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Model 8750 Service Manual

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9. float by reversing steps thru 7 Safety wire 5 16 18 bolts when installed Outer face of actuator arms should be flush to actuator shaft It 1s recommended to leave the spring disconnected during gear rigging P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 4 2 MAIN GEAR ASSEMBLY SETUP 17 18 19 20 2 22 AND ADJUSTMENT CONT Reattach rod linkages to actuator arms Loosen the rod linkage jamb nuts and lengthen the rods slightly Item 3 Make equal adjustments to each rod Rotate actuator arms until the internal piston is against the Down Adjustment Screw Shorten the Rod Linkage until the Top Arm Contact Face Item 15 touches the contact face of the Top Mount Item 7 Make equal adjustments to each rod Actuator needs to be rotated fully against the Down Adjustment Screw Visually inspect the Rod Linkage position Item 3 versus the actuator shaft Item 4 When rigged correctly the bottom edge of the rod linkage should pass through the shaft as shown in Figure 4 4A Ensure gear is in down and locked position Using a small digital protractor the over center angle will be verified Lay the protractor across the bottom of the lower two screw holes in the actuator arm Note Older float models may not have flat spot P N 1005723 Doc No W8750 24 01 254 24 29 26 Page 56 of 104 shown use the same lo
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11. lines at the strut pylon attach points P N 1005723 Doc No W8750 24 01 Page 66 of 104 The only electrical difference between the standard and retrofit hydraulic system is the addition of a port and starboard low power wire that runs to the powered proximity switch that commands main gear position indication See drawing number 1006012 revision A or later approved revision for electrical information pertaining to the hydraulic system See drawing number 1006004 latest revision for hydraulic system descriptive information for the retrofit installation For Cessna 208 see drawing number 1006005 revision A or later approved revision or for Cessna 208B see drawing number 1006016 revision A or later approved for hydraulic system descriptive information for the current production installation From the aircraft belly up the hydraulic system should be maintained with ICA document number 1002554 revision G or later approved revision as applicable to the model 8000 installation From the aircraft belly down the hydraulic system shall be maintained with these ICA Revision C SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B The following instructions pertain to the current production dry handle system configuration with reversible pumps BASIC DESCRIPTION A pressure of between 500 psi and 700 psi in the DOWN position and 500 psi and 1200 psi in the UP position
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13. fluid pickup tubes that do not reach the with the hand pump alone bottom of the hydraulic fluid reservoir This prevents the electric pump from being able to pump all the fluid out of the system P N 1005723 Doc No W8750 24 01 Page 64 of 104 Revision C SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B CHAPTER 5 HYDRAULICS Revision C Page 65 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 5 0 HYDRAULIC SYSTEM WET HANDLE VS DRY HANDLE SYSTEM These instructions are for the later model dry handle hydraulic system that 1s used for new 8750 float installations For legacy installations retrofitted from 8000 s to 8750s the wet handle pump system may be installed The dry handle system is characterized by a gear selector head containing an electrical switch that is connected with wires to the aft fuselage mounted pump The pump direction 18 reversible The legacy wet handle system 1s characterized by a gear selector head that contains a mechanical valve and is connected with hydraulic lines directly to the gear The pump direction 18 not reversible For retrofit installations where the model 8750 1s mated to the wet handle equipped aircraft operation of the hydraulic system 1s the same as with the model 8000 installation pressure and return lines at the fuselage exits are connected to pressure and return
14. 01 Page 82 of 104 Revision D SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B Wheel Bearings Main Gear Retract Hydraulic Fluid Mechanism Nose Gear Pivot and Rod Ends Mil H 5606 HCF Grease P N 605 Electrical Insulating Compound HCF Industries Dow Corning 4 0 4 Dow Corning Corporation Aeroshell 22 Shell Global Solutions Bolt Torque Green Grease Multi Purpose Green Grease Inc Aviation Grease SHC 100 ExxonMobil Aviation Lubricants Bolts in Critical Areas For common correct torque when installed or when visual inspection indicates a need for a torque check Tension Nut Nut Bolt Size Torque Limits in Ibs Min Max f existing grease cannot be identified 8 36 12 15 you must lubri flush all float grease 10 32 20 23 fittings until visibly exhausting all old 1 4 28 50 70 grease and new grease is coming out 5 16 24 100 140 Additionally if you cannot determine 3 6 24 160 190 existing grease in wheel bearings 7 16 20 450 500 completely clean and repack bearings 1 2 20 480 690 with new grease 9 16 18 900 1 000 5 8 18 1 100 1 300 Metal Corrosion Protection 3 4 16 2 300 2 500 Boeshield T9 Rust Protection 7 8 14 2 500 3 000 Comping 1 14 3 700 4 500 1 1 8 12 5 000 7 000 Corrosion X 1 1 4 12 9 000 11 000 ACF 50 Rust Protection Shear Nut Nut Bolt Size Torque Limits in Ibs Tef Gel Min Max Ultra Safety Systems Inc 8 36 I 9 10 32 12 I5 Float Sealant
15. 1 4 28 30 40 990 B2 or 5 16 24 60 85 Pro Seal Company 3 8 24 95 110 7 16 20 270 300 1440 C 1 2 20 290 410 PPG Aerospace 9 16 18 480 600 5 8 18 600 780 RTV Silicones 3 4 16 1 300 1 500 General Electric 7 8 14 1 500 1 800 1 14 2 200 3 300 SIKAFLEX 201 or 252 1 1 8 12 3 000 4 200 Sika Manufacturing 1 1 4 12 5 400 6 600 Teflon Spray 6P 730A Comet Industries A Torque of 80 should be used when Tef Gel is applied to the bolt Revision E Page 83 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 9 1 CORROSION REMOVAL Corrosion is usually detected visually which is why Wipaire strongly recommends the previous cleaning and inspection procedures It can appear as a white or pale green powder discoloration of the metal surface or bubbles and blisters under the surface of the paint j ad Pylon Fully Repaired Light corrosion is removed by gentle sanding After removing the corrosion restore the area or chromic acid Moderate and severe to the original finish like prime and enamel corrosion blistering flaking and pitting can or coat the metal with a waterproof grease be removed by heavier sanding or grinding CORROSION X or equivalent should also be applied to stop corrosion and repel moisture Reinforcement or replacement of affected aud areas may be necessary if there is critical loss 2 of strength in parent metal and d
16. 24 01 Page 96 of 104 Revision C SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B CHAPTER 10 TROUBLESHOOTING Revision B Page 97 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B U9IIMS 1581 Jojerounuue eoe deu nss d eoejdaJ 5 16 900 sunJ 1 19891 3A291109 uedo SI 19Xe9Jq s osne5 149104 891 10 sJ0ojeoipur uonisod uni jou IR 1510 Page 98 of 104 Doc No W8750 24 01 P N 1005723 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B peuinbaJ se sjueuoduuoo 10 ueo o pue osip eoe deu ueejo pue 6 6 usniJ 6 40191459 6u eu Jepui Ao 491seuJ eoejdai JO sued 4 sjuiod JOAId jeped eui eoejdayu 3A291109 Duiouise4 seyeig Doc No W8750 24 01 asou 5 591 qing 1591 10 10jeoipur uonisod
17. AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B CHAPTER 8 TKS SYSEM EQUIPPED AIRCRAFT REQUIREMENTS 79 8 0 TKS SYSTEM 80 BASIC DESCRIPTION ue 80 CHAPTER 9 RECOMMENDED PROCESSES PRODUCTS AND INSP CHECKLISTS ok anore e eaa eanas 81 9 0 SERVICING INSTRUCTIONS 55555585 82 9 1 5 84 9 2 MAINTENANCE CHECKLIST u u citt retento poti PER uc Deb 85 9 3 FLOAT REMOVAL AND RE INSTALLATION GUIDE reete tnter tnnt 90 9 4 WEIGHING PROCEDURES FOR CESSNA 208 208B CARAVAN eeeeeen entente en tnnt 96 CHAPTER 10 TROUBLESHOOTING 97 CHAPTER 11 INSTALLATION PRINT INFORMATIONN 101 CHAPTER 12 AIRCRAFT INSTALLED PERFORMANCE ITEMS AND DECRIE TIONS uu a unu 103 12 1 WING 104 12 2 VORTEX GENERATORS 104 12 3 FLOAT SUCTION BREAKERS 104 P N 1005723 Doc No W8750 24 01 Page 8 of 104 Revision D SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B THIS PAGE INTENTIONALLY LEFT BLANK Revision IR Page 9 of 104 P N 1005723 Doc No W
18. B SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B ASSV T33HA 3NIHO 4 AN 1335 1515 ASSV 13 M20d NIV ANIHD LAV b WP d ASON ee pL LnodWnd 3 p ERR 2 22 nm MT 401 i oz esc SINYLS ASSV p Ec IN3IAHOV LLV 1 i A m I e TIVMNnO9 syood ee j NOTAd NIYIN LNANHOVLLV SSA0OV 439 NOTAd 1 NOILOAdSNI NMOd FLOAT TERMINOLOGY FIGURE 1 5 Doc No W8750 24 01 P N 1005723 Page 19 of 104 Revision IR SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B S318VO SialvM ANY SANIT LOAdSNI OL Q3AOWZ3H 38 NYO NO TAd 39Q3 SNITIVH E ANY SNIOV31 SANIT LNAWHOVILV M V39 NIVW LO3dSNI OL Q3AOWZH 38 NYO NMOHS LON 979001 2979001 SONIMIVS 39v 13s L IVAOW3H NO NOILVINHOANI 3ONVN3LLNIVIN VNSS3O 33 STANVd HOO 14 JHL ONIAOWSY Q3SS399V 38 NYO SANIT 41 0 OI LO3 13 QV3H 1n8 NISVO 13V AHL 9NIAOIW3H 3S 392V 38 NYO 55 dAI
