 2 Minimum Prev
33. Amphib Floats 35A 59301 Rudder Cable Attachment Detail 180 185 STA 209 35A 59400 Installation Convex Spot Mirror 35A 60000 Hydraulic Pump Installation 35A 60001 Wire Assembly Relay to Terminal Block Model 3400 Float STC s 35A 60010 Hydraulic Line Routing 35A 60015 Float Wiring Schematic Cessna 180 185 182 206 Aerocet 3400 Amphib Floats 35A 61000 Hand Pump Assembly 35A 61200 Hand Pump Bracket Assembly 35A 62000 Walk Wire Plate Installation 35A 64000 Emergency Hand Pump Installation K 65 Montana Float Company Gear Advisory Superseded by Aerocet Model GC600 Gear Advisory K 66 Auxiliary Gear Advisory Not Applicable to Aerocet Model GC600 Gear Advisory End of Cessna 180 185 3400 Installation Listings EROCET Appendix TSSUE Incorporated poe DATE 8 12 03 82 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 Appendix B Cessna 206 per STC SA01257SE Aerocet Document A 26 Part Application Listing Weight Affidavit for Cessna 206 Seaplanes on Aerocet Model 3400 Amphibious Floats 35 24001 TSO Rudder Assembly also in CPL 35A 46010 TSO Float Wiring Schematic 36 15000 Master Drawing List Aerocet Model 3400 Amphibious Float Installation on Cessna 206 Aircraft 35 11052 Tie Rod Assembly 35 24011 Water Rudder Retract Handle 35A 60010 Hydraulic Line Routing
34. Cabin Placards Note 1 If working sand wash out tracks daily to remove abrasive potential and lubricate with a dry Teflon coating spray Note 2 Nose block grease warning Introduction of grease through the grease fitting during normal operation should be minimal 1 2 pump max of a hand grease gun per week always watching for hydraulic lock and any damage from grease gun pressure Introduce grease very slowly Note 3 Spray coat with a migrating corrosion material ACF 50 Boeshield T9 or Corrosion X Note 4 Coat hardware with PUR AL KETONE or LPS 3 EROCET Incorporated ERCE 8 12 03 65 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 10 1 1 Exceptional Inspections In a variety of circumstances it is necessary to perform prompt inspections for damage Details relating to these investigations are addressed in Section 2 Section 8 of this manual and Table 1 above It is the responsibility of the pilot to determine the severity of damage and the flightworthiness of the aircraft in the field Inspections and repairs are to be performed as necessary and per practices outlined throughout this manual A list of possible scenarios includes but is not limited to the following 1 Landing completed on grass or other runway surfaces with the wheel gear inop
35. Co Zip D 5029NS EZ Turn Lubricant United Erie 8 Composite Materials for Hull Repair Contact Aerocet Inc for resin cloth gel coat resin thickeners 8 12 03 REVISION DATE 8 27 2010 TITLE SUBTITLE EROCET Incorporated Service amp Maintenance Manual Model 3400 Amphibious Floats This page intentionally left blank except this line PAGE 66 of 82 FILE NO A 10031 REVISION 6 EROCET ISSUE Incorporated eon DATE 8 12 03 67 of 82 FILE NO TITLE Service amp Maintenance Manual REVISION A 10031 REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 11 Tire Pressures NOSE WHEEL TIRE PRESSURE 70 PSI on 10 3 50 4 Ply Rated Tires MAIN WHEEL TIRE PRESSURE 55 PSI on 6 00 6 8 Ply Rated Tires Gross Weight above 2950 Ibs 40 PSI on 6 00 6 8 Ply Rated Tires Gross Weight 2950 Ibs 6 8 12 03 REVISION DATE 8 27 2010 TITLE SUBTITLE EROCET Incorporated Service amp Maintenance Manual Model 3400 Amphibious Floats This page intentionally left blank except this line PAGE 68 of 82 FILE NO A 10031 REVISION 6 EROCET Incorporated ERCE 8 12 03 69 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION Date 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6
36. EROCET ISSUE Incorporated eee DATE 8 12 03 1 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 ae 8 27 2010 SUBTITLE Model 3400 Amphibious Floats Baa 6 DATE SERVICE MANUAL AND INSTRUCTIONS FOR CONTINUED AIRWORTHINESS FOR AEROCET 3400 AMPHIBIOUS SEAPLANE FLOATS Aerocet Inc P O Box 2119 265 Shannon Lane Priest River Idaho 83856 Phone 208 448 0400 Fax 208 448 1644 This ICA must be followed when Aerocet 3400 Floats are installed in accordance with Supplemental Type Certificate STC No SA01257SE The information contained in this document supplements or supercedes the basic manuals only in those areas listed herein For limitations procedures and performance information not contained in this manual consult the basic aircraft ICA or maintenance manual Digitally signed by Ryan Beck R a n DN cn Ryan Beck o Aerocet Inc ou Engineering email ryan aerocet com c US eC C Date 2010 12 01 09 59 53 08 00 EROCET Incorporated ERCE 8 12 03 2 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 Log of Revisions Page REV PAGES DESCRIPTION DATE AFFECT jo O AUL 1 Initial Release 8 12 03 1 2 15 22 25 Calendar time added to inspection schedule 9 25 04 eee E i i 3 Corrected tir
37. Inspect all connections and look for fluid along all routes No Leak apparent pump failure or actuator piston seal failure Isolate the pump and each actuator for pressure tests Replace the pump or repair the actuator EROCET Incorporated ERCE 8 12 03 35 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION Date 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 e Slow gear operation i Mechanical interference Check gear for damage and debris Check adjustments especially for the nose gear assembly Ref Sections 4 amp 5 ii Check hydraulic lines for damage such as kinks or blockages iii Check screens electrical connections pump gears motor needs replacing 6 6 Backup Hand Hydraulic Pump 1 Normal operation the Hand Pump selector handle should be in the OFF position 2 Hand Pump operation should be according to the Pilots Operating Handbook 3 If pump should leak contact Aerocet Inc for replacement EROCET ISSUE Incorporated ee 36 of 82 DATE 8 12 03 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION ene 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 6 7 Gear Advisory System Reference Component Maintenance Manual CMM A 10037 or Drawing K 65 CPL 1 General For all information regarding the Aerocet Model GC600 Gear Advisory please refer to
38. Manual Model 3400 Amphibious Floats This page intentionally left blank except this line PAGE 54 of 82 FILE NO A 10031 REVISION 6 EROCET Incorporated ERCE 8 12 03 55 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION Date 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 9 Repairing Composite Float Hulls 9 1 General Description Composite float repair done correctly will obtain the strength required to put the float back into service and cosmetically show little or no evidence of damage having ever taken place The materials used for original construction and repair are conventional to the industry Any damage on the bottom of the float should be repaired immediately because of the tremendous water pressures encountered Contact Aerocet Inc prior to beginning a repair to obtain correct materials resin resins have shelf lives catalyst cloth gel coat resin thickeners Epoxy underwater patch kits may be used in an emergency if the damage is relatively small but the repair must be replaced with correct materials for equal strength status Damage larger than 4 in size require consulting Aerocet Inc for proper laminate orientation and assuring number of laminates in the damaged area 9 2 Repair Types and Procedures All repaired areas on the exterior must be surface coated gel coated with a minimum of 10 mil t
39. S REQ D LOCATED ALONG HOLE CENTERS 8 1 7 Ventral Fin Installation Cessna 180 or 185 aircraft only For Cessna 180 185 Installation 35A 59030 8 1 8 Aileron Fence Installation Cessna 206 aircraft only Disregard installation if original equipment for later model aircraft or through Wipair float installation For Cessna 206 Installation 36 15500 8 1 9 Hydraulic Pump Installation 1 For Cessna 180 185 Installation 35A 60000 35A 60001 35A 60010 35A 60015 35A 61000 35A 62000 35A 64000 2 For Cessna 206 Installation 35A 60015 36 15400 36 15410 36 15460 36 15480 36 15490 3 This portion of the installation incorporates the in aircraft hydraulic and electrical components There is an electric hydraulic pump mounted in the aft of the aircraft a mechanical hand pump and a gear advisory in the cockpit and the connection systems necessary to operate the float gear 4 You will need to familiarize yourself with the overall installation before proceeding The drawings contain necessary details for the proper installation Assess any difficulties or obstructions prior to beginning this portion of the installation Using the Cessna Maintenance Manual Procedures it may be helpful or necessary to create new access holes and covers and plates in certain areas of the floorboard The locations and quantities of original access holes can vary due to either modifications or to model variations even within the aircraft types 5 Prepare for and
40. S or FedEx by request Fees and delivery charges may apply Notification of any changes that require service for airworthiness shall be distributed to all applicable Aerocet owners on record with Aerocet Inc In such a case copies of the applicable revised portions of this manual shall be provided Aerocet Inc maintains record of purchasers and or owners collected at the time of purchase in order to comply with the above as well as to maintain a high standard of service If you have moved since your original purchase have purchased a used product or otherwise have reason to believe that the contact information on file is incorrect please provide the following information to Aerocet Inc Aerocet contact information is on the front of this document Float Information Float Model Float S N R L Aircraft Information Aircraft Make Model Aircraft Registration Aircraft S N Owner Information as applicable Previous Owner Previous Address Present Owner Present Address Present Phone Number Present Email Address 1 2 Component Maintenance Manuals Certain accessories that are more complex that require additional inspection and maintenance procedures are described in Component Maintenance Manuals CMM or Maintenance Manuals MM References to the necessary manuals are placed in relevant areas of this manual Depending upon the optional equipment you have installed on your Aerocet Model 3400 floats you may also require the followi
41. T 1 WALK WIRE TAB DECK CLEAT WATER RUDDER Ss V i ACCESS PANELS LEFT HAND FLOAT A ACCESS PANELS ASSEMBLY EROCET Incorporated ERCE 8 12 03 9 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 2 Float Hull Maintenance Because of the composite structure in the design of the floats hull corrosion and leakage are basically eliminated The floats should be kept clean with soap and water The sides and the bottoms from the step aft can be waxed to help in the cleaning process The bottoms of the floats from the step forward should not be waxed as this gives unpredictable water performance Stains from the waterline on down may be removed using marine fiberglass stain remover We have used a product called FSR with good success Do not use abrasive cleaners or pads these will scratch the white gel coat surface The gel coat color surface should always be maintained on the floats for ultraviolet protection The metal chine strips are abrasive wear surfaces used to protect the floats from docks and pilings These are extrusions bonded on using a one part urethane adhesive These should be kept intact The keels have wear strips bonded on for protection and optional wear strips can be added up from the keel in the step area where the float would nest in the rocks on the beach These