19. IR SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 4 1 MAIN GEAR RETRACTION DESCRIPTION Refer to Figures 4 1 4 2 4 3 4 4 4 4 4 5 and 4 6 for visual reference Retraction and extension of the main gear 18 accomplished with a hydraulic rack and pinion type actuator The actuator consists of two opposing pistons connected by a geared rack with a rotating pinion gear in the middle Hydraulic fluid is transferred from one piston to the other using an electrically reversible hydraulic pump located in the empennage of the aircraft The differential pressure build up causes the piston to move pushing the rack and rotating the pinion gear and its attached drive shaft Attached to each end of the drive shaft are actuating arms that drive separate rod linkages with adjustable rod ends The drive shaft and actuating arms have a keyway to prevent slippage on the rotating drive shaft The rod linkages push and pull on the Main Gear Top Arm Assembly causing it to pivot around a fixed point Also attached to the actuators drive shaft 1s a visual gear position indicator Revision IR Page 47 of 104 This indicator consists of colored bands that rotate with the drive shaft allowing the pilot to visually determine the position of the main landing gear by looking at a placard on the deck of the float Since the actuator rotates through approximately 193 degrees the rod linkages and the actuati
20. ON CESSNA 208 208B TABLE OF CONTENTS SECTION PAGE CHAPTER 1 INTRODUCTION AND GENERAL 14 1 1 GENERAL INFORMATION 5 uquniq upaqas aaa ERE ERE NE RE RE DEN S dera 21 TZ eR eps ET 24 LS CORROSION Mec 25 1 4 FLOAT HANDLING amp JACKING 27 1 54 lcm a a ua Suk a 28 CHAPTER 2 AIRWORTHINESS LIMITATIONS cscscssscossccssscsesccseccusscnecsseccssecsees 30 CHAPTER 3 NOSE 33 3 0 NOSE GEAR c s 34 3 1 ADIUSTMENT TEST 55252224 36 3 2 NOSE GEAR BASIC SERVICING 5 u a ados curae e cvs o eon E De eua Tus OV Eu E 37 3 3 NOSE GEAR DISASSEMBLY uuu uu uu E ETE 38 NOSE GEAR 1 lu u sued ase oce ia 39 CHAPTER 4 MAIN LANDING GEAR BRAKES amp GEAR 42 T O GENERAE uuu E RR D 43 4
21. Qm a aa wa a uu aG 52 FIGURE 4 6 MAIN GEAR DOWN STOP 53 FIGURE 4 7 ROTARY ACTUATOR 62 FIGURE 4 5 MAIN SHOCK STRD T se 63 FIGURE 6 2 WATER RUDDER STEERING 73 FIGURE 6 3 WATER RUDDER STEERING A 74 P N 1005723 Doc No W8750 24 01 Page 10 of 104 Revision D SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B THIS PAGE INTENTIONALLY LEFT BLANK Revision IR Page 11 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B SWIPAIRE INC NEW CUSTOMER INFORMATION Customer Name Billing Address Shipping Address Phone Number Purchasing Contact Phone Number Accounts Payable Contact Phone Number Type s of Aircraft Owned or Maintained Model s of Floats and Skis Owned or Maintained FedEx and or UPS account number if applicable Please return to Wipaire Customer Service Fax 651 306 0666 Phone 651 306 0459 CustomerService wipaire com P N 1005723 Doc No W8750 24 01 Page 12 of 104 Revision D SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B THIS PAGE INTENTIONALLY LEFT BLANK Revision IR Page 13 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEA
22. a split type rim To remove the tire 1 Remove air from tire 2 Remove six 6 bolts that hold the wheel together 3 Split rim and remove tire and tube Nose tires should be replaced when the tread 1s worn through in any area Reinstallation is the reverse of removal Revision IR SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B CBRASS KNUCKLE aam ddl EXE NOSE GEAR PROXIMI TY SWITCHES ROLLER SLIDE LOCKS 4 MAGNET FOR SWITCH SIROKE ADJUSTMENT NOSE WHEEL RETRACTED Revision IR FIGURE 3 1 NOSE WHEEL amp BOX Page 35 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 3 1 ADJUSTMENT TEST NOSE GEAR Refer to Figure 3 1 for visual reference Adjustment of actuator stroke 18 provided at the ends of the piston rods The length of the nose gear rod is adjusted such that the over center knuckle brass rollers just bottom out on the down side and the piston just bottoms out on the mounting flange The up stops nests in the up stop pins Nose gear proximity switches are located on clips that are mounted on the outer cylinder body one on each end The most forward switch 15 for the gear down lights and most aft 1s for the gear up position lights Set the proximity switch mounting clip along outer cylinder body to a position such that the light goes out when the o
23. at step speed can help flush the floats themselves but additional rinsing should be conducted on struts and fittings The float interior should be flushed out especially if salt water or polluted water gets inside the compartments If the floats are being stored inside a building either installed on the aircraft or not it is strongly recommended to remove the inspection covers so the interior of the floats can dry out P N 1005723 Doc No W8750 24 01 OPERATORS IN SALT WATER ARE STRONGLY CAUTIONED RINSING THE AIRCRAFT AND FLOATS WITH FRESH WATER AT THE END OF EACH DAY IS CRITICAL ADHERING TO THESE CLEANING RECOMMENDATIONS ARE VITAL FOR KEEPING CORROSION TO A MINIMUM FAILURE TO CLEAN THOROUGHLY CAN SEVERLY SHORTEN THE LIFE OF THE FLOATS SALT WATER POLLUTED WATER AND THEIR ENVIROMENTS ARE STRONGLY AND DIRECTLY LINKED TO CORROSION AND MUST BE HANDLED PRO ACTIVELY Even without direct contact with saltwater this hydraulic pump in the aircraft fuselage has severely corroded due to being in a saltwater environment without being kept clean Page 24 of 104 Revision IR SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B Forward strut attach point under cosmetic fairing on aircraft fuselage CORROSION HOT SPOTS DISSIMILAR METAL CONTACT LIKE LANDING GEAR FLAOT ATTACH POINTS AND OTHERS ENCLOSED SPACES THAT STAY MOIST LIKE LANDING GEAR FLAOT INTERIORS SKIN LAP JOI
24. pue 506116 1015 146014 04 sou sBui MO9 oje d 49A02 SON SW 9 eAouleH Ayajes 10J 5 1 esu 5 uonoj 1 1 5 os eJ2JIe J9M07 P N 1005723 No W8750 24 01 Page 91 of 104 AHL SV SONIMVdd NOILVTIVLSNI ASN SAVWIV 53 34440 31805 AVIN NOILVTIVLSNI HOV4A AGINS 1IVB83N39 V SV 1 SI SIHL JINVHOMIN SIC DHT O Id SNOLLO LLSNI 13VHOuIV 3NOG GINOHS WHOM TIV 39ON383438 TVNId VI Revision C 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B SERVICE MANUAL amp ICA JINVHOMIN 5 51896 Aue jeisu ye pue j e1su 4896 asou jesul L JAMO 1 151 IQAOD Ie 9uoo ie jJeisu 16826 N d z Assy lqeO 2 6826 N d Z Assy eoejdeg Sei quiesse 491 10 id 02 pue 10 14 jesu SHUNT 10 15 1404 pue 1 0 Ajjaq jesul Se qqnq
25. sjeo y O18 sso uoisoJ409 Sinis pepJjuuM Joedsul 1e0 J uonejeisu 120 9 SINH sBuiweJp 1 pue 2 HOd INAV y yoouy Jenuesse si oiseq Aeq UOISO4JOO 10 SuOIjoeuuoo SOSE9JOUI 001801100 JO 19 eM 1115 pue seoeyns 1290601 Doc W8750 24 01 pein Jod 10 168 pesodxe s eue dire y pue 5160 pue 5 SNOILONULSNI P N 1005723 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B SLIWIT 8 01 26 2 epis 99u2 ejds euooi is ediw pue JO pue syoojq pue 950 Jo suononuisu Bulas 0 6 uonoes uoiso4J09 pjnous Ily 8416 Sq 06 uoisue JO 471 aqn pue UOI E O1 JO SJ9 OJ pue do y939uo 4 541 pue pue 09 1sod ured 0150102 jo Ajunoes 1oedsui 1504 pue Jeppnu
26. switch initially illuminates with the gear arm in the full down over center locked position then thread the set screw in an additional half turn P N 1005723 Doc No W8750 24 01 Page 60 of 104 5 Reposition the gear to the position Loosen the jam nuts on the gear up proximity sensor Adjust the gear up proximity sensor switch to have between a 0 030 0 060 gap between the proximity sensor plate and the proximity sensor Tighten the jam nuts on the proximity sensor to 10 3 inch pounds At this point check to insure that the built in LED on the proximity sensor 1s illuminated when the sensor plate is rotated in front of the sensor With the gear in the full up position loosen the ANO bolt holding the proximity sensor plate to the Main Gear Top Arm and the socket head cap screw that prevents rotation of the sensor plate Rotate the sensor plate so that the sensor 1s near the edge of the plate with the gear in the up position Reference Figure 4 5 inset Tighten the ANO bolt socket head screw and re safety ANO bolt Revision C SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 12 Check for proper light illumination on the gear selector in the cockpit in both the up and down position 13 If necessary reattach the oleo shock strut to the Top Arm Assembly 14 Remove aircraft from jack stands Revision C Page 61 of 104
27. this drawing and all drawings listed thereon can be obtained from Wipaire Inc These drawings are necessary to properly maintain the aircraft P N 1005723 Doc No W8750 24 01 Page 102 of 104 Revision B SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B CHAPTER 12 AIRCRAFT INSTALLED PERFORMANCE ITEMS AND DECRIPTIONS Revision B Page 103 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 12 1 WING FENCES GENERAL DESCRIPTION Wing fences are flat plates fixed to control surfaces on top of the wing The Cessna 208 comes standard with one fence attached to the inboard edge of each aileron As part of the float installation on the Cessna 208B four fences are installed one of the inboard edge of each aileron and one on the inboard edge of each spoiler The fences are installed to aid in lateral stability and stall characteristics All of the appropriate fences must be in place prior to flight For location and installation of Wing fences on the Cessna 208B see Wipaire drawing number 1006698 Rev A or later approved revision 12 2 VORTEX GENERATORS GENERAL DESCRIPTION The Vortex Generators are typically a triangular shape design made of various materials that are used to energize airflow over control surfaces or wings There are typically ten 10 equally spaced Vortex Generators on each upper wing just aft of the leading edge on the