42. ace existing clamps with larger size as necessary Do not pinch wires refer to notes 1 and 6 for secondary support MS 21919 CABLE CLAMP OR EQUIVALENT a LOCKWASHER EXTERNAL TEETH MS 21044 NUT SELF LOCKING MS 35338 LOCKWASHER AN 340 NUT SPLIT FROM AC43 13 1B PAR 11 49 5 Clamps on wire bundles should not allow the bundle to move through the clamp when a slight axial pull is applied The cable or wire may be wrapped one or more turns of electrical tape when required to achieve this fit Leave sufficient slack between the last clamp and the termination to prevent strain or allow any future servicing Wherever possible orient clamps with the attachment hardware EROCET Incorporated ERCE 8 12 03 49 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 positioned above the wire so that they are unlikely to rotate as the result of wire bundle weight or wire bundle chafing 6 Nylon ties such as MS3367 4 9 or equivalent or approved lacing may be used at intervals of 12 to 18 to provide secondary support or grouping for lacing practices please refer to AC43 13 1b par158 7 Non adhesives tapes may be used for protection so long as drainage is provided to avoid moisture entrapment may require additional means of securing such as nylon ties Adhesive tapes shall not be used except p
43. ailing Torque Values for Re used Self Locking Nuts from AC43 13 1B Table 7 2 WHEN USING A TORQUE WRENCH ADAPTER WHICH CHANGES THE DISTANCE FROM THE TORQUE WRENCH DRIVE TO THE ADAPTER DRIVE APPLY THE FOLLOWING FORMULAS TO OBTAIN THE CORRECTED TORQUE READING Short Open End Adapter TORQUE ADAPTER WRENCH DRIVE HANDGRIP CENTERLINE CENTERLINE PREDETERMINED WRENCH DRIVE Set Screw Adapter TE FORMULA LE Y EXAMPLE WITH E AS PLUS DIMENSION T 135 LB IN Y UNKNOWN Hose Clamp Adapter L 10 0 IN E 1 5 IN Y 117 LB IN LEGEN T ACTUAL DESIRED TORQUE Y APPARENT INDICATED TORQUE L EFFECTIVE LENGTH LEVER E EFFECTIVE LENGTH OF EXTENSION Open End Wrench TORQUE WRENCH Adapter WRENCH HANDGRIP DRIVE CENTERLINE CENTERLINE ADAPTER PREDETERMINED E Flare Nut Wrench Adapter TxL FORMULA Y L E EXAMPLE WITH E AS MINUS DIMENSION T 135 LB IN Fie SOO ASSO cen ae i Y UNKNOWN Spanner Wrench Adapter L 10 0 IN E 1 5 IN Y 159 LB IN Figure 2 2 3 Torque Wrench with Various Adapters from AC43 13 1B Figure 7 2 EROCET Incorporated ERCE 8 12 03 13 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION Date 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 2 3 Fastener Use and Discretion 2 3 1 Fastener Lengths Rivets Where replacement or repair of rivets is re
44. anel gaskets bolts or pump out plugs or leakage from a damaged float hull These pump locations will also show hydraulic leakage which is red in color The main landing gear utilizes a trailing arm link design using a 6 00 X 6 tire and a oleo shock strut The nose gear is full swiveling has a centering device and uses a composite strut for absorbing the landing loads Steering of the airplane is done through differential braking A panel mounted landing gear advisory and gear position switch is used It includes an up and down lever lights for each gear and their position a pump operation light and an audio output to advise the pilot of gear position when triggered at a set speed An optional smaller dash mounted landing gear position light system is available giving the pilot more heads up awareness of the landing gear condition prior to landing Note The K 66 auxiliary unit is only available with the K 65 Gear Advisory and is not useful or compatible with the newer Model GC600 Gear Advisory units EROCET Incorporated ERCE 8 12 03 6 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 Meee 8 27 2010 SUBTITLE Model 3400 Amphibious Floats REVISION 5 1 1 Availability One complete hard paper copy of this manual shall be provided with each new set of Model 3400 Twin Amphibian Floats Additional copies and minor revisions shall be available via email U S P S mail UP
45. aps are necessary lap widths of at least 1 2 shall be maintained for fiberglass pieces in any given ply and no more than one of the component plies shall be lapped at any one place The number of laps shall be kept to a minimum 9 6 Surface Coat Application Gel Coat All surface coats must be applied to a thickness of 10 to 15 mil Use a mil gauge and check often Waterline down is very critical to prevent blistering from water absorption All surface coats must be catalyzed with 2 MEKP Thinning of surface coats can only be done to manufacturers recommendations 9 7 Keel amp Wear Strip Bonding UHMW plastic style UHMW Style keel and wear strips are no longer offered on new Aerocet floats being replaced with aluminum keel strips and fiberglass wear strips These instructions are still applicable to re bond existing strips otherwise contact Aerocet to order replacements of the new styles Keel strips are bonded and or fastened to the keel of the floats in areas the typically receive abuse from rocks debris and beaching Keel strips are not optional Wear strips are bonded along either side for the same reasons but do not normally require replacement as often Wear strips are optional but Aerocet installs them standard with every float and strongly recommends them UHMW strips do age with UV and environmental exposure resulting in discoloration and cracking Prepare keel by sanding surface with 80 grit paper Bond keel amp
46. ar down are provided to show landing gear position An additional indicator light shows landing gear motor operation The landing gear system is also equipped with an emergency hand pump selector valve and hand pump 6 2 Hydraulic Lines Reference 35A CPL 47000 Sheets 1 8 and 35A 60010 Sheet 1 1 All hydraulic lines are serviceable according to the drawings The aluminum lines are made up of 5052 0 4 outside diameter 035 wall with conventional 37 degree flared ends These can be purchased by part number or made up by a certified mechanic The flexible lines are custom sized and may be purchased according to their part numbers 2 Assure lines are all clean and flared properly upon replacement 3 Hydraulic lines that run up the struts need to be placed in position prior to installation of the aircraft onto the floats Assure that the lines are centered in the struts as they enter from either end not allowing wear from vibration Also assure that the step attachment bolts clear the lines upon installation 4 All hydraulic lines need to be clear of all electrical and control cables and must be secured and isolated from surrounding structures to avoid damage during service Ref AC 43 13 EROCET ISSUE DATE 8 12 03 Incorporated ERCE TITLE 30 of 82 FILE NO Service amp Maintenance Manual REVISION DATE 8 27 2010 SUBTITLE A 10031 Model 3400 Amphibious Floats eae F
47. ated pivot pin part 35A 42110 is heat shrunk into the nose block The nose block and pivot pin are supplied from Aerocet Inc assembled If the pivot pin is pressed out the anodized surface is opened up causing dissimilar metal contact between the two components when reassembled 4 Lightly grease all parts prior to reassembly using marine grade waterproof grease Be careful not to introduce too much grease around the compression spring causing it to hydraulic lock EROCET PAGE 8 12 03 Incorporated 20 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 5 Lightly grease through the grease fitting on the top of the bottom block Initial amounts should be two very slow pumps with a conventional hand grease gun Continually check pivoting action of the nose assembly to assure proper function watching for hydraulic lock and proper vertical movement If too much grease has been introduced push down on the grease check ball and rotate the nose gear 360 degrees a couple of times to expel excess amounts 6 Introduction of grease through the grease fitting during normal operation should be minimal 1 2 pump max of a hand grease gun per week always watching for hydraulic lock and any damage from grease gun pressure Caution Be very slow introducing grease into the grease fitting on the bottom block in order to keep
48. bly and Internal Cable Tubing Reference 35 CPL 24001 Sheets 1 3 and appropriate STC installation drawings 1 Assemble and disassemble water rudders according to drawings 2 Assure that water rudders are free in movement and rudder links and springs don t have excessive wear 3 Any hardware that passes through the rear bulkhead should be sealed with a one part urethane sealant 4 Regarding the internal cable tubing look for any breaks or wear points especially where the retract cable comes out the inside of the float and replace as necessary 7 3 Rudder Pulleys Reference 35 CPL 24001 Sheets 1 3 1 Check freedom of pulleys in all locations Remove and clean if there is any buildup in the bushing to pulley interface 2 Remove any pulleys that have wear flats from lack of rotation 7 4 Rudder Rigging Reference 35 CPL 24001 Sheets 1 3 and appropriate STC drawings 1 The rudder steering rigging should align the rudders straight ahead with the airplane rudder centered Cables should be just taught There should be no pre stretching of the springs which connect them to the airplane rudder system This keeps the friction low not hampering yaw stability 2 The rudder retract cables should be rigged so that the rudders are close to the stops when retracted and that the cables are just becoming slack in the down position 3 All cables should be examined for deterioration especially around the pulleys at the stern of the
49. ceccsceeececseeceseeeceeneeceaeeeesaeceeaeeceeeeeaeeeeaaeceeneeesas 43 9 Repairing Composite Float Hulls eee eeceeseeeseesseeeseeeaeceaeceaecsaeeeseeseesseeeseeeeneeeneeeaaeeaaeenaees 55 10 Recommended Service Schedule General Practices and Product Listings for Service 61 11 Tire PRESSUPCS 35 siccecsiedavsyaaindavesenncessnteiauevendeadenndewtevasadagaenqequssbeesdcesadedaaesdesenesundeaadas S NEUSE RESEN 67 12 Troubleshooting srerssnistpeee ooreis o o E a DA E AEE E E A aaoi A E AREE 69 13 Airworthiness Limitations seisoene iisen aneen e En ene oS REEE ESTEE EEEE NEESER aea 79 8 12 03 REVISION DATE 8 27 2010 TITLE SUBTITLE EROCET Incorporated Service amp Maintenance Manual Model 3400 Amphibious Floats This page intentionally left blank except this line PAGE 4 of 82 FILE NO A 10031 REVISION 6 EROCET Incorporated ERCE 8 12 03 5 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION Date 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 1 Introduction and General Float Information This service and maintenance manual is applicable to Aerocet Model 3400 Amphibious Seaplane Floats and their general application to a variety of airplanes The Customer Parts List in the appendix provides pertinent data referenced to in the text of this manual Strut geometry boxing flyin
50. during cure Immediately clean Sika Flex from any work areas or unintended float surfaces using acetone but leave squeeze out adjacent to the keel until cured Usually cure is about 12 hrs After cure use a knife to slice the squeeze out along the edges of the keel peeling the bead away as you go Avoid cutting into the gel coat 9 9 Wear Strip Replacement EROCET Incorporated ERCE 8 12 03 59 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 UHMW wear strips Remove using a thin metal scraper or similar device Older UHMW will likely have deteriorated over time due to UV and environmental exposure so it may not peel but will come off in chips instead There is a woven backing that serves to bond the strip and this should also be removed if it remains bonded to the float Fiberglass Wear strips Removal of fiberglass wear strips will require a large amount of sanding or of careful grinding Do not penetrate the gel coat on the float hull itself if possible If you penetrate the fiber glass laminate then follow the repair procedures above Small repairs to the fiberglass wear strips may also be made using the same repair procedures listed above Bonding of new wear strips Use a resin cabosil mixture applied to the mating face of the strip s and affix them to the float using a similar p