28. touch the actuator arm should continue to rotate and snap past Top Dead Center TDC Make sure that there 1s preload on the linkage rods so that contact faces remain touching past TDC Push and pull on the Top Arm Assembly Item 2 to ensure it is locked over center The Top Arm Assembly needs to be contacting the Top Mount Item 7 when the gear 18 extended to properly transfer the landing loads Ensure Top Arm and Top Mount are making contact by sliding a 3 inch wide piece of paper in See Figure 4 4B and photo on this page then moving gear to down and locked position If paper 1s tight 30 Loosen the Fig 4 6 Item 1 jam nut on the gear is rigged correctly If paper is able to Main Gear Down Stop Assembly and screw slide out then the Top Arm and Top Mount in the NAS 428 adjustment bolt Fig 4 6 are not making proper contact and need Item 2 Verify the bolt does not touch the further adjustment Top Arm when gear is in the down position When the aircraft 1s off the Jack stands and 29 Reattach spring the weight of the aircraft fully on the Revision C Page 57 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B wheels adjust the NAS 428 bolt to lightly make contact with the Main Gear Top Arm when the gear is in the full down position then turn the bolt one and a half turns in so that the bolt no longer makes contact with the Top Arm Gap s
29. 08B 10 Repeat procedure at each caliper 6 When complete brakes should not feel 11 When complete brakes should not feel soft or spongy when actuated soft or spongy when actuated BLEEDING BRAKE SYSTEM ALT When the Hydraulic Brake system is disconnected use the primary procedures listed in the previous section or as an alternative method to bleed the brake system 1s cross bleeding between main gear calipers and to brake reservoir Back Bleeding To bleed the brakes system using this alternate method 1 Connect pressurize brake bleeding system to outboard caliper CAUTION WHEN PERFORMING CROSS BLEEDING IT MAY BE NECESSARY TO REMOVE RESIDUAL FLUID FROM BRAKE RESEVERIOR TO PREVENT OVERFLOW 2 Open inboard and outboard bleeders on main gear and pump fluid between calipers till all air has been purged from calipers 3 Tighten inboard caliper bleeder and continue pressurization to reservoir till all air has been purged from line 4 Perform steps 1 thru 3 on opposite main gear 5 When complete check brake fluid in reservoir service to max line if necessary Revision IR Page 45 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B OLEO SHOCK STRUT BRAKE CALIPER GREASE INSERT AND PADS MAIN GEAR ASSY WHEEL ASSY AXLE NUT FIGURE 4 2 MAIN GEAR LOWER P N 1005723 Doc No W8750 24 01 Page 46 of 104 Revision
30. 1 MAIN GEAR RETRACTION uuu sui u 47 4 2 MAIN GEAR ASSEMBLY SET UP u u u u uu u 54 4 3 ADJUSTING THE GEAR UP POSITION 59 4 4 ADJUST MAIN UP AND DOWN POSITION SWITCHES 60 4 5 EMERGENCY GEAR OPERATION 5 55 os ex 64 CHAPTER 5 HYDRAULICS esssssssssscssssccssscssccscscsseccssscsseccnseccnsccssecsseecssecssssensesesseessees 65 5 0 HYDRAULIC SYSTEILD 14548854 66 5 1 BLEEDING THE HYDRAULIC SYSTEM eee ao aera o eoa e oO ERE Pa eo E exon baa a Ure sapo Pe 69 CHAPTER 6 WATER RUDDER cessscssssscssscsssscssscsssccssscssscsseccssscssscssecsscecseecsesesseesseeesees 71 6 0 BASIC DESCRIPTION Iz Load iu iu i 72 CHAPTER 7 75 PO ELECTRICAL SYSTEM LES 76 Revision D Page 7 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750
31. 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 3 0 NOSE GEAR The nose gear consists of composite fiberglass beams that are attached on top to a moving carriage and on the bottom to blocks that caster Inside the block 1s a castoring pin that is set into the machined fork assembly the castoring pin allows the nose wheel to pivot 360 degrees Geometry is such that no shimmy dampers are necessary The nose gear has an over center down lock Retraction occurs when pressure 18 applied to the forward face of the actuator piston and the carriage is drawn along the tracks in the nose box Gear position light proximity switches are closed when the piston containing magnetic material has reached either end of its travel Refer to Figure 3 1 for visual reference The nose gear has single 5 00 x 5 10 ply tire All tires must be approved to TSO C62 type III P N 1005723 Doc No W8750 24 01 Page 34 of 104 NOSE WHEEL AND TIRE REMOVAL To remove each nose wheel 1 Jack the aircraft completely lifting both hulls It is not recommended to jack only one hull 2 Cut cotter pin and remove axle nut 3 Remove the ANA bolt securing the opposite side of the axle 4 Pull Push the axle through the side plate either direction taking care to set spacers aside as they are removed 5 Wheel will drop out between side plates once axle has been removed a sufficient distance Each nose wheel 1s
32. 4 Revision IR SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 4 0 GENERAL The main landing gear incorporated within the amphibious floats are retractable quadricycle type with four main wheels in a dual tire formation Air oil shock struts on the two main landing gear assemblies provide shock absorption The main landing gear has dual 6 00 x 6 8 ply tres All tires must be approved to TSO C62 type III The gear system 1s hydraulically actuated and driven by two hydraulic pumps Brakes are hydraulic and there is a caliper on each main wheel BRAKE REMOVAL amp INSPECTION Each main wheel has a dedicated brake caliper To remove the brake caliper 1 Remove two mounting bolts on each caliper 2 Compress the caliper piston using a c clamp 3 Slide caliper off of the brake disc Brake pads should be replaced when the minimum section thickness 1s less than 0 100 see Figure 4 1 Generally the brake discs should be checked for wear grooves deep scratches and excessive pitting Pitting deeper than 0 015 or thickness below 0 327 1s cause for replacement Revision IR Page 43 of 104 MAIN WHEEL AND TIRE REMOVAL To remove each main wheel 1 Remove brake caliper 2 Cut cotter pin and remove axle nut 3 Pull wheel off of axle Each main wheel 1s a split type rim To remove the tire 1 Remove air from tire 2 Remove 3 bolts that hold wheel together 3 Split rim and
33. 8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B LIST OF FIGURES FIGURE 1 1 FRONT VIEW CESSNA 208 CARA VAN 15 FIGURE 1 2 TOP amp SIDE VIEWS CESSNA 208 CARA VAN 16 FIGURE 1 3 FRONT VIEW CESSNA 208B CARA VAN 17 FIGURE 1 4 TOP amp SIDE VIEWS CESSNA 2088 CARA VAN 18 FIGURE 1 5 FLOAT TERMINOLOGY Lu k s Sa uuu 19 FIGURE 1 6 MAINTENANCE ACCESS POINIS 20 FIGURE T 7 HYDRAULIC uuu yuyansun nuan uz 22 FIGURE 3 1 NOSE WHEEL amp BOX 35 FIGURE 3 2 NOSE WHEEL 5 37 FIGURE 3 3 NOSE GEAR amp BOX ITEM 40 FIGURE 4 1 MINIMUM BRAND 43 FIGURE 4 2 MAIN GEAR LOW ER PE eoe noscar oiae 46 FIGURE 4 3 MAIN GEAR GREASING POINTS 4 FIGURE 4 44 MAIN GEAR ADJ DOWNN 50 FIGURE 4 48 MAIN GEAR ADJ DOWN 51 FIGURE 4 5 MAIN GEAR ADJ LIP u L
34. BIAN SEAPLANE FLOATS ON CESSNA 208 208B CHAPTER 8 TKS SYSEM EQUIPPED AIRCRAFT REQUIREMENTS Revision C Page 79 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 8 0 TKS SYSTEM BASIC DESCRIPTION CAUTION THE CESSNA 208 208B WITH MODEL 8750 FLOATS IS NOT APPROVED FOR FLIGHT IN KNOWN ICING The TKS ice protection system 15 a system that releases glycol based fluid through laser drilled panels on the leading edges of the wings horizontal vertical stabilizers and other components to prevent ice accumulation A slinger ring on the propeller also emits fluid to keep the prop windshield cargo pod and landing gear free of 1ce TKS SYTEM MODIFICATION WHEN FLOATS INSTALLED For requirements and guidance on modifying the TKS Icing System on Cessna 208 208B Caravan when 8750 series floats are installed refer to Wipaire installation drawing 1004806 revision A or later approved revision The TKS fluid pod must be removed and connections capped and covered For additional control surface movement changes see Wipaire installation drawing 6C1 2023 Control throws are different for the floatplane and TKS equipped landplane The TKS system 18 disabled when the floats are installed P N 1005723 Doc No W8750 24 01 Page 80 of 104 CONDITIONS Revision C SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B CHAPTER 9 RECOMMENDED PROC
35. Cessna 208B only Cessna 208B aircraft previously equipped with a TKS fairing have roughly 34 Vortex Generators installed With the addition of the Vortex Generators the aircraft will have 1mproved controllability and safety at low speeds No more than two non adjacent vortex generators per wing can be P N 1005723 Doc No W8750 24 01 missing at any one time If a Vortex Generator is missing replace as soon as possible Refer to Cessna 208 models Configuration Deviation List 12 3 FLOAT SUCTION BREAKERS GENERAL DESCRIPTION The suction breakers are angled aluminum channel riveted to the bottom surface of the float afterbody There are four suction breakers installed on each float afterbody two inboard and two outboard The suction breakers are installed to decrease a tendency for the afterbody to stay attached to the water on takeoff particularly on glassy water conditions Any number of suction breakers can be missing but must be reinstalled as soon as possible For installation and location of Suctions breakers see Wipaire drawing number 1006575 Rev A or later approved revision CAUTION Missing suction breakers will result in longer water takeoff runs particularly in glassy water WARNING If suction breakers are found to be missing ensure that holes are adequately sealed prior to any further water operation to prevent float compartment filling with water Page 104 of 104 Revision C