51. dvisory Unit itself If the gear goes to a landing position and remains there without all four gear in place for a period of time beyond normal cycle time the gear will advise the pilot that the gear is unsafe with the following message Landing gear unsafe check gear The message will repeat until canceled Upon operational start up the Landing Gear Advisory Unit will announce all three messages at once to indicate their availability and this should be canceled using the buttons provided The audio output level may be adjusted using a slotted screwdriver in the identified place on the back of the unit The Gear Advisory unit is a sealed unit and it should be returned to Aerocet Inc for any servicing Aerocet Inc endeavors to have exchange units available to minimize down time EROCET Incorporated ERCE 8 12 03 38 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 pene 8 27 2010 SUBTITLE Model 3400 Amphibious Floats REVISION A 6 8 Spot Mirror Assembly 35A 59430 Spot Mirror and Bracket Assembly is intended to provide a visual verification of landing gear position Itis designed to install on an inspection panel under the aircraft wings both port and starboard Figure 6 8 1 OUTBOARD a S _7 EXISTING ACCESS PANELS AEROCET MIRROR ASSEMBLY WING STRUT Figure 6 8 2 EXISTING ACCESS COVER PLATE MIRROR BRACKET FORWARD gt N INBOARD
52. e Figure 2 1 LOCKER DOOR ASSEMBLY LATCH RING OUTBOARD WHITE DOTS ON LATCH POSTS INDICATE LATCH POSITION SHOWN CLOSED EROCET Incorporated ERCE 8 12 03 10 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 Investigation should be prompted if excessive water is pumped from any of the pump out cups during operation Water can leak through the pump out plugs where the nylon pull line penetrates older style plugs only and may seep through the access panel seals Condensation will also generate water inside the float compartments More than 4 or 5 full pumps of water using an aircraft float pump should raise concern for maintenance In contrast if a pump out tube is cracked or broken there will not be a significant sucking sound when the pump is removed from the pump out cup If there is question regarding the integrity of the pump out tube investigate Attention should be given to any bolts that pass through the stern nosebox and main gearbox area for leakage These should be sealed into place using a single part urethane such as Sikaflex 292 It should also be noted that more water is typically pumped from the stern and bow compartments because they are often covered with water during operation and allow more seepage through the plugs and seals Pump out plugs must have some venting capabilit
53. e 8 27 2010 SUBTITLE Model 3400 Amphibious Floats REVISION P 4 If damage has occurred where there is sandwich construction involving the core work each layer separately Fix either the outside or inside skins Then cut to fit like core material to replace the damaged core Bond the core onto the repaired skin using the proper resin and thickener A mixture of Hydrex resin and Aerosil 202 thickener should be applied to the bonding surface of the core using a squeegee Torin Corebond alt OK A film of approximately 015 should be used Pressure needs to be applied for the bond to assure proper adhesion to the skin eliminating air voids This pressure can be applied to small area core bonding by weights ex lead shot bags with a release film to keep from sticking to any excess Larger areas require core bonding using a vacuum bag Consult Aerocet Inc for this procedure Fill any seam voids with a resin glass bubble mixture Apply the final laminates accordingly to finish the repair 9 3 Impregnation of Fabric Resin impregnation can be accomplished by laying cloth cut to a suitable pattern on a flat table and applying resin mixture with a squeegee so as to achieve an even impregnation It may also be done similarly directly on the part with the cloth is being applied using either a squeegee or brush providing voids and starved areas are not produced Itis very helpful to apply a thin coat of resin to the area to be laminat
54. e caliper free from brake mount One need not disconnect the brake line unless further inspection and maintenance to the brake system is intended Secure the caliper in a manner that does not stress the brake hose Remove brake mount Remove axle Note larger tensioner bushing is on the brake caliper side 4 5 6 Slide wheel down and away from the truck assembly 7 Be sure to deflate tire before any disassembly of the main wheel 8 Inspect all components for corrosion and wear according to procedures provided by Cleveland Wheels and Brakes Maintenance Manual 9 Reassemble in reverse order of disassembly Consult the proper Component Maintenance Manual for further inspection and maintenance of wheel and brake assemblies 10 Assure the notch in the axle lines up with the inset on the left side arm of the truck assembly See Figure 5 2 10 11 Tighten the axle nut assuring the proper amount of friction on the wheel bearings Use procedures outlined in the appropriate Component Maintenance Manual or a Fully tighten axle nut until the tire and wheel assembly begin to drag when spun This will assure that the tapered roller bearings are seated properly b Loosen the axle nut until the wheel assembly will spin freely again No torque c Tighten the axle nut until the nut begins to tighten but the wheel assembly spins freely and has no perceptible play Axle nut may be backed off to align the nearest slot to the nearest cotter
55. e float level and align the floats across from one another Two people one for each spreader and two additional people for each end of the loose float will be initially required to stabilize and align everything unless you are otherwise able to secure the floats Start the spreaders into the opposite float slowly working them inward in small increments alternating fore and aft The spreaders will tighten up as they are inserted more deeply until is ineffective to continue simply pushing on them CAUTION DO NO USE SLEDGES OR OTHER IMPACTING DEVICES IN AN ATTEMPT TO MOVE THE FLOATS TOGETHER OR APART THIS MAY RESULT IN DAMAGE TO YOUR FLOATS At this point it may be helpful to install a strap or a strong rope to the deck cleats and cinch the floats together incrementally More force can be applied by twisting the strap from the center This method creates a great amount of force so do not insert the spreader too deeply continually cinching the floats together fore and aft alternately Monitor the progress by measuring the depth marks made earlier Once the holes are aligned place the applicable deck fittings and bolts and finalizing the bolt torques Seal the spreader with a fillet of marine grade urethane such as Sika Flex 292 Upon its cure create a small hole in the bead to help relieve internal pressure from later greasing 8 1 4 Strut and Tie Rod Installation For Cessna 180 185 Installation 35A 59100 also 35A 60000 for hydraulic li
56. e now two versions of gear retracted sensors One is the original having a yellow plastic barrel and red light The newer version has a stainless barrel and is somewhat longer Both hook up electrically in the same manner The newer does require an additional threaded mount from Aerocet 35A 45071 See Figures 5 7a and 5 7b for an illustration of the two sensors a Ni8U S12 AN6X H1141 Sensor Originally supplied With proper hook up this sensor will activate red lights in the upper barrel when the target main gear drag link is in range If the plastic barrel is broken the light will remain on no matter the gear position Figure 5 7a YELLOW PLASTIC BARREL 4X RED LED LIGHTS 2X LN P12 LOCK NUT PLASTIC TURCK P N LOOSEN BOTH TO MAKE ADJUSTMENTS LIGHTLY HAND TIGHTEN ONLY Ni8U 812 AN6X H1141 SENSOR SENSOR END 8 12 03 REVISION DATE EROCET Incorporated PAGE 28 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 b Ni8U EM12E AN6X H1141 Sensor Supplied as original or as replacements after 12 08 With proper hook up sensor will activate green lights in the upper barrel These lights will become amber when target main gear drag link is in range Figure 5 7b STAINLESS BARREL LN M12 LOCK NUT TURCK P N LOOSEN TO MAKE ADJUSTMENTS TO SENSOR POSITION
57. e ply from 6 to 8 ply rating 8 1 06 Incorporated changes to the lower nose gear 3 17 08 assembly keel and wear strip installation main gear TH and edited troubleshooting in gear advisory hydraulic pump 10 Added 35A 45700 Wheel Installation amp references 7 06 09 to A 10036 CMM TH 15 17 Added Ni8U EM12E AN6X2 H1141 Sensor to main gear section 11 13 16 Added Figures 5 2 10 5 3 5 6 5 7a 5 7b Added Section 11 Troubleshooting 8 17 09 Added note Re K 66 compatibility T Hamilton Added 1 1 Availability of this manual Added 1 2 Applicable CMM s Added 1 3 Dimensions Locations and Nomenclature Deleted UHMW Plastic from Keel Strip description Added Figure 2 1 Added for old style plugs only Added 2 1 2 2 and 2 3 for Fasteners Added Figure 3 1 1 5 2 11 Expanded Axle Nut Installation Added Figures 6 2 1 6 2 2 6 2 3 6 2 4 amp 6 2 5 Added Figure 6 7 to differentiate between old and new Gear Advisories Added Note to define text applicable to only the K 65 Gear Advisories Added 6 8 with illustrations for Spot Mirror Added removal to Para 2 amp 3 Changed title of Section 9 from Continued Airworthiness Schedule to Recommended Airworthiness Schedule Added Section 12 Airworthiness Limitations to comply with 14 CFR Part 23 Appendix G Added new section 8 on installation of floats to 8 27 2010 aircraft including weights of remaining components MHH Other changes t
58. ed Then lay the cloth down rolling the cloth into the resin Any air in the laminate should be squeegeed or brushed out See section 8 4 regarding resin mixing 9 4 Resin Mixing Gel times or pot life is the time it takes the resin to set up in the container after proper and thorough mixing with accelerators and catalysts Gel times can be adjusted significantly by varying the amounts of these materials Gel times also will vary significantly with the batch size if left in a bucket or with a very thick laminate TYPICAL GEL TIMES HYDREX 33 253 100gm castings only laminate times typically double 33 MEKP Catalyst Resin Qty Note Under no circumstances should more than 2 0 catalyst mixture be used Also do not use less than the recommended minimum amount of catalyst 75 or the resin may never completely cure resulting in a reduction of strength WARNING Be careful with the MEKP catalyst Contact with eyes must be prevented Blindness may result Flush eyes immediately contact a physician immediately Never mix MEKP catalyst into the resin without eye protection EROCET Incorporated ERCE 8 12 03 57 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 9 5 Preparation of Fiberglass Materials Fiberglass shall be trimmed on a clean table to prevent contamination When l
59. ed their gear up positions If an indicator light should fail to come on when pressed for testing remove bulb for a new bulb or double check the circuit by interchanging a bulb from a lit indicator light The WATER LAND and PUMP light circuits are protected by the Landing Gear Advisory circuit breaker and are therefore independent of the landing gear motor circuit and will function when using the emergency hand pump The Landing Gear Advisory Unit includes an audio output that is connected to an audio output source ie radio or audio panel for verbal pilot information regarding gear position A static and pitot pressure source is connected to the Unit which determines airspeed The Landing Gear Advisory Unit has a trigger point set at approximately 90 knots This adjustment is set using a small slotted screwdriver in the hole above the gear handle on the face of the Advisory Clockwise is for increasing the trigger speed As the airplane passes through this speed the system is armed When the airplane slows back through this speed an audio voice will announce the position of the gear and what kind of landing it is suited for With the gear up the message will say Gear up for water landing With the gear down the message will say Gear down for runway landing This message will continue and repeat itself until acknowledged by the pilot by canceling out the message either by the button on the optional dash mount or on the Landing Gear A