36. ESSES PRODUCTS AND INSP CHECKLISTS Revision C Page 81 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 9 0 SERVICING INSTRUCTIONS As coded in the Inspection Time Limits chart in this section there are items to be checked each 25 50 100 and 200 hours Also there are notes on special items which may require servicing at more frequent intervals When conducting an inspection at 25 hours all items marked for 25 hours would be accomplished at 50 hours the 25 and 50 hour items would be accomplished at 100 hours the 25 50 and 100 hour items would be accomplished at 200 hours the 25 50 100 and 200 hour items would be accomplished A complete inspection Annual Inspection would include all 25 50 100 200 hour items Below 18 a list of recommended lubricants and protection products when servicing float hull and other amphibious components This lists products used by Wipaire during assembly of the floats There may be equivalent products just as satisfactory for protection However it is recommended 11 trying different products to inspect them frequently so as to determine their effectiveness Protection of nuts bolts hydraulic lines metal surfaces or electrical connections Dinitrol AV30 Dinol Group CRC SP400 Soft Seal CRC Industries General Lubricants LPS 1 LPS 2 and LPS 3 LPS Industries P N 1005723 Doc No W8750 24
37. IN NOILVTIVLISNI HOV3 AGINS 1VB83N39 V SV 1 SI SIHL 2JOINVHOMIN CLNOO SWTHOGAOONd SNOLLOQLLSNI TIVLSNI AY LVO LI P N 1005723 Doc No W8750 24 01 Page 95 of 104 Revision C SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 9 4 WEIGHING PROCEDURES FOR CESSNA 208 208B CARAVAN Level aircraft per manufacturer s instructions or use the cabin door lower sill Place scales under the right and left main and nose gears Place blocking under the right and left main gears to level aircraft Draw lines on the floor from the centerline main wheels and centerline nose wheel left to right Drop a plumb bob from the face of the firewall This 1s station 100 00 Measure 100 00 inches forward of this point this 1s the datum 0 0 Draw another line between the nose wheel centers and a 4 line between the main wheel centers Measure the distance from 0 0 to the nose wheel line This 15 and X2 Measure the distance from 0 0 to the main wheel line This 1s Y1 and Y2 If the floats are seaplane floats the scales go under the step point in the rear and a point towards the front of the float These distances are measured and become the same X and Y as for the amphibian Scale Reading Distance from 0 0 Weight x Arm Weight X Arm Moment Left Front Right Front Left Rear Right Rear Totals Notes 1 Zero out or deduct tare weights at the Y arm P N 1005723 Doc No W8750
38. IPAIRE INC WIPLINE FLOATS SKIS MODIFICATIONS AIRCRAFT SALES AVIONICS INTERIOR MAINTENANCE PAINT REFINISHING T x SERVICE MANUAL and INSTRUCTIONS FOR CONTINUED AIRWORTHINESS for the WIPAIRE MODEL 8750 AMPHIBIOUS SEAPLANE FLOAT ON THE CESSNA MODEL 208 208B CARAVAN Revision B P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B THIS PAGE INTENTIONALLY LEFT BLANK P N 1005723 Doc No W8750 24 01 Page 2 of 104 Revision IR SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B LOG OF REVISIONS FAA ACCEPTANCE Nc P e p d d m F i PAGES AFFECTED REVISION DESCRIPTION selist Add green grease as an approved 4 18 2013 grease See lisi Added 2086 eligibility updated 6 28 2013 Hydraulic powerpack image A Updated Fig1 8 for new oleo updated photo p25 changes to MLG rigging procedure update to C See List inspection procedures defined 5 30 2014 water rudder rigging procedures remaining pages repaginated removed p107 Added Shear Torque chart PR 1440 C Sealant Tef Gel and full contact info Removed Warranty Claim See List Form Corrected 1200 was 1000 1400 was 1150 and 1900 was 1300 Added Dow Corning DC4 and Mobil See List Aviation Grease SHC 100 to approved product list View the most current revision of this ICA at www w
39. NAS1103 2 bolts and The T Seal in the Cylinder End Cap Item washers attaching the Nose Ram Item 2 to 11 can be replaced by removing the the flange assembly Item 3 and slide the NAS1103 2 bolts and removing the cap Nose Ram off of the flange assembly from the Cylinder 3 Inspect interior bore of the Nose Ram for 8 Slide the Trolley Item 12 out bottom of corrosion and pitting nose gear track 4 Loosen AN316 10R Jam Nut Item 4 on 9 If worn or damaged replace the 4 Slide Nose Ram Rod End Item 5 Blocks Item 13 and the 2 Track Rollers Item 14 5 Using a strap wrench or other suitable non marring tool unthread the Ram Item 6 10 Grease the 2 axles Items 15 amp 16 when from the Nose Ram Rod End Do not reassembling attempt to remove the ram piston top brass from the ram shaft stainless steel They are assembled as a unit and permanently secured 6 Remove Ram Assembly Item 3 if desired to replace the T seals Item 10 felt wiper Item 7 and plastic wiper Item 8 P N 1005723 Doc No W8750 24 01 Page 38 of 104 Revision IR SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 3 4 NOSE GEAR ASSEMBLY Items refer to areas on Figure 3 3 I Revision IR Insert the Ram Assembly Item 6 Into the Flange Assembly Item 3 if removed during disassembly Slide the Trolley Item 12 with installed blocks and rollers into nose box track from bottom Pull forward on the Li
40. NTS AND OTHERS CONTAMANINATES ON THE METAL LIKE DIRT SALT ENGINE EXHAUST AND OLD OR OTHERWISE COMPRISED GREASE Badly corroded fly wire fitting Revision IR 1 3 CORROSION Corrosion is the process by which metals are turned into oxides It is a natural and ultimately unavoidable chemical reaction that 1s accelerated by dissimilar metals 1n contact with each other and enclosed spaces and contaminants like dirt and exhaust deposits that hold moisture against the metal If that moisture is salt water or fresh water that 1s polluted it conducts the electrolytes better and the process of corroding is faster Most aircraft and most floats are made out of aluminum due to its strength to weight ratio and its ability to withstand fatigue and remain field repairable Steel 1s used for strength in hardware and landing gear parts and these are often areas where these dissimilar metals cause corrosion Areas where moisture and dirt mix and stay wet against metal are common sites of oxidation Float strut attach points water rudders and skin Joints are examples of areas where this occurs Page 25 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 1 3 CORROSION CONT Cladding plating anodizing painting greasing and waxing are all processes used to help protect metal from corrosion Wipaire uses all these techniques during manufacture But due
41. Nd SLNIOd HOV LLV SONI LLIJ 11416 SSADOV OL Q3AONNGH 38 NYO SONITMOO MAINTENANCE ACCESS POINTS FIGURE 1 6 Revision IR Page 20 of 104 Doc No W8750 24 01 P N 1005723 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 1 1 GENERAL FLOAT INFORMATION The model 8750 amphibious float 1s an all aluminum structure The alloy used throughout is mostly corrosion resistant 6061 T6 with 2024 T3 and 7075 T651 used in strength critical fitings and panels Interior parts are cleaned acid etched and then primed prior to being riveted for enhanced corrosion resistance Exterior surfaces are cleaned alodine is applied as a corrosion resistant barrier and then primed and custom painted Model 8750 floats contain sixteen 16 water tight compartments per hull Access to the inside of the floats for cleaning inspection and repairs 18 through the access covers on the float deck and the access covers inside the wheel well Figures 1 1 and 1 2 show three view drawings of the Cessna 208 as installed on Wipline model 8750 amphibious floats Figures 1 3 and 1 4 show three view drawings of the Cessna 208B as installed on Wipline model 8750 amphibious floats Revision B Page 21 of 104 As a part of the float installation the following additional changes are made to the landplane 1 The hydraulic landing gear retraction system components and cockpit con
42. OATS ON CESSNA 208 208B 1 5 MOORING For land operations the aircraft is equipped with three fixed mooring points Two are located on the outboard edge of the wing struts and the other 1s located on the underside of the tail section of the aircraft Mooring Procedure on Land 1 Position the aircraft near mooring location and it point into the wind Set the parking brake and or chock the main wheels 3 nstall the aircraft control column lock Install the flight control gust lock 5 Tie down the aircraft to anchor points on the ground Install provided engine inlet covers pitot tube covers and propeller anchor assembly Attach a static ground cable to one of the aircraft tie down eyelets and the ground anchor point P N 1005723 Doc No W8750 24 01 For water operations the floats are equipped with two deck cleats on each float one forward near the pilot copilot doors and one aft near the cargo door Mooring Procedure on Water at Dock 1 Position the aircraft near the dock and point into the wind as much as able 2 Install the control column lock 3 Install the flight control gust lock 4 Tie down using both deck cleats to secure aircraft to dock and keep it from moving if wind direction shifts Mooring Procedure on Water at Buoy 1 Position the aircraft near buoy 2 Install the control column lock 3 Install the flight control gust lock 4 Tie to buoy us
43. P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B BACKUP RING SEAL O RING SNAP RING SEAL O RING SEAL O RING BEARING SEAL O RING BACKUP RING FIGURE 4 7 ROTARY ACTUATOR P N 1005723 Doc No W8750 24 01 Page 62 of 104 Revision C SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B SNIH O OFE 5 BESIN 79 5 1 SEO EDOSBSL LP SNI 3LITIVH 5 1 OLELSEB dY ONS NOLLOS 9NIH O fEOdlL00gSLLP X 142 H31fP0 H30VHHOS 5 145 HJUN T1A2 H31f1O H3CONI LAO YANNI ONO 6822 5448251 ONTO LEZSA BESIN dO 1 MAIN SHOCK STRUT FIGURE 4 8 Doc No W8750 24 01 P N 1005723 Page 63 of 104 Revision C SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 4 5 EMERGENCY GEAR OPERATION An emergency hand pump is provided in l The remaining small reserve quantity of case of total electric pump failure or loss of f f f f fluid below the electric pump pickup tube 1s fluid The emergency hand pump draws l then reserved exclusively for the emergency hydraulic fluid from the bottom of the f f hand pump The quantity of reserve fluid hydraulic power pack reservoir The l l l below the electric pump pickup tubes 18 hydraulic power pack electric pumps have l l sufficient to raise or lower the landing gear
44. PLANE FLOATS ON CESSNA 208 208B CHAPTER 1 INTRODUCTION AND GENERAL INFORMATION 1 0 INTRODUCTION This manual is provided for the owners of Wipaire model 8750 Floats as installed on the Cessna 208 Caravan and 208B Grand Caravan It has two main priorities To inform owners of the level and amount of servicing required to properly maintain their floatplane and to provide technical data and servicing as specified to maintenance professionals charged with servicing the floats The service products referred to throughout this manual are described by their trade names and may be purchased from the Wipaire Parts Department We at Wipaire welcome your purchase and look forward to years of satisfying exchanges with you Your floats are built with pride and attention to detail but we want that care to extend beyond your purchase Our customer service department is available for your questions 24 hours a day 7 days a week where ever you are in the world Parts Sales and Technical Support Dept Wipaire Inc 1700 Henry Avenue Fleming Field South St Paul MN 55075 Telephone 651 306 0459 Fax 651 306 0666 Website www wipaire com Email CustomerService wipaire com P N 1005723 Doc No W8750 24 01 Page 14 of 104 In this service manual we have worked hard to include many repair scenarios in addition to the recommended products practices and routine maintenance required to keep your floats in working
45. ROSS FITTINGS LOWER FUSELAGE UNION FITTINGS FOR WHEEL FLOAT SWAP PUMPS PREASURE SWITHCES AND CHECK VALVES RET EMERGENCY HAND PUMP IN CABIN DOWN DOWN HYDRAULIC RAMS LOCATED IN FLOATS UP NOSE GEAR RAMS W POSITION SWITCHES o DOWN DOWN MAIN GEAR RAMS W PROXIMITY SWITCHES IIl FIGURE 5 1 HYDRAULIC SCHEMATIC Doc No W8750 24 01 Page 68 of 104 Revision C SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 5 1 BLEEDING THE HYDRAULIC SYSTEM The system automatically bleeds provided sufficient oil is maintained in the reservoir To check the fluid level fill the reservoir through the servicing point on the power pack assembly with MIL H 5606 hydraulic oil and cycle the gear If the reservoir empties stop the cycle by pulling the pump motor circuit breakers Fill the reservoir again and complete the cycle Continue this procedure until the fluid level in the reservoir stabilizes it will vary in level between gear up and down positions If the fluid level continues to decline during gear cycles check for external leaks When the fluid level stabilizes fill the reserv
46. W8750 24 01 Page 52 of 104 Revision C SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 23 9 9 2 9 6 gt DETAIL B em C MAIN GEAR DOWN STOP ADJ 6 FIGURE 4 Doc No W8750 24 01 P N 1005723 Page 53 of 104 Revision C SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 4 2 MAIN GEAR ASSEMBLY SETUP AND ADJUSTMENT 3 Remove the 4 nuts connecting the rod Put aircraft on jacks to allow free extension and linkages Item 5 to the actuator arms Item 5 Remove the rod linkages from the arms Note There are qty 2 NAS1149F0463P retraction of the landing gear Use safe operating practices when working around moving hydraulic components The actuators washers between the rod end and the operate at high pressures and generate high actuator arm forces when repositioning the landing gear 4 Remove the spring attached to the actuator Adjusting the Gear Down position arm See figure 4 4 and 4 4 NOTE Steps 5 through 16 are for re rigging the 1 Bleed pressure off the hydraulic lines by actuator If no changes are done to actuator moving emergency gear position selector skip to step 17 P N 1005723 both directions to Up and Down This will relieve pressure in the lines allowing hydraulic lines to be unhooked wi
47. ardless the gear should be inspected visually at least every 25 hours for cleanliness and proper lubrication P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B s WHY YOLVNLOV LAVHS YOLVNLOV Q 8 C N 2 oc N ws Pi 2 2 gt 2 z Pipe B 9 2 9 OD 9 lt gt OA o x 200 2 m x lt X o lt D S 2 23 2 7 2 62 2 0 2 2 Ce m I x 2 5 Ag FIGURE 4 4 MAIN GEAR ADJ DOWN P N 1005723 Doc No W8750 24 01 Page 50 of 104 Revision C SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B TOP ARM CONTACT FACE INSERT TEST PAPER 5 4 1 TOP MOUNT 8 DOWN ADJUSTMENT SCREW DOWN ADJUSTMENT JAM NUT 111 11 3 ROD LINKAGE bia L4 d HH 11101 ACTUATOR ARM 5 FIGURE 4 48 MAIN GEAR ADJ DOWN Page 51 of 104 P N 1005723 Doc No W8750 24 01 Revision C SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 5 m 2 7 4 m lt gt m 4 gt 0 8 54 CX z E a 0 4 Vv E 4 Os Q A I8IN3SSV WHY dO 1 Q FIGURE 4 5 MAIN GEAR ADJ UP P N 1005723 Doc No
48. cation as shown Zero the protractor See Figure 4 4B Then place the protractor on the top or bottom of the rod linkage The measured angle should be 4 1 Repeat for the other actuator arm and rod linkage by zeroing the protractor on the other actuator arm and measuring the rod linkage angle If angle is lower than required the down Adjustment Screw Item 8 should be turned out to allow more rotation If the angle is greater than required the actuator is over rotating and the adjustment screw should be turned in One turn of the adjustment screw changes the angle by approximately 2 If adjustments have been made to the Down Adjustment Screw the Rod Linkage Item 3 may need to be shortened or lengthened so that the Top Arm Contact Face Item 15 still makes contact with the Top Mount Repeat steps 22 through 24 until angles measure within tolerance With setscrew positioned against the piston face tighten the adjustment screw jam nut Item 9 Revision C SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 4 2 MAIN GEAR ASSEMBLY SETUP AND ADJUSTMENT CONT 27 Preload the rod linkages by shortening each rod by 1 2 turn after the contact faces touch on the Top Arm and Top Mount Tighten the Rod Linkage jamb nuts m m 2 _ 28 Check the operation of the over center down lock As the actuator rotates causing the contact faces to
49. directed 1n line with the centerline of the oleo assembly rotates the contacting face on the top arm assembly into contact with the main gear top mount at all positions of oleo stroke This transfers the landing load into a structure designed to withstand the generated landing forces as well as prevents the top arm from rotating and collapsing the main landing gear There are two proximity switches on each main gear unit One for sensing gear up position and the other for gear down position These are easily replaceable and can essentially be adjusted during maintenance see figure 4 4A and 4 5 The proximity sensors have a built in LED to indicate when they are sensing the gear position This feature greatly aids in the setup and servicing of the sensors Revision C Page 49 of 104 There are several service points on the main landing gear to pay attention to during maintenance Grease zerks are located on the pivots of the main gear draglinks each wheel axle top and bottom pivot points on the oleo pneumatic shock strut and the rotation point of the top arm assembly see figure 4 3 The adjustable rod end bearings are permanently sealed and do not require servicing Inspect the rod ends for freedom of movement and corrosion Replace the rod ends when necessary Depending on the operating environment greasing requirements may vary Highly corrosive environments such as salt water may require more frequent inspections Reg
50. egacy installations retrofitted from 8000 s to 8750s the wet handle system may be installed The dry handle system is characterized by a gear selector head containing an electrical switch connected with wires to the aft fuselage mounted pump The pump direction 18 reversible The direction the pump turns 15 controlled by the gear position switch The legacy wet handle system 1s characterized by a gear selector head that contains a mechanical hydraulic valve and 18 connected with hydraulic lines directly to the gear The pump direction 1s not reversible For retrofit installations where the model 8750 is mated to the wet handle equipped aircraft operation of the hydraulic system 1s the same as with the model 8000 installation pressure and return lines at the fuselage P N 1005723 Doc No W8750 24 01 Page 76 of 104 exits are connected to pressure and return lines at the strut pylon attach points The only electrical difference between the legacy 8000 and retrofit 8750 system is the addition of a port and starboard low power wire that runs to the powered proximity switch that commands main gear position indication For Cessna 208 see drawing number 1006012 revision A or later approved revision for electrical information pertaining to the retrofit For Cessna 208 208B see drawing number 1006011 revision A or later approved revision for electrical system descriptive information for the current pr