60. eering cables _ Correct the alignments of the exit holes stiff _ through the floats to the aircraft mounted ll l Over tightened internal float oosen the fittings and re snug them by _ fittings _ hand Reduced water rudder Broken cable Replace as necessary steering ebris caught in the tiller EROCET Incorporated ERCE 8 12 03 70 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 eee 8 27 2010 SUBTITLE Model 3400 Amphibious Floats REVISION A Table 12 1 Troubleshooting Model 3400 Amphibious Floats Float Hull Assemblies Excluding Amphibian Gear Detected Problem Possible Cause Corrective Action l Jammed Cable Check all pulley assemblies for missing i _ keepers and fouled cables place as necessary _ Broken rudder retract spring s Rudders do not deploy fully Water Rudders do not Cable jammed Check for fouled cables and debris retract _ especially at tiller 8 12 03 TITLE REVISION DATE 8 27 2010 SUBTITLE EROCET Incorporated Service amp Maintenance Manual Model 3400 Amphibious Floats PAGE 71 of 82 FILE NO A 10031 6 REVISION Table 12 1 Troubleshooting Model 3400 Amphibious Floats Cont d Hydraulic System Detected Problem Possible Cause Corrective Action _ Hydraulic system is compromised pressure switc
61. eize lubricant of good quality to prevent galling upon assembly 2 1 3 Torque Procedure Assure that hardware is clean and properly prepared for installation Assemble nuts to bolts measuring the tension required to turn the nut and add this to the required final torque Where possible apply torque to the nut and not to the fastener head Apply a smooth even pressure stopping and re torquing if chattering or premature loading occurs This may warrant disassembly and subsequent inspection for burrs or galling Replace any damaged hardware Access panels should be torqued only to hand tight the fiberglass should exhibit only mild deformation A portable hand drill could be used provided that the clutch is set properly Do not apply more pressure to the hatch screws than is necessary to engage the tool to the fastener head as this will risk damaging the Tinnerman style nuts below EROCET Incorporated ERCE 8 12 03 11 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 ee 8 27 2010 SUBTITLE Model 3400 Amphibious Floats REVISION P All other nuts shall be torqued per Section 1 4 unless otherwise noted 2 2 Fastener Torque Values Except where otherwise noted such as Deck Fitting bolts see installation drawings CAUTION THE FOLLOWING TORQUE VALUES ARE DERIVED FROM OIL FREE CADMIUM PLATED THREADS TORQUE LIMITS RECOMMENDED FOR INSTAL MAXIMUM ALLOWABLE TIGHTENING LATION BOLTS LO
62. ement verbiage may vary at this point due to unknown or moving gear positions See A 10037 for GC600 5 Let the pump run until it cycles fully in one direction unless it keeps running or empties the reservoir See Troubleshooting check for leaks or re fill reservoir 6 Turn Master Switch to OFF 7 Check the fluid level in the hydraulic pump reservoir fill as necessary 8 Repeat in the same manner and gear direction until the gear reach full extent of this cycle pressurize and the pump shuts off independently 9 Repeat the above sequence in the opposite gear direction refilling pump as necessary 10 Cycle the gear in both directions to ensure that all air is purged throughout the system that the gear transition smoothly in both directions that the pump stops at the full extents and that the Gear Advisory shows the proper light indications Audio should activate upon all lights being activated See A 10037 for troubleshooting of GC600 Gear Advisories 11 Turn Master Switch to OFF 12 Replace all access covers in the aircraft and the floats 13 Install all pump out plugs Optional Secure pump out plugs to floats using weather resistant line attached to access panel screws on the undersides of access panel 8 2 Conversion from Floats to Wheels 1 Hoist and secure aircraft using lifting rings installed with the Cessna float kit and other tie down rings as necessary 2 Assure that float gear are in fully dep
63. er note 5 8 Permanently identify wires using codes shown in Dwg No 35A 60015 schematic within 3 to 6 of each termination It is recommended that additional permanent identification be applied at approximately 15 intervals and in practical and suitable areas where maintenance may be anticipated 9 Grounds Use existing ground stud where applicable or as specified to aircraft structures Do not exceed 3 terminations Ensure that system types AC DC Static are not mixed Prepare surface s by removing any paint debris corrosion or surface treatments to ensure a clean bond Resistance shall not exceed 0025Q to aircraft structures Keep wire length less than 6 inches EQUIPMENT AIRCRAFT STRUCTURE SURFACE SURFACE SOURCE Adjust R1 rheostat for 10 amperes on ammeter Record the millivolt reading Example Millivolt reading is 30 MVS 30 MVS _ 0 AMPS 3 MILLIOHMS RESISTANCE FROM AC43 13 1B PAR 11 188 8 1 11 Checklist Note Check all work before proceeding minimum checklist 1 Torque for all bolts See Tables in Section 2 2 Except where otherwise noted 2 Spreaders and Deck Fittings 25 ft lbs to self locking nuts on AN8 Bolts 3 Fuselage and Strut attachments 4 Water Rudder Rigging all attachments pulleys and retract handle 5 Hydraulic and electrical fittings and hardware leave access points open for troubleshooting and leakage checks 6 Check for proper installation of any
64. erative or retracted 2 Harsh landings on either runway or water 3 Impact with a submerged object during taxi take off or landing on water 4 Suspected damage incurred during tie down or mooring e g damage from wind or wave action 5 Excessive water during pump out on pre flight inspection 10 2 General Practices 1 Wiring attachment to terminals damaged or corroded terminals melting of insulation chafing of insulation 2 Metal Parts check for corrosion stress cracks or metal distortion elongation of holes rivet damage 3 Critical Bolts check for corrosion rust wear torque 4 Composite Parts check for stress cracks gel coat presence UV protection punctures 5 I Glide Bushings inspect for wear cracking obliqueness 6 Nose Wheel Slide Tracks clean and lubricate with a dry Teflon coating spray 10 3 Product Listings 1 Hydraulic Fluid Mil H 5606 updated Mil PRF 5606 2 Teflon Spray Accupro Dry Lube 0024636 Comet Industries 6P 730A 3 Wheel Bearing and Nose Gear Lock Bracket Grease Texas Refinery Corp TRC 880 C amp C BG Products HCF 605 Parker P N 219 06300 4 Wheel seals to tensioner bushings after installed LPS Industries LPS 2 5 Float Sealant for Bolts and Chine Strip attachment Sika Manufacturing Sikaflex 292 6 Rust corrosion Protection ACF 50 Corrosion X Boeing Co Boeshield T9 7 Bolt Protection PUR AL KETONE LPS Industries LPS 3 Zip Chemical
65. for shipping Please refer to the instructions in the drawings and the following advice to assemble the floats together in preparation for accepting the aircraft Identify the position and orientation of the spreader bars using the markings centered on the bottom sides of each The front or forward spreader is marked with an F and an arrow shape that indicates the forward orientation The back or aft spreader is marked with a B and an arrow shape that also indicates the forward orientation See Figure App 1 1 The arrow shape always points forward AS a precaution is advisable to measure the socket depth high side is short due to the angle of the float sides and transfer the measurement to the spreaders so that you can later confirm your progress during the installation Do not allow the spreader holes to go past the matching holes in the float decks SPREADER BARS ACCORDING TO FORE AND AFT POSITIONS F TO INDICATE FORWARD SPREADER B TO INDICATE AFT SPREADER A ALWAYS INDICATES FWD DIRECTION FWD P DETAIL A 1 2 HOLES ARE PRE DRILLED AND RA IT UNIQUELY FIT TO EACH FLOAT BOTTOM VIEW NOTE ORIENTATION MARKS SHOWN IN DETAIL A WHICH ARE LOCATED ON THE BOTTOM SIDES OF EACH SPREADER BAR IN THE LOCATIONS SHOWN SPREADER BAR Figure App 1 1 Note this is a Bottom View 4 WARNING DO NOT INSERT THE SPREADERS TOO DEEPLY INTO THE SOCKETS OR YOU MAY DAMAGE THE OUTER SKINS OF THE FLOATS
66. force against the stop Do not allow more than this as the travel of the actuator rod in the extended position sets the wheel height in the wheel well for water operation The Gear Down submersible sensor is adjusted so that the drag link sensor tab is 035 040 away from the face of the sensor when the drag link is in the complete retracted position It is very important that the sensor does not trigger prematurely Assure that the drag link is over centered and against the stop bracket at the time that the sensor is triggered See Figure 5 6 EROCET Incorporated ERCE 8 12 03 27 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 eee 8 27 2010 SUBTITLE Model 3400 Amphibious Floats REVISION Figure 5 6 LOOSEN TO MAKE ADJUSTMENTS HAND TIGHTEN TO SNUG FIT LOCK NUT TURCK P N 040 ASSURE ACTIVATION ONLY WITH GEAR PROPERLY 035 AND FULLY EXTENDED HAVING THE DRAG LINK SEATED AGAINST THE STOP BRACKET 35A 45023 STOP BRACKET 35A 45022 MAIN DRAG LINK Bi 5 P18 AN6 8139 SS90 SUBMERSIBLE SENSOR ACTIVATED WITH GEAR FULLY EXTENDED AND DRAG LINK FULLY SEATED AGAINST STOP BRACKET 35A 45200 OLEO ASSEMBLY 5A 45400 MAIN GEAR ACTUATOR ADJUST THE ROD END ON THREADED ROD TO ENSURE PROPER POSITION OF DRAG LINK AGAINST STOP BRACKET 7 The gear up position sensor is adjusted to where the drag link triggers it within 1 8 of full up travel There ar
67. ft gear show by their illumination that each landing gear is fully retracted The four amber indicator lights labeled LAND illuminate when the landing gear is down fully deployed Neither set of lights is illuminated when the landing gear is in transit The single red indicator light labeled PUMP comes on when current is being supplied to the landing gear motor If the motor continues running during flight or goes on and off repeatedly the motor should be shut off by pulling the LANDING GEAR MOTOR circuit breaker since continual running of the motor can result in premature motor failure Prior to landing the circuit breaker should be pushed in to reactivate the circuit All the indicator lights can be dimmed for night operation using the dimmer knob on the Landing Gear Advisory Unit EROCET Incorporated ERCE 8 12 03 37 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION Date 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 An optional dash mounted remote light system is available to assure gear position It incorporates two lights one blue one for water landing all gear up and an amber light for land landing all gear down These lights do flash when the landing gear is in transit to the desired position ex the blue light flashes when the gear is in transit to a gear up water landing position and then becomes a solid blue light when all the gear have reach
68. g wires specific hydraulic line routing pump mounting electric and emergency specific wiring water rudder retract routing and landing gear advisory mounting are unique for each STC or TC application to aircraft Installation of the Aerocet Model 3400 Amphibious Seaplane Floats should be done according to the FAA approved drawings supporting these different applications The Aerocet Model 3400 Amphibious Seaplane Floats are twin all composite float hulls separated by spreader bars which incorporate hydraulically operated retractable landing gear allowing for landing on either water or land An airplane mounted electric hydraulic pump with a backup hand pump operates the hydraulics The float utilizes a double fluted bottom contour from the step forward and has a flat top deck design with built in antiskid Each float offers a single large storage locker Each float has six compartments for safety Access to the inside of these compartments is through screwed on access panels on the deck or through the storage locker hatch cover Water rudders are mounted on the stern of each float for water taxi operations The floats are mounted to various airplanes by aerodynamic aluminum struts These are rigidly mounted Boxing flying wires are used to stabilize the mounting of the floats to the airplane The floats incorporate pump locations into each compartment and these are used to remove any excess water through condensation leakage from the access p