51. epends on Allowable Area Thick I location and other factors Side Skins fwd of Step Side Skins aft of Step Top Deck 0 015 0 030 NOTES 1 Maximum surface area for skin corrosion up to to the maximum depth shall not exceed one 1 square inch and must be separated by at least 14 inches from any other skin corrosion damage For machined fittings struts and pylons re gt AT corrosion limits are provided as maximum Pylon before repair MEM pitting depths Corroded surface area for these limits shall not exceed 0 5 square inches and must be separated by at least 5 inches from any other corrosion damage FIGURE 8 1 CORROSION LIMITS te XN me rae we A E h is 195 ur E P N 1005723 Doc No W8750 24 01 Page 84 of 104 Revision C SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 9 2 MAINTENANCE CHECKLIST Revision C Page 85 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 FLOATS ON CESSNA 208 208 X X s sou pue Aunoes JO 1290501 uome eisu egn i ooz 088 Os s sed S IIWI1 Sojejd 5141 Jo suononujsu Buas 0 6 uonoes jnu UOISOIJOD pue 56 0 Jed 19 10 4 eseaJD uoisoJ09 nue qe ins uoneJedo Ajunoes uomnipuoo 10 128dsul
52. for each gear engine power or being towed The hydraulic pumps are located in the aircraft The main landing gear has dual 6 00x6 8 ply empennage and can be accessed by removing tires and the nose gear has a single 5 00x5 10 the aft cabin bulkhead The hydraulic actuators ply tire All tires must be approved to TSO are located adjacent to each gear C62 type III Differential use of the main wheel brakes steers the aircraft on land Hydraulic system fluid level should be checked Item O Fluid Fluid Type Qty Main Gear Cen MIL H indc ali k 20 mL I Strut 33 0 7507 levels in accordance with the installed placard Main Gear Shock 425 47 25 psi using MIL H 5606 red hydraulic fluid The Strut Air l f Main Gear Tires Nitrogen or 60 0 5 psi fluid level placard Figure 1 7 18 installed on Air Nose Gear Tires Nitrogen or 60 5 psi Air Hydraulic Pump MIL H 5606 per placard reservoir FIGURE 1 8 FLUID TYPES AND QUANTITIES at 25 hour intervals and should be serviced to the forward hydraulic Reservoir P N 1005723 Doc No W8750 24 01 Page 22 of 104 Revision C SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B LANDING GEAR CONTINUED Grease zerks are provided in many locations that have pivoting joints Greasing 18 recommended at 25 hour intervals or more often depending on operating environment with HCF Grease or equivalent See Figure 3 2 for nose gear grease zerk
53. he cables are just slack in the down position Water rudders should be centered when the air rudder is centered by adjusting turnbuckles There is no left or right rigging adjustment related to the maximum travel of the water rudder system For 208 cable routing see figure 6 2 or installation drawing 1006006 revision A or later approved revision For 208B cable routing see figure 6 3 or installation drawing number 1006015 Rev A or later approved Page 72 of 104 Revision C SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B SEE INSTALL DRAWING 1006006 REV A OR LATER APPROVED REVISION FIGURE 6 2 WATER RUDDER STEERING CABLE ROUTING MODEL 208 Revision C Page 73 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B SEE INSTALL DRAWING 1006015 REV A OR LATER APPROVED REVISION FIGURE 6 3 WATER RUDDER STEERING CABLE ROUTING MODEL 208B P N 1005723 Doc No W8750 24 01 Page 74 of 104 Revision C SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B CHAPTER 7 ELECTRICAL Revision C Page 75 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 7 0 ELECTRICAL SYSTEM WET HANDLE VS DRY HANDLE SYSTEM These instructions are for the later model current production dry handle electrical system that is used for new 8750 float installations For l
54. hould be about 0 050 inches Tighten the jam nut NOTE There are three center locks on the main gear when the gear is down The first is the over center rod linkages that are adjusted in the above steps The second 18 from the spring pulling on the actuator arm when the gear is in the down position The spring prevents the actuator from moving in the event of a loss of hydraulic pressure The third comes in the form of the angle between the oleo pneumatic shock strut and the Top Arm Assembly The vector of the oleo force 1s over center about at the rotation point on the Top Arm Assembly Thus one could effectively remove the entire gear actuator and the geometry of the Oleo and the Top Arm alone would force the contact faces of the top arm and top mount together and lock it over center There are also two over center locks when the gear is in the retracted UP position The first is a spring installed on the actuating arm that prevents motion of the rack and pinion actuator in the event of a hydraulic failure The second P N 1005723 Doc No W8750 24 01 Page 58 of 104 over center lock comes from the geometry of the gear in the up position Since the retraction mechanism is driven over center the weight of the landing gear and oleo when retracted prevent the retraction mechanism from rotating past the over center point The weight of the gear wants to rotate the Top Arm Assembly however
55. ing one deck cleat and leave sufficient slack in the rope so that the aircraft can move as the wind direction shifts without causing damage to aircraft Page 28 of 104 Revision IR SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B THIS PAGE INTENTIONALLY LEFT BLANK Revision IR Page 29 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B CHAPTER 2 AIRWORTHINESS LIMITATIONS P N 1005723 Doc No W8750 24 01 Page 30 of 104 Revision IR SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B AIRWORTHINESS LIMITATIONS This Airworthiness Limitations section is FAA approved and specifies maintenance required under paragraphs 43 16 and 91 403 c of the Federal Aviation Regulations unless an alternative program has been FAA approved The aircraft Airworthiness Limitations are unchanged as a result of installation of the amphibious floats and the associated systems addressed by this STC 2 gom cnm FAA APPROVED 47 a 2 2 Revision IR Page 31 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B THIS PAGE INTENTIONALLY LEFT BLANK P N 1005723 Doc No W8750 24 01 Page 32 of 104 Revision IR SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B CHAPTER 3 NOSE GEAR Revision IR Page 33 of 104 P N 1005723 Doc No W8750
56. ipaire com Revision E Page 3 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B THIS PAGE INTENTIONALLY LEFT BLANK P N 1005723 Doc No W8750 24 01 Page 4 of 104 Revision IR SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B LIST OF EFFECTIVE PAGES PAGES REVISION 5 REVISION PAGES REVISION 1 B 83 R BZ NN a 00 SN gt N 13 R 49 8 14 50 _ 15 R 5 8 16 R 835 C C 17 B 53 8 _ 18 B 54 9 cC 19 R 55 9 _ 20 R 356 92 _ 21 B 5 93 2 C 58 9 D _ 3 59 95 24 60 96 C _ 5 R 6 9 B 26 6 98 27 R 68 9 28 R 164 100 R 29 R 6 101 30 R 6 C 12 B 3 R 67 D 3173 33 R 6 10 33 R 69 j 0 J 34 R 70 85 7 9 36 72 Revision E Page 5 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B THIS PAGE INTENTIONALLY LEFT BLANK P N 1005723 Doc No W8750 24 01 Page 6 of 104 Revision IR SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS
57. is maintained in the supply line When the pressure falls below 500 psi in the UP and DOWN position the pressure switch activates the pump solenoid providing power to the pump When the pressure reaches 700 psi in the DOWN position and 1200 in the UP position the pressure switch deactivates the solenoid and the pump motor stops A check valve on the output side of the pump retains pressure in the system while the pump 15 off The pump has an interval relief valve that directs fluid back to the un pressurized pump reservoirs when the line pressure exceeds 1400 psi The system also has an internal relief valve to protect against thermal expansion when line pressure exceeds 1900 psi A timer circuit 18 included on the powerpack that commands pump operation briefly regardless of pressure switch position when a new gear position 18 selected this allows the gear system to avoid potential thermal lock caused by fluid expansion during flight or on the ground POWERPACK PUMP ASSEMBLY IN AFT FUSELAGE Revision D Page 67 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B UP AND DOWN PREASURE SWITCHES FOR EACH PUMP UP 500 1000 PSI DOWN 500 700 PSI DUAL DIRECTION PUMP INTERNAL SHUTTLE VALVE WITH 1150 RELIEF 150 PSI 1400 PSI THERMAL RELIEF P N 1005723 FUSELAGE 2 MOUNTED POWER PACK WITH C
58. locations See Figure 4 3 for main gear grease zerk locations STRUT PACKAGE The strut package attaches the floats to the aircraft The strut package is comprised of the forward struts main pylons rear cross wires and front cross wires or flying wires The streamlined struts are made from extruded aluminum alloys The main pylon is built from machined aluminum trusses internal ribs and skinned with aluminum sheet WATER RUDDERS The floats are equipped with water rudders attached at the rear of the float structure These rudders steer when the floats are 1n the water Rudder controls are integrated into the existing aircraft rudder system and should move in the same direction as the air rudder Water rudders are extended and retracted with a handle installed to the right of the pilot seat Water Rudder amp Springs Revision C Page 23 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 1 2 CLEANING The outside of the float should be kept clean by washing with fresh water and soap Special care should be taken to remove engine exhaust trails water line marks and barnacle deposits After salt water operations washing with fresh water should be done daily with special attention paid to hard to reach places like skin seams Wheel well areas float attach points hardware Alternatively water taxiing in fresh water
59. n done the remaining steps are for re rigging the actuator to be installed back in the float With the actuator assembled and removed from float attach Wipaire Tool 1004800 to the actuator taking note that the FORWARD arrow is pointing forward on the actuator Use the 5 16 18 bolts to attach the tool to the actuator Rotate the actuator shaft fully to the DOWN position If the two keyway slots do not line up when the actuators internal piston contacts the DOWN adjustment set screw Item 8 the actuator needs adjustment It may be necessary to use one of the actuator arms removed in step 5 to help rotate the actuator To adjust the DOWN position loosen the DOWN adjustment screw jamb nut Item 9 and back off the adjustment screw 12 13 14 15 16 Page 55 of 104 Align the keyway on the actuator shaft Item 4 with the keyway on Wipaire Tool 1004800 Insert the parallel key removed in step 5 into the aligned keyways Thread in the Down Adjustment setscrew until light contact is made between the setscrew and the actuators internal piston Do not over tighten as the actuator cannot rotate with Wipaire Tool 1004800 and the key installed Over tightening can damage the face of the actuator piston With setscrew positioned against the piston face tighten the adjustment screw jamb nut Item 9 Repeat steps 10 14 for setting the UP position setscrew See figure 4 5 Install actuator
60. ng arm pass an over center point preventing reverse driving of the rack and pinion actuator in both the fully extended and fully retracted positions The actuator rotation 1s adjusted by setscrews that determine the length of travel of the actuator pistons Providing an over center up lock prevents inadvertent main gear extension in the case of a hydraulic failure As a secondary safety to ensure the geometry remains over center with a hydraulic failure a spring 18 installed on the actuating arm preventing motion of the rack and pinion actuator Since the retraction mechanism is over center the weight of the landing gear and oleo when retracted also prevent the retraction mechanism from rotating past the over center point P N 1005723 No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B ARM ZERK gt FIGURE 4 3 MAIN GEAR GREASING POINTS P N 1005723 Doc No W8750 24 01 Page 48 of 104 Revision IR SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 4 1 MAIN GEAR RETRACTION DESCRIPTION CONTINUED In addition to the over center locking provided by the rod linkages and actuator arm for the gear extended position a second down locking method is provided as well The geometry of the main gear drag link oleo pneumatic shock strut and the top arm assembly provide an additional over center locking method The force vector from the oleo
61. nk still attached to the Rod End Item 5 to place the rollers Item 14 into the down lock pocket on the nose box track Thread the Ram Assembly Item 6 onto the Rod End Item 5 until the ram piston contacts the Flange Assembly Item 7 while at the same time the rollers are seated in the down lock pocket Both the piston and the rollers need to bottom out against their respective mating parts at the same time Tighten the AN316 10R jam nut against the rod end Page 39 of 104 Install the Nose Ram Item 2 onto the Flange Assembly Item 3 being careful not to nick T Seals on bolt holes Fasten with NAS1103 2 bolts and necessary washers Oil felt wiper through oil cup on the Flange assembly Item 3 Connect hydraulic lines to cylinder and cycle gear to fill cylinder with fluid Service hydraulic system with Mil H 5606 if necessary P N 1005723 No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B FIGURE 3 3 NOSE GEAR amp BOX ITEMS P N 1005723 Doc No W8750 24 01 Page 40 of 104 Revision IR SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B THIS PAGE INTENTIONALLY LEFT BLANK Revision IR Page 41 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B CHAPTER 4 MAIN LANDING GEAR BRAKES amp GEAR RETRACTION P N 1005723 Doc No W8750 24 01 Page 42 of 10
62. oduction dry handle reversible pump installation For Cessna 208 wet handle installation the pump handle electrical system should be maintained with the ICA pertaining to the model 8000 installation document P N 1002554 revision G or later approved revision with consideration for the two additional power wires shown in drawing 1006012 revision A or later approved revision For Cessna 208 208B dry handle installation the pump handle electrical systems should be maintained with these ICA The dry handle Revision C SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B system 1s installed standard for all new 8750 installations starting May 2012 BASIC DESCRIPTION The following electrical systems are added with the installation of Wipline 8750 floats on the Cessna 208 208B 1 24V DC Hydraulic pumps 2 each pump with its own dedicated circuit breaker 2 Gear selector head for changing pump flow directions to actuate the landing gear up and down and indicate gear position For detailed schematic information regarding the electrical system refer to the previously listed Wipaire Inc wiring diagrams ELECTRIC HYDRAULIC PUMPS The installed 24V DC electrically reversing hydraulic pumps are wired independently to allow failure of one pump without affecting the other pump The pump is electrically shut off in the up and down directions by a fluid pressure switch that cuts pump powe
63. of aircraft when single float jacking check that wing fuel tank valves are confirmed closed if possible use wing tie rope from float side to be jacked and tie off to tug Raise the float slowly making sure the aircraft stays balanced After raising block up the keel in several places and lower the jack Raise only one float at a time with the opposite float wheels Revision IR Page 27 of 104 chocked Position a sawhorse under main and after body keel to keep aircraft from tipping fore and aft TOWING When towing the amphibian aircraft two lugs are provided on the lower forward side of the nose spring A rigid V frame can be fabricated to attach to these lugs for towing the aircraft with a tractor Wipaire parts has this tow bar available for purchase HOISTING Hoisting the aircraft can be performed using a lifting apparatus that attaches to the aircraft with lifting rings which are installed at the wing spar Joints Contact Wipaire Parts for details if necessary to remove or install floats LEVEL The level reference for the Caravan is two jig located nut plates and screws installed on left side of fuselage below side windows and forward of cargo door Weight and balance information should be taken with aircraft in a level attitude The float deck 1s at a 4 degree nose down incidence from the aircraft level reference P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FL
64. oir to the normal operating range as placarded on the pump reservoir Revision C Page 69 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B THIS PAGE INTENTIONALLY LEFT BLANK P N 1005723 Doc No W8750 24 01 Page 70 of 104 Revision C SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B CHAPTER 6 WATER RUDDER Revision C Page 71 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 6 0 BASIC DESCRIPTION Water rudder retract handle with lock pull finger lock to move handle Water rudder retract and hand pump mounted to cockpit floor The water rudder retract system is manually operated by a lever through a system of cables and pulleys A lever in the cockpit controls the position of the rudders The lever has a locking feature that prevents inadvertent operation of the rudders in flight Steering is directed from the aircraft rudder steering system The controls are interconnected and seamless to the operator The water rudder moves with the air rudder WATER RUDDER RIGGING All cables in the water rudder steering system should be rigged to 30 5 Ibs Retraction cables should be rigged P N 1005723 Doc No W8750 24 01 such that the top of the rudder blade is approx 1 inch from the rudder stop on the rudder post in the up position and that t
65. ons Page 59 of 104 Bleed air from hydraulic system by actuating the gear several times with the electric hydraulic pumps See Chapter 5 Section 5 1 for specific bleeding instructions Ifitis necessary to adjust gear up and down position switches proceed to next section If not lower gear and reattach oleo shock strut to top arm assembly When aircraft weight is fully on the wheels remember to set the NAS 428 bolt on the Main Gear Down Stop Assembly refer to Section 4 2 Step 30 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B l 4 4 ADJUST MAIN UP AND DOWN POSITION SWITCHES With the aircraft still on jacks position the gear in the UP position This allows access to the gear down proximity switch Loosen the jam nut on the Gear Down Proximity Switch located on the back of the Main Gear Top Mount Thread the Gear Down Proximity Switch in or out until the face of the sensor 185 flush with the face of the Main Gear Top Mount Reference Figure 4 4B Tighten the jam nut on the proximity switch to 10 inch pounds Thread out the Set Screw Adjustment Item 6 located on the Top Arm Assembly Item 2 Position the gear in the DOWN position With the aircraft master switch on thus providing power to the proximity switch thread the Set Screw Adjustment located on the Top Arm Assembly in until the LED light built into the proximity