69. gh the seals on the oleo bottom Use a large socket and dead blow hammer to assist in getting the chrome upper started through the seal and wiper pushing on the metering insert Continue pushing until at least 4 of the chrome sleeve is showing through the rod wiper Install the high pressure charging valve Remove the metering insert turn the oleo upside down and fill the chrome upper to within 1 25 inches of the snap ring inset with MIL H 5606 aircraft hydraulic fluid Put the metering insert back into place assuring the dome is properly positioned as shown in the figure Put internal snap ring into place Reassemble the bottom cap to the oleo bottom and torque should be 80 foot pounds using Oleo Sleeve Wrench 35A T45260 and Torque Spanner Tool 35A T45267 Align the top cap shear pin holes with that of the lower cap Use the two 2 rods and eye their alignment Turn the chrome upper and top cap clockwise to align the lug holes Fill the oleo with the proper amount of fluid Assure the oleo is upright as it would be in the float The use of the Oleo Bleeder Assembly tool 35A T45201 helps facilitate this process and assures final alignment of the pin holes when charging the oleo with nitrogen Hook a clear piece of tubing to the charge valve Place the other end into a clean bucket of MIL H 5606 aircraft hydraulic fluid Cycle the oleo full travel slowly Repeat stroking the oleo full travel slowly until there is little or no air in the t
70. h is activating whenever the trigger pressure is reached Electric Hydraulic Pump cycles frequently without pilot input Check all lines for damage Replace as Check all fittings for leakage Torque or eplace as necessary ydraulic Actuator Pistons for the Nose or Main Gear have a worn or damaged seal Isolate the Actuator s check pressure losses and replace worn parts Electric Hydraulic Pump does not run when gear position is selected Hydraulic Lock is ocurring in the _ system l Hydraulic Lock due to drastic _ temperature or altitude changes Gear Advisory is not connected properly _ Electrical Power is insufficient or _ non existent to the Hydraulic Pump Cycle the Hand Pump Selector to the UP and DOWN positions then to the Neutral or _ OFF position Retry See Placard _ instructions SAFM Instructions or Section _ 6 5 of this Manual check 35A 60025 Accumulator Tubes for _ leakage by loosening or removing them _ from the fitting at the electric Hydraulic Pump If Hydraulic fluid exits then there is a leak in the tube assembly Replace as i continues periodically ensure that larger Check connector in the back of the unit Re connect _ battery buss bar s circuit breakers relays _ at the Hydraulic Pump location and the hook ups to pump leads _ Check all relevant wiring for damage corrosion or incorrect installatio
71. hickness to assure UV protection A Resin Starved Areas Exposed Fibers or Small Impact Damaged Soft Spots 1 2 Dia or less 1 If necessary sand surfaces to remove gloss 2 Use brush squeegee or hypodermic to work resin into defective area use same resin as the original laminate B Small Bruises Punctures Less than 1 4 diameter or Surface Voids 1 Sand surface surrounding defect to remove gloss 2 Use same fabric as the original part 3 Cut patches to fit correction area extending a minimum of 1 2 past the damaged area All patch corners must be rounded 4 Apply a light brush coat of resin similar to original 5 Place one or more plies on detail covering correction area using impregnation of fabric as described in section 8 3 C Cuts Fractures or Punctures 1 4 diameter or Larger 1 Cut back material as required to ascertain extent of damage Trim back plies to a smooth oval 1 2 per ply generally 2 Ifthe area is large enough supply backing to hold the shape of the original contour Put a parting agent on this backing to assure its release 3 Replace the fabric on a ply for ply basis overlapping 1 2 minimum on each succeeding ply using impregnation of fabric as described in section 8 3 Any smooth areas need to be sanded with 80 grit sandpaper to assure proper bonding EROCET Incorporated ERCE 8 12 03 56 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 Mee
72. hydraulic lines from the hydraulic piston Remove the position sensors and tie them back to protect them damage Remove the 1 8 pipe and fitting from the front of the hydraulic actuator and the aft hydraulic tube fitting from the rear Remove the 10 fasteners which hold the slide brackets onto the front of the float Remove the 4 fasteners which hold the rear of the nose box to the attach brackets Pull the complete nose box and gear forward including the hydraulic actuator Note that single part urethane sealant is used where the box attaches to the front of the float and seals the bolts that hold it on Reverse these procedures for installation EROCET Incorporated ERCE 8 12 03 19 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION Date 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 4 6 Nose Wheel Removal and disassembly Reference 35A CPL 42100 Sheets 2 amp 3 and nose wheel drawing 35A CPL 50000 Make sure gear is in the down position and hydraulic gear motor circuit breaker is pulled Jack the airplane according to Section 3 Remove cotter pin castellated nut and AN8 50A bolt Note position of tensioner bushings and Stat O Seal Be sure to deflate tire before any disassembly of the nose wheel Disassemble wheel as necessary SON a ee he Note condition of wheel bearings bearing seals tensioner bushings and Stat O Seal Replace as
73. iginal bonding resin This should be a white ish colored hard substance Coloration may vary if repair has been done before There is a woven backing that serves to bond the strip and this should be removed if it remains bonded to the float Continue to sand until reaching a smooth uniform surface in the affected area Avoid sanding through the gelcoat if possible If you do sand through the fiberglass then follow the repair procedures outlined above to maintain original strength For aluminum style removal Remove Sika Flex with a knife as needed to obtain a flat and clean bonding area Some sanding may also be helpful Thoroughly clean the affected areas of the keel with acetone Temporarily position the keel strip s in place using them as a template to mark drill points Masking tape may be helpful here Drill 24 1520 holes perpendicular to the keel about 1 4 deep This will penetrate through the shell laminates and begin to enter the keel stringer allowing the screw to thread in directly Do not oversize the holes Check the fit of the holes position and screws ability to be secured The next two steps are time dependent and it would be a bad time to discover a problem Thoroughly clean the keel strips and apply Sika Primer per manufacturer s instructions Apply a bead of Sika Flex 292 to the keel strip and fit it to the float Install the screws and use masking tape as necessary to apply pressure and hold it in place
74. igure 6 2 1 Hydraulic lines for 182 206 similar see drawings INBOARD CESSNA 182 INSTALLATION SHOWN Figure 6 2 2 82 60642 BRAKE LINE TO FLOAT DECK FRONT STRUT 82 23025 L FRONT DECK FITTING LHS DIAGONAL STRUT 82 60014 6 STRAND CONDUCTOR CABLE MS35489 6 RUBBER GROMMET OR URETHANE SEALANT DETAIL A SHOWING FWD DECK FITTING LHS RHS OPPOSITE ALONG CENTERLINE REF DWG NO 82 60014 FOR INSTALLATION DETAILS 6 EROCET ISSUE PAGE DATE 8 12 03 Incorporated 31 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 Figure 6 2 3 REAR STRUT 82 60640 DOWN LINE TO FLOAT DECK USE 82 60644 FOR FLAT GEAR 82 23030 INSTALLATIONS AFT DECK FITTING LHS 82 60641 UP LINE TO FLOAT DECK USE 82 60645 FOR FLAT GEAR INSTALLATIONS DETAIL B SHOWING AFT DECK FITTING LHS RHS OPPOSITE ALONG CENTERLINE HYDRAULIC INSTALLATION DETAILS PER DWG NO 82 60014 CESSNA 182 INSTALLATION SHOWN NOTE UP OR RETRACT LINES ARE ALWAYS INSTALLED INBOARD AND DOWN OR DEPLOY LINES ARE ALWAYS INSTALLED OUTBOARD ON ALL MODEL 3400 FLOATS EROCET PAGE 8 12 03 Incorporated 32 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION Date 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 Figure 6 2 4 Sh
75. kinks or Hydraulic Lines are damaged lockages Replace lines as necessary _ Hydraulic Pump screens are nspect and clean or replace as necessary obstructed _ Replace Electric Hydraulic Pump l Hydraulic Pump Motor is worn Assembly Hydraulic Pump i Hydraulic system is compromised Check all lines for damage Replace as activates but does not move the gear fully into position and does not shut off Check all fittings for leakage Torque or _ replace as necessary ydraulic Actuator Pistons for the Nose or Main Gear have a worn or damaged seal Isolate the Actuator and replace worn parts ernal parts within the Hydraulic Pump _ are compromised Replace the Pump Hydraulic Pump Air in the hydraulic system With the floats suspended ensure that the activates but sounds Electric Hydraulic Pump reservoir is and works erratically properly filled Proceed to activate the may eventually pump in one direction only re filling the reach full position reservoir as necessary Repeat for opposite and shut offinsome _ direction until all air is purged from system cases Hydraulic Pump Hydraulic lines are reversed Check installation to appropriate drawings activates in the T E __ Hydraulic Pump is wired reverse ex Selecting ae incorrectly Up with the position y switch results in Gear eck for proper hook up according to 5A 60015 schematic
76. l to obtain desired settings GC600 Models Refer to A 10037 CMM l Factory presets are not desirable Speech is garbled Hook up wiring is compromised Check for faults with installation wiring during normal flight l This includes corrosion damaged insulation procedures i _ or improper hook up Ref 35A 60015 chematic and maintenance manual l Internal components are eturn the Gear Advisory unit to Aerocet compromised _ for repair EROCET ISSUE Incorporated Boe DATE 8 12 03 79 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 Mee 8 27 2010 SUBTITLE Model 3400 Amphibious Floats REVISION A 13 Airworthiness Limitations 13 1 GENERAL The Airworthiness Limitations section is FAA approved and specifies inspections and other maintenance required under 43 16 and 91 403 of the Federal Aviation Regulations unless an alternative program has been FAA approved 13 2 DESCRIPTION D TIME LIMITED ITEMS None E REQUIRED INSPECTIONS INTERVAL None F Scheduled Maintenance for Aerocet recommended Inspection or Replacement are located in Section 9 8 12 03 REVISION DATE 8 27 2010 TITLE SUBTITLE EROCET Incorporated Service amp Maintenance Manual Model 3400 Amphibious Floats This page intentionally left blank except this line PAGE 80 of 82 FILE NO A 10031 REVISION
77. lic lines may be left in place if it is determined that no adverse conditions or conflicts exist Cap ends of all fittings no longer used 11 Cessna 206 Remove brake line 36 15442 or 36 15443 beneath aircraft floor near the main gear fittings between the fuselage skin and existing bulkhead fitting Temporarily cap the existing bulkhead fitting to prevent fluid loss or contamination until brake line for land plane gear or wheel skis is installed Float brake fitting at aircraft skin may be capped and left in place if no adverse conditions or conflicts are determined to exist 12 Cessna 206 Remove nose gear cover panels part of the Cessna float kit to gain access to front strut fittings beneath the aircraft engine 13 Disconnect conductor cables remove terminations and remove from the fuselage and struts 14 Disconnect and remove the tie rods 15 Hydraulic lines and electrical wiring should either be removed from the struts entirely or at least disconnected to avoid damage Lower the aircraft with the hoist until the floats are just resting on the ground Try to raise and lower the hoist as needed to take the load off of the fittings to remove the bolts In any case take precautions to provide support as you free things from the aircraft to prevent unnecessary damage to the struts floats or hydraulic tubes 16 Cessna 180 or 185 Take the load off of the aft struts by adjusting the hoist and rocking the rear fuselage Disconnect the aft st
78. lic system Emergency Hand Hydraulic Lines are reversed Trace the hydraulic lines to the installation Pump does not move _ drawing applicable to the Aircraft the float gear in the Provided with Installation Package correct direction available from Aerocet Inc or Seaplanes West Inc for 182 Aircraft See also 35A emove the lever and turn it 180 degrees _ Ensure that the label matches the correct selection If necessary trim the closed end _ flip the orientation and reinstall _ Selector lever is installed backwar _ for this aircraft EROCET Incorporated ERCE 8 12 03 75 of 82 7 7 FILE NO TITLE Service amp Maintenance Manual A 10031 eee 8 27 2010 SUBTITLE Model 3400 Amphibious Floats SAEED 6 Table 12 1 Troubleshooting Model 3400 Amphibious Floats Cont d E Detected Problem Possible Cause _ Corrective Action 1 amp Circuit Hook up wiring is compromised Check for faults with installation wiring Breaker on bus bar CB for internal relays only This includes corrosion damaged insulation opens i _ or improper hook up Ref 35A 60015 schematic l Internal components are Return the K 65 unit to Aerocet for repair compromised CB for electronics i only 25 amp circuit Hook up wiring is compromised Check for faults with installation wiring to breaker on bus bar _ the Electric Hydraulic Pump This includes
79. ll the newly marked holes You may wish to use the bracket as a guide Install the remaining fasteners Reinstall the access cover using the existing aircraft hardware and instructions Repeat process for the other wing 8 12 03 REVISION DATE 8 27 2010 TITLE SUBTITLE EROCET Incorporated Service amp Maintenance Manual Model 3400 Amphibious Floats This page intentionally left blank except this line PAGE 40 of 82 FILE NO A 10031 REVISION 6 EROCET Incorporated ERCE 8 12 03 41 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 Mee 8 27 2010 SUBTITLE Model 3400 Amphibious Floats REVISION P 7 Water Rudder Retraction and Steering System 7 1 General Description The water rudders are used for steering when taxiing on the water They are steered through 3 32 stainless cables that connect to the airplanes rudder system and are retracted manually through a lever in the cockpit again using 3 32 stainless cables They should always be retracted before take off and never deployed until off the step Damage may result if a take off or landing is attempted with the rudders down Typically this damages the blade and the stainless tiller post Internal sealed tubing in which the 3 32 cable passes through prohibits water transfer between the two rear water tight compartments in each float 7 2 Rudder Assem
80. losely as possible to the float hulls without touching the hulls Figure 3 1 1 9 72 0 100 0 JACKING POINT 6 0 8 12 03 REVISION DATE 8 27 2010 EROCET Incorporated TITLE Service amp Maintenance Manual SUBTITLE Model 3400 Amphibious Floats This page intentionally left blank except this line PAGE 16 of 82 FILE NO A 10031 REVISION 6 EROCET TSSUE Incorporated eee Date 8 12 03 17 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 4 Nose Gear 4 1 General Description The nose gear utilizes a composite fiberglass strut to absorb energy on landing along with the deflection of the nose tire The nose gear is full swiveling utilizing braking for steering and incorporates a centering device to keep the nose gear aligned for landing Retraction of the nose gear is done by a hydraulic ram which pulls the gear along a slide track stowing the landing gear strut into a box in the nose of the float leaving the tire exposed on the front of the float A towing lug is located on the lower clamp block Reference should be made to Nose Gear Assembly 35A CPL 42000 Sheets 1 amp 2 and Lower Nose Gear Dwg No 35A 42100 Sheets 1 3 4 2 Nose Gear Partial Removal Reference 35A CPL 42100 Sheets 1 3 1 Make sure
81. loyed condition with all lights appearing on the gear advisory 3 Turn Master Switch OFF 4 Pull one amp breakers for the gear advisory pump relays and the twenty five amp breaker for the electric hydraulic pump 5 Disconnect aircraft from power sources and battery first assuring the proper shut down of all other aircraft equipment per Cessna or other applicable service manuals 6 Disconnect water rudder control cables from springs and remove springs and pedal extensions Cessna 206 or rudder centering device Cessna 180 185 7 Disconnect water rudder retraction cables from the aircraft 8 Loosen boarding steps as necessary The boarding steps can be left on if they allow the floats to come off the fittings 9 Assuring that power is off battery is disconnected so that the hydraulic pump does not function cycle the selector on the emergency gear hand pump to relieve any residual system pressure Drain EROCET Incorporated ERCE 8 12 03 51 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 hydraulic fluid from deploy and retract lines below each float deck into a suitable container for proper disposal It may be suitable to use the hand pump to drain residual fluid from each side manually 10 Disconnect all hydraulic lines from the fuselage near the aft strut fitting Internal hydrau
82. move the rub strips and set them aside Prepare the bonding area of the floats sanding as closely as possible to the masking without sanding beyond it Thoroughly clean and prime the bonding areas of the float and the prepared rub strips Apply a generous bead of Sika Flex 292 or equivalent urethane adhesive to the rub strips Position the rub strips and firmly push them onto the floats so that there is a consistent bead of squeeze out Aerocet uses a three foot 2 x 2 with a 1 2 90 degree notch near the middle to apply heavy pressure with a rocking motion to work out any air pockets in the adhesive A second person should follow closely applying strips of 2 masking tape firmly to the float as you work your way down the length of the strips Immediately clean Sika Flex from any work areas or unintended float surfaces using acetone but leave squeeze out adjacent to the keel until cured Usually cure is about 12 hrs After cure use a knife to slice the squeeze out along the edges of the keel peeling the bead away as you go Avoid cutting into the gel coat 8 12 03 REVISION DATE 8 27 2010 TITLE SUBTITLE EROCET Incorporated Service amp Maintenance Manual Model 3400 Amphibious Floats This page intentionally left blank except this line PAGE 60 of 82 FILE NO A 10031 REVISION 6 ISSUE DATE 8 12 03 TITLE REVISION DATE 8
83. n Ref 35A 60015 for Float Hook Up ee above for immediate relief Then ecessary 5A 60025 2 tube assemblies are installed eck power source voltages at the aircraft Check Aircraft electrical grounds Ref 35A 60015 for Float Hook Up EROCET Incorporated Pane 8 12 03 72 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 RAS TA 8 27 2010 SUBTITLE Model 3400 Amphibious Floats REVISION p Table 12 1 Troubleshooting Model 3400 Amphibious Floats Cont d Hydraulic System Detected Problem Possible Cause _ Corrective Action Gear Advisory Unit has failed Check 1 Amp circuit breakers One is for l the Gear Advisory Internal Relays One is r the Gear Advisory Electronics If the CB for the Internal Relays is open then check for faults with installation _ wiring This includes corrosion damaged _ insulation or improper hook up Ref 35A 60015 f the CB for the Gear Advisory electronics _ is blown then return the Gear Advisory to Aerocet for repair ll other Gear Advisory symptoms refer to Section 6 7 of this manual for K 65 Units or to CMM A 10037 for GC600 Units Electric Hydraulic _ Electrical Power is insufficient to Check for faults with installation wiring Pump runs _ the Hydraulic Pump _ This includes corrosion damaged insulation perceptibly slower l _ or improper hook up Ref 35A 60015 than normal
84. n the pump on and off are at a lower setting These have a range from 350 500 psi 6 It should also be noted that the dipstick is replaced with a breather plug and the hydraulic fluid filled through this orifice 7 Reassemble in reverse order of disassembly 8 The reservoir should be filled to one inch from the top of the sight gauge On initial installation the fluid will go down dramatically as it fills the lines Don t run the pump dry Stop as necessary refilling the reservoir to maintain the proper level until all the air is out of the system EROCET 8 12 03 Incorporated ERCE 34 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION pate 8 27 2010 REVISION SUBTITLE Model 3400 Amphibious Floats 6 9 Troubleshooting Hints e Pump will not start i ii iii iv V1 Check circuit breaker Replace if necessary Check motor ground and wiring Repair if necessary Ref 35A 60015 for schematic Faulty pressure switch motor will not start at low cut in or will not shut off at completion of cycle Replace Switch if necessary Faulty solenoid pressure switch motor will not start Replace Pump if necessary Faulty or dirty pressure relief valve clean and check Refer to exploded view and instructions in the back of the manual Pressure build up in system from both sides of up and down lines Background The accumulator tube
85. nes through the struts For Cessna 206 Installation 36 15100 also 36 15400 for hydraulic lines through the struts Prepare the aircraft for float installation assuring that all prerequisite float gear has been installed See Installation Instructions above STC Limitations if applicable and Installation Drawings Use a hoist with plenty of capacity to handle the floats and the weight of the aircraft together Remove landing gear per Cessna Manuals As shown in the Installation Drawings Aerocet intends the use of washers beneath the head of the fastener preferably a thin washer and beneath the nut This helps to isolate the steel of the fasteners from the aluminum of the struts If necessary it is permissible to change the thickness of the washers or add up to two washers beneath the nut to avoid bottoming the nut on the bolt shoulder A properly sized bolt will have less than 2 threads penetrating the assembly hole after tightening If necessary use one dash number bolt larger or smaller to obtain the proper grip for the installation Please refer directly to the drawings for callout details EROCET Incorporated ERCE 8 12 03 46 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION 6 7 REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 NOTE The hydraulic lines will have to be routed through the struts before the
86. ng CMM s MM s or Parts Catalogs 1 Cleveland Wheels and Brakes AWBCMMO001 7 or later Maintenance Manual 2 Cleveland Wheels and Brakes AWBPCO0001 7 or later Product Catalog 3 Aerocet A 10036 Component Maintenance Manual Aerocet 6 00 6 Wheel Assembly 4 Aerocet A 10037 Component Maintenance Manual Aerocet Model GC600 Gear Advisory EROCET ISSUE Incorporated ee DATE 8 12 03 7 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 1 3 Dimensions Locations and Nomenclature Figure 1 3 1 Showing Model 3400 Amphibious Float installation on a Cessna 180 Aircraft 185 similar The Cessna 206 series has a tail height of 13 2 13 8 Figure 1 3 2 Showing Front View of Model 3400 Floats 100 000 132 5 EROCET Incorporated ERCE 8 12 03 8 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 RN A 8 27 2010 SUBTITLE Model 3400 Amphibious Floats REVISION P Figure 1 3 3 WATER RUDDER NOSE GEAR BOW DECK STERN gt TRANSOM CHINE Ce 4 MAIN GEAR KEEL a KEELSON STEP Figure 1 3 4 RIGHT HAND FLOAT PUMP OUT WELLS DECK PLATE ASSEMBLY J 8 TOTAL FLOAT SPREADER BAR _ FWD y _ SPREADER BAR y AFT DECK CLEA
87. ngs as necessary 11 Inspect slide truck and lock bracket for wear and replace as necessary 12 If removal of the rod end part 35A 42403 from the nose gear hydraulic actuator is necessary it will dictate readjustment upon reassembly Mark with a permanent marker or masking tape the original location of the rod end on the actuator rod prior to disassembly to aid in the reassembly process EROCET TSSUE Incorporated eee Date 8 12 03 18 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 4 4 Reassembly of the Nose Gear to the Nose Gear Box Reference 35A CPL 42000 4 5 eh SS Sheets 1 amp 2 35A CPL 42100 Sheets 1 3 35A CPL 42300 Sheet 1 and 35A CPL 42400 Assemble in reverse order 4 3 Make sure the lock bracket part 35A 42252 is positioned with the grease holes facing out Setting the proper adjustment of the rod end to the hydraulic piston is critical Assure that the rod end part 35A 42403 is screwed onto the nose gear hydraulic actuator at least as far as it was prior to disassembly If uncertain screw the rod end onto the actuator until it bottoms Danger if the rod end adjustment is incorrect the piston rod may be bent with full gear extension Put the gear into the down position and adjust the rod end to the piston rod until the lock bushings part 35A 42254 just
88. nst the spreader There are a number of options to use please refer to the installation drawings for details The float cable exit points for the remaining steering and retract cables will have to be located once the aircraft is positioned on the struts Refer to the installation drawings for locations and instructions Take time to align these carefully opening the exit hole if necessary up to 9 16 diameter securing with cabo sill resin mixture or with marine grade urethane adhesive such as Sika Flex 292 Water Rudder Steering cables are routed per the installation drawings attaching to the rudder cables They run aft on the 180 185 and on the 206 run forward to the rudder pedal extensions part of the Cessna float kit that extend below the fuselage Water Rudder Retract cables route forward meeting below the fuselage and then attaching to the retract handle assembly in the cockpit The rudders should be approximately 5 from the upper stops on the tillers when fully retracted and should come to rest on the lower stops when fully deployed The best exit angle for this cable through the float will be found at the mid point of the retraction deployment positions Assure clearances to tie rods or aircraft structures that might protrude nearby Cable travel or slack should not be able to deflect into such things NOTE It is highly advisable to install optional zinc anode to water rudders when used in a marine salt water air environmen
89. o include 206 Added Appendix with Install drawings for CPL EROCET Incorporated ERCE 8 12 03 3 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 A 8 27 2010 SUBTITLE Model 3400 Amphibious Floats REVISION P Table of Contents Section POPC ssncvsetisseciocteseas ie veetlecdves a aa i a Dae lvesieeees Page LOS OF REVISIONS Page ccss ticsiecises tessa sesaeseuedscdessiaesies E E ENE E A EAER OEE EREE EEE EEE OAE EST ESES 2 T bleot Combe mts osceni neee E EEE EES ESENE EE EES E E TE EA E EES aT RESET Si 3 1 Introduction and General Float Information ccceeccceesseceececeeeeeceaeeeeaaeceeaeeceeeeeeaeeeeaaeceeaeeenaees 5 2 Float Hull Maintenance ir ss cess sa ssscessasesenssasted ssaasevensanteneesaasesenstosduassavovess ss asentesoncssinnns avbatesane cds OESE 9 3 Float Handling and Jacking ccc ccccistecssvessicccetaccevessaidccvedstaassvideades ila sctveues ianei narii aii 15 4 NOS Gal steeds iii ies hihi ee ati elie Hae Bilas dele aslibas E Medes 17 5 Main Gedi arrere ereire rendere cnsadcgauacenveacnsd eas sweden EA E EEE che suee E eSEE TEE EREE TEES a EN 21 6 Landing Gear Retraction System eseeseeseesestrsrssiesrrsresstsrisserrtsstestrstestestessetrisstestnstentssresenrese 29 7 Water Rudder Retraction and Steering System eseeseessesrsesesrrsrestesresreeresrtsserriesrestesrestestensesreses 41 8 Float Installation and Removal to Aircraft 0 ccc
90. or landing with the rudders down Cables Inspect for fraying especially around the stern pulleys amp cable guards cotter pins Pulleys and Bushings Inspect for freedom of rotation amp condition of pulleys Internal Cable Tubing Inspect for signs of leakage and wear around the exit for the rudder retract cable EROCET TSSUE DATE 8 12 03 Incorporated 64 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 eee 8 27 2010 SUBTITLE Model 3400 Amphibious Floats REVISION A INSPECTION TIME HOURS MONTHS INTERVALS Whichever occurs first 100 200 25 50 12 24 Hulls amp Struts Inspect for damage surface coat gel coat UV protection keel wear strips chine wear strips Inspect for evidence of Float interior damage from the interior vantage point Inspect seals cracks in Access Panels amp pump out tubes Pump Out System jattachment of pump out tubes tube routing Spray coat protection according to Note 3 Hardware according to Note 4 If working saltwater protect more frequently Inspect for damage corrosion Inspect seals latches internal damage from baggage alk Wire Inspect for corrosion of all if installed Float Bow parts wear fatigue or fray Inspect for placement amp legibility Float exterior Deck Blocks Deck Plates and Hardware Struts Baggage Compartment
91. owing Cessna 180 or 185 or 206 FWD Deck Fitting Hydraulic Fittings and conductor cable installation FWD STRUT DECK FITTING _ M27500 CONDUCTOR CABLE PER 35A 60000 DRILL 250 450 THRU DECK BRAKE LINE AS1040D0404 ELBOW AN837 4D OBSOLETE OTE 3 BRAKE LINES MAY BE ACCOMODATED BY ADDING BELOW FLOAT DECK 35A 60046 REDUCER FITTING WITH 35A 47016 L OR R BRAKE LINE AS1040D0303 ELBOW SHOWING FWD DECK FITTING LHS AN924 3D NUT CESSNA 180 185 AIRCRAFT ADDITIONAL INSTALLATION DETAILS ABOVE FLOAT DECK PER 35A 60000 35A 60045 BRAKE LINE 3 16 TUBING Figure 6 2 5 Showing Available Aerocet 3 Brake Line Conversion AS1040D0303 ELBOW AN837 3D OBSOLETE AEROCET 35A 47016 L OR R MAY REQUIRE NAS1149D0663J BRAKE LINE 3 TO FLOAT DECK LHS WASHER BENEATH FITTING OR R FOR RHS J d BULKHEAD AT FLOAT STA 107 50 no ee Ws i e s AEROCET 35A 60046 REDUCER FITTING AN924 3D NUT Pii A EROCET Incorporated ERCE 8 12 03 33 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 6 3 Hydraulic Actuators Reference 35A CPL 42400 Sheet 1 35A CPL 45300 Sheet 1 and 35A CPL 45400 1 Both the nose and main gear actuators can be rebuilt 2 Disassemble according to the reference drawings 3 Note that the nose gear actuator
92. quired use rivets of proper specifications only For instance MS203426AD4 xxx Lengths may be determined by measuring the thickness of the material s to be assembled and adding 1 5 X Diameter of the rivet to be used Over sized rivets may be substituted where holes have been drilled out Bolts and screws shall have a minimum of one thread visible through the nuts upon final torque Washers may be rearranged if necessary to accommodate proper fit up to two washers beneath the nut and one beneath the fastener head Typically Aerocet intends to put one thin washer beneath the fastener head and one thicker washer beneath the nut 2 3 2 Fastener Reuse Fasteners are to be inspected for condition per Section 9 of this manual Such fasteners that are acceptable may be cleaned re lubricated and re installed as determined Self locking nuts shall meet the minimum prevailing torque as listed in Figure 2 2 2 or shall be replaced 8 12 03 REVISION DATE 8 27 2010 TITLE SUBTITLE EROCET Incorporated Service amp Maintenance Manual Model 3400 Amphibious Floats This page intentionally left blank except this line PAGE 14 of 82 FILE NO A 10031 REVISION 6 EROCET Incorporated ERCE 8 12 03 15 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6
93. re too high e g the _ Manual cancel button _ aircraft is hovering near the Arm For GC600 Units Refer to A 10037 _and Trigger speeds re arming the CMM unit and triggering it again during _ pattern work Audio Volume is too Aircraft Panel Adjustments are Adjust the panel settings according to the low _ incorrect or have been _ appropriate Maintenance Manual or Pilot _ inadvertently lowered Operation Handbook or Flight Manual nsure adequate current and power storage heck recharge or replace the battery EROCET Incorporated ERCE 8 12 03 78 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 eee 8 27 2010 SUBTITLE Model 3400 Amphibious Floats REVISION p Table 12 1 Troubleshooting Model 3400 Amphibious Floats Cont d Gear Advisory Includes K 65 Models See A 10037 for additional details applicable to GC600 Models Gear Advisory Audio Detected Problem Possible Cause _ Corrective Action Factory presets are not desirable K 65 Models Refer to Section 6 7 of this _ manual to obtain desired settings GC600 Models Refer to A 10037 CMM Audio Volume is too Aircraft Panel Adjustments are Adjust the panel settings according to the high _ incorrect or have been _ appropriate Maintenance Manual or Pilot inadvertently raised Operation Handbook or Flight Manual K 65 Models Refer to Section 6 7 of this _ manua
94. rocedure as detailed in 8 7 4 and 5 A small amount of gel coat will whiten the mixture and help blend the appearance at the edges If preferred use Sika Flex 292 or equivalent urethane adhesive for bonding Note Remove excess cabosil squeeze out before it fully hardens 9 10 Chine Rub Strip Replacement Chine rub strips are aluminum extrusions that are fitted to the outside edges of the float bottoms These are necessary to prevent damage to floats in certain docking beaching or other practices On the model 3400 floats there are two shapes used to accommodate the forebody forward of the step and the afterbody aft of the step These rarely require replacement in most cases and partial replacement may be a good option as well Chine rub strips are bonded to the floats with Sika flex 292 adhesive Removal may be accomplished by carefully slicing the adhesive and or peeling the pieces Some fitting will be necessary to match any existing abutting pieces Most of this is best accomplished with the float being upside down and stably supported on saw horses Work from the step area first as this is the most detailed trimming the fore and aft ends once things are ready to bond Firmly secure any fitted but un bonded pieces with masking tape to help you accurately arrange and finalize the trimming Remove any sharp edges to avoid injury With all strips firmly taped to the float mask the float along the edges of the strips Then re
95. ruts at the floats carefully allowing the main gear of the floats to reach the floor 17 Cessna 206 Take the load off of the front struts by adjusting the hoist and rocking the aircraft Disconnect the front struts at the deck fitting carefully allowing the nose gear of the floats to reach the floor The front struts will hinge inward when disconnected from the floats someone should hold on to each to keep them from being damaged by swinging freely Secure as necessary 18 Disconnect the mid and aft struts at the aircraft fittings hydraulic lines as applicable 19 Disconnect the remaining struts for complete disassembly with the floats sitting on the floor 20 Cap the hydraulic fittings three on each float Clean excess fluid from the floats as soon as practical to avoid staining the gelcoat 21 As applicable Cap any unused hydraulic fitting left in the fuselage 22 Install landing gear per Cessna manuals and instructions refill brake master cylinder and bleed the brakes 23 Winter storage where temperatures may drop below freezing is addressed by adding a quart of RV antifreeze through each of the pump out cups Taping over the pump out holes will minimize the amount of moisture that will enter each of the six compartments Do not use masking tape 24 The floats may be stored on the wheels resting on the keels or hung from a sling around the floats near the spreader bars EROCET ISSUE Incorporated ee DATE 8 12
96. s that are mounted to the hydraulic pump serve to absorb pressure variations from two primary sources Pressure can build up in the system due to environmental variations such as extreme temperature swings or with altitude The tubes also absorb the differences in the volumes of the gear actuators being retracted or being deployed The piston and shaft in an actuator assembly causes a difference in the volumes in the different gear configurations To diagnose Cycle hand pump selector into up and down positions to relieve the pressure and return to OFF position In this circumstance the pump will then operate normally 1 If this problem persists check the seal on the accumulator tubes 35A 60025 at the pump Empty the tubes of all hydraulic fluid replace and assure seal at all fittings 2 Replace the original straight tubes with 35A 60025 2 parts that have a greater volume and may resolve this problem These are a coiled tube and are easily differentiated from the 1 style which is straight 3 The pump itself may not be working properly It may be necessary to bench test it or isolate it from the system for testing Replace the pump if tests fail e Gear stops mid position Pump cuts off i ii Binding gear will shut motor off because of a premature pressure build up Pressure switch failure Uncommon e Pump running continuously or intermittently without pilot input i ii Hydraulic leak
97. should be located near left of the A C Centerline and within unobstructed reach of the pilot Refer to Component Maintenance Manual A 10037 for GC600 Also see 35A 60000 for Cessna 180 185 For 206 refer to 36 15410 12 Circuit breakers are to be installed near existing breakers Some aircraft may have modified separate busses for essential equipment or non essential equipment In this case install the 25 Amp breaker which supplies the electric hydraulic pump to the non essential buss The remaining two 1 Amp breakers should be installed on the essential or primary buss in order to provide gear position indication in the event of an electrical problem in which the pilot would shut down the non essential buss 8 1 10 Wire Routing 1 Assure clearances to all control cables pulleys and structural members Plastic ties must not be used where their failure could result in interference with moveable controls equipment or chafing damage 2 Wires routed near hydraulic or fuel lines must be positively separated by 6 inches or with MS21919WDG size clamps 3 Where wires pass through bulkheads or other structural members a grommet or suitable clamp should be used to prevent abrasion grommets such as MS3489 size or MS21266 size support such as angle brackets amp MS21919WDG size clamps 4 Secure all wiring by using existing wiring where possible Primary support such as MS21919DWG clamps shall be used at intervals not exceeding 21 Repl
98. t Abrade metal surfaces to ensure electrical conductivity to rudder blades using an ohm meter through cables and bonded to the aircraft A proper installation will result in the zinc anode s corrosion instead of other expensive aluminum parts 8 1 6 Boarding Step Installation For Cessna 180 185 Installation 35A 59100 For Cessna 206 Installation 36 15300 Boarding Steps are installed to the outboard sides of the struts as shown in the drawings creating a ladder for loading and boarding of the aircraft All installations typically use an AN4 bolt with a washer EROCET TSSUE Incorporated eon DATE 8 12 03 47 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 beneath the head and another beneath the nut and a plastic washer between the boarding step and the strut For some struts pre drilled holes are provided to mount the steps The boarding steps are provided with a mounting hole in one end allowing them to be pinned and leveled to locate and drill the opposite end Locate new step mounting holes between the strut fitting hole centers which are near center of the internal flats of the strut shape Position the steps at the heights shown in the Installation Drawings or to the existing mounting holes and level them Drill holes perpendicular to the strut and step surfaces 1 4 THRU A
99. ting for faults Components are compromised _ Inc for Repairs Gear Position Lights Mechanical Obstructions Check gear and hydraulic systems for do not illuminate _ mechanical damage debris or other _ obstructions Assure normal freedom of movement throughout the Floats Nose and Main Gear Assemblies len heck for faults with installation and float wiring This includes corrosion damaged insulation or improper hook up Ref 35A 60015 schematic Position Sensors are ocate the malfunctioning sensor and _ malfunctioning eplace as necessary ll Internal Gear Advisory eturn the Gear Advisory Unit to Aerocet _ Components are compromised Inc for Repairs Gear Position Lights Mechanical Obstructions _ Check gear and hydraulic systems for remain illuminated i mechanical damage debris or other _ obstructions Assure normal freedom of movement throughout the Floats Nose and malfunctioning eplace as necessary _ Internal Gear Advisory eturn the Gear Advisory Unit to Aerocet Components are compromised Inc for Repairs EROCET PAGE 8 12 03 Incorporated 77 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION DATE 8 27 2010 SUBTITLE Model 3400 Amphibious Floats pitas 6 Table 12 1 Troubleshooting Model 3400 Amphibious Floats Cont d Gear Advisory Includes K 65 Models See A 10037 for additional details applicable to GC600 Models
100. tion 36 15010 These instructions will direct you through the installation drawings which contain requirements for the float installation Where applicable hints advice or relevant specifics are added Obtain or locate the applicable drawings and documents listed below and familiarize yourself with the contents These drawings are FAA approved data Deviation from them is subject to some other approval process such as a field approval or an add on STC Determination must be made that the installation does not conflict adversely with any previous modifications See the applicable STC Cessna 180 185 and 206 aircraft require the previous installation of the Cessna float kit for that aircraft This will include among other things certain reinforcements such installations as cabin vee brace anti corrosion treatments hoisting rings and in the case of the Cessna 206 a ventral fin and larger air rudder The required parts are listed in applicable Cessna Parts Catalogs and Cessna Floatplane Owner s Manual Supplements Aerocet provides float and fuselage fittings struts tie rods gear advisory wiring hydraulics and water rudder rigging with all new floats Prior to beginning the installation verify the entire equipment list of the aircraft against installed equipment and obtain a certified weight and balance NOTE It is highly recommended to re weigh the aircraft especially if the equipment list has changed or it has been more than t
101. ubing Check final alignment 12 Charge the oleo using nitrogen according to the placard on the oleo This can be done in the Bleeder Assembly tool to assure alignment 500 psi for 3735 Ib gross weight 470 psi for 3600 Ib gross weight 425 psi for 3350 Ib gross weight and 350 psi for 2950 lb gross weight Replace oleo into the float using shear pins washers and cotter pins or retaining rings Retaining rings have been a later improvement and new rings and securing hardware may be substituted in place of the original cotter style if desired Assure that the top shear pin is oriented with the cotter pin toward the right side of the float looking forward EROCET Incorporated ERCE 8 12 03 26 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION DATE REVISION 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 5 5 Complete Disassembly of Main Gear Reference 35A CPL 45000 Sheets 2 7 Oy Ho e en pP e J Make sure gear is in the down position and hydraulic gear motor circuit breaker is pulled Jack the airplane according to Section 3 Remove oleo and main wheel according to Sections 5 2 and 5 3 Remove truck assembly according to sheet 2 Remove extension springs and drag link according to sheets 2 4 Disconnect hydraulics as necessary and remove the main gear hydraulic actuator Note the seals on the bolt that attaches the actuator to the main bulkhead
102. wear strips on using a mixture of Hydrex resin and Aerosil 202 thickener A thick epoxy resin clear type non yellow may be used as well Saturate the fiberglass backing on the keel or wear strip and put a thick film on the mating surface Hold the keel strip in place using an abundance of masking tape Remove tape before the resin cures to a totally hard condition allowing clean up of excess material to be achieved with greater ease Wear strips are more difficult to hold in place during cure with the floats on the airplane This can be achieved using tape and small lengths of wood to create leverage See diagram below EROCET Incorporated ERCE 8 12 03 58 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 KEEL STRIP MASKING TAPE WEAR STRIPS d TN i i FLEXIBLE WOOD STRIP OR SERIES OF BLOCKS BOTTOM OF FLOAT HULL SHOWING WEAR STRIP INSTALLATION 9 8 Keel Strip Replacement Aluminum Style Remove any existing worn or damaged keel strip Use a thin metal scraper or similar device beneath the strip to avoid peeling off excessive gelcoat or resin Older UHMW will likely have deteriorated over time due to UV and environmental exposure so it may not peel but will come off in chips instead For UHMW style removal Use 80 grit or similar sandpaper to remove or
103. wo years since a full weighing Follow the procedures in the Cessna Manuals 8 1 1 Float Preparation Spreader and Deck Fitting Installation For Cessna 180 185 Installation 35A 59300 35A 59 100 For Cessna 206 Installation 36 15011 You will need a large clear work floor Uncrate and remove all protective wrapping of the floats and associated boxes containing small parts hardware etc needed to install noting identifications and keeping things in groups as you go Certain items are boxed and stowed in the float lockers while others may be shipped separately 8 1 2 Before Completion of the Installation Apply grease or oil to main gear wheels per applicable component maintenance manual s See Section 1 2 If installing used floats disassemble clean inspect lubricate and reassemble It may be EROCET TSSUE Incorporated eon DATE 8 12 03 44 of 82 FILE NO TITLE Service amp Maintenance Manual A 10031 REVISION REVISION pate 8 27 2010 SUBTITLE Model 3400 Amphibious Floats 6 desirable to do this before mounting the aircraft Nose Gear wheels are pre packed Disassemble inspect and re pack if installing a used set of 3400 s 8 1 3 Float Assembly You will need the help of at least four people to align the floats and install the spreaders 1 2 3 The Aerocet floats are shipped with pre fitted spreaders which are individually wrapped and packaged
104. y to allow for expansion and contraction of the air in each compartment during flight If the pilot when on the water runs over rocks or debris assess the damage as soon as possible Continuing into a high speed situation with the floats will typically exaggerate the damage due to high water pressure If the pilot makes a hard landing on the runway stop and examine the landing gear parts and supporting structure for damage The composite nose strut should not have any delamination the main gear truck should not have any sheared rivets and all the metal should have no distortion The drag brace the metal part which connects the oleo strut to the step bulkhead should not be bent especially in the area of the over center stop contact point 2 1 Fastener Torque Torque Value Conversion To convert in lbs to ft lbs Value ft lbs x 12 Value in lbs To convert ft lbs to in lbs Value in lbs x 0 0833 Value ft Ibs 2 1 1 Tooling Requirements Calibrated torque wrench Adapters that affect the length of the torque wrench will affect the required torque indication and must be calculated according to Figure 1 4 3 2 1 2 Hardware Cleanliness All hardware is to be free of dirt grit and grease All dirty hardware shall be thoroughly cleaned and lubricated with a dry film lubricant such as LPS 1 or Teflon products per manufacturer instructions It is recommended that all stainless hardware be thoroughly lubricated with anti s

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