66. order When a float part is significantly changed or an additional inspection is recommended or required often a service letter and or kit is issued If a warranty is issued most commonly it is for an 18 month time period so it is crucial to check for service letters specific to your float model at each periodic inspection to be eligible Service Manuals and the installation prints included are also revised periodically and also to be kept updated Service letters Service Kits and Service Manuals are available on our web site at no charge WWW Wipaire com NOTE IT IS CRITICAL TO CHECK FOR MANUAL UPDATES EACH TIME AN INSPECTION IS EXECUTED Revision D SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B FIGURE 1 1 FRONT VIEW CESSNA 208 CARAVAN Revision IR Page 15 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 2 0 de FIGURE 1 2 amp SIDE VIEWS CESSNA 205 CARAVAN P N 1005723 Doc No W8750 24 01 Page 16 of 104 Revision IR SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B FIGURE 1 3 FRONT VIEW CESSNA 2088 CARAVAN Revision B Page 17 of 104 P N 1005723 Doc No W8750 24 0 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B FIGURE 1 4 TOP amp SIDE VIEWS CESSNA 208B CARAVAN P N 1005723 Doc No W8750 24 01 Page 18 of 104 Revision
67. r fashion measuring between the face of the clevises and loosening then tightening the wires until they are of equal Secure with jamb nuts P N 1005723 Doc No W8750 24 01 Page 44 of 104 BLEEDING BRAKE SYSTEM Whenever the hydraulic brake lines are disconnected and reattached the brake system should be bled To bleed the brake system 1 Check that all lines are properly attached between the brake calipers and brake master cylinders 2 Check brake fluid reservoir level and fill to MAX line located on the pilot side of the engine compartment mounted to the firewall 3 Depress brakes using pilot pedals brakes will likely be spongy and need significant travel to build braking force 4 Loosen hydraulic fitting at one brake caliper just enough to let fluid and air seep out when brakes are actuated 5 While one person actuates the brakes a second person should watch the brake caliper with the loose fitting 6 If airis in the system actuating the brakes will cause bubbles in the fluid coming out of the loosened brake caliper fitting 7 Actuate the brakes through full travel several times until all the bubbles have been released and fluid is being expelled at the loose caliper without signs of air 8 Tighten the loose caliper fitting 9 Check fluid level in brake fluid reservoir and refill to MAX line as necessary Revision IR SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 2
68. r when sufficient hydraulic pressure 18 obtained in the gear system Gear swings should take less than 45 seconds with both Revision C Page 77 of 104 pumps operating If the gear cycle time 18 greater than 45 seconds it 1 likely that one pump is not pumping efficiently and or not operating correctly This can be verified by pulling each pump breaker to see if the system functions on one pump but not the other GEAR SELECTOR HEAD The installed gear selector head 18 similar to units used in several other models of Wipline floats This selector head switches current directions to the electric pumps reversing their pumping direction It also indicates gear positions using four blue and four green incandescent lights The lights for the nose gear are turned on with a magnetic switch that senses a magnet in the hydraulic cylinder piston The lights for the main gear position are triggered by inductive proximity switches that are triggered by metal flags on the main gear arm Lights are a cartridge style and can be replaced by pulling them out from the bezel A suspected defective light can be quickly replaced with an adjacent light for troubleshooting a suspected defective bulb P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B THIS PAGE INTENTIONALLY LEFT BLANK P N 1005723 Doc No W8750 24 01 Page 78 of 104 Revision C SERVICE MANUAL amp ICA 8750 AMPHI
69. remove tire and tube Main gear tires should be replaced when the tread 1s worn through in any area Reinstallation 1s the reverse of removal for tires wheels and brakes 0 100 2 54 mm MINIMUM MINIMUM PRESSURE BACK PLATE PLATE FIGURE 4 1 MINIMUM BRAKE LINING THICKNESS P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B MAIN GEAR WHEEL ALIGNMENT There 18 no way to adjust the alignment within each main gear wheel set If the tires are showing signs of abnormal unsymmetric wear some component has likely been worn bent Starting with the axle examine each main gear component and mounting point for signs of damage deformation Replace damaged components once found If no gear bulkhead airframe components are found to be damaged use the following procedure to align left and right floats 1 Move aircraft to level surface ensure both nose wheels are facing aft 1 e positioned for forward motion 2 Measure the length of the forward flying wires from the aft face of the clevis on each end These distances should be equal If they are not loosen the jamb nuts and adjust the wires as required so the length of each is equal 3 Tighten each forward wire until 1s snug then tighten the jamb nuts Wire should not be overly tight but should be tight enough to prevent excessive motion at the center 4 Next tighten the aft wires in a simila
70. thout spilling fluid that 18 under pressure Item 1 Leave emergency gear position selector in the Up position to allow actuator movement Remove the ANI2 bolt at the top of the oleo shock strut attaching it to the top arm assembly Item 1 This will allow the retraction mechanism to be repositioned by hand without having to move the weight of the tires oleo and drag link assembly Place a rag between the drag link and the bulkhead as the gear will rotate and make contact with bulkhead possibly scratching the finish Doc No W8750 24 01 Page 54 of 104 Loosen the 4 bolt and nut holding the actuator arms Item 5 to the actuator shaft Remove the two arms from the shaft being careful not to lose the parallel keys It is not necessary to remove the visual gear position indicator assembly from the outboard actuator arm Remove the qty 4 5 16 18 bolts that hold the actuator into the channel that runs across the top of the wheel well Allow the actuator to drop down from channel and remove the up and down hydraulic lines Revision C 8 10 11 Revision C SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 4 2 MAIN GEAR ASSEMBLY SETUP AND ADJUSTMENT CONT NOTE The actuator should not need adjustment while in service The only time adjustment should be necessary 18 when the actuator 18 disassembled in order to replace internal seals Assuming this has bee
71. to the rugged way our floats are used and the environment these surface sealers become abraded or wear away leaving the metal exposed Removal of corrosion 1s detailed more fully in Chapter 9 but there are a few things an owner can do to stop the spread of corrosion and minimize the damage Aside from the already detailed cleaning and inspection procedures an anti corrosion spray like Corrosion X or its equivalent should be used liberally Because it has the ability to displace moisture and contaminants 1t can be used when the floats are still wet or when they are dry Periodically hardware should be covered with waterproof grease Especially in a salt water environment bolts should be removed at least once a year and grease applied to the shafts bolt screw heads and nuts P N 1005723 Doc No W8750 24 01 Page 26 of 104 Revision C SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 1 4 FLOAT HANDLING amp JACKING To jack the floats for servicing tires brakes or doing retraction tests it is recommended that a floor type jack three ton minimum be used if lifting apparatus is not available These jacks are commonly used for truck repair The jack should be positioned on the keel centerline on the first bulkhead forward of the step The jack should contact the keel squarely and if room permits slip a board between the jack and keel CAUTION Due to critical angle
72. trols are added 2 The landing gear emergency gear operation hand pump and system are added A water rudder steering system 1s installed Auxiliary Vertical Fins Finlets are added A seaplane extended chord rudder is installed QN Un WwW TKS pod amp reservoir if equipped is removed Operational information 1s detailed in the Cessna 208 Airplane Flight Manual Supplement or Cessna 208B Airplane Flight Manual Supplement Actual displacement for each float in fresh water 18 Amphibian at 100 Buoyancy 8240 pounds at 80 Reserve 9155 pounds Seaplane at 100 Buoyancy 8741 pounds at 80 Reserve 9712 pounds P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B LANDING GEAR The landing gear incorporated within the amphibious floats 1s a retractable quadricycle type with two swiveling nose or bow wheels and four 4 two 2 dual sets of main wheels Shock absorption 18 provided by air oil shock struts on the two main landing gear assemblies and composite flat springs on the nose gear assemblies Each main wheel is equipped with a hydraulically actuated disc brake FIGURE 1 7 HYDRAULIC FLUID LEVEL PLACARD The nose wheels are fully castoring for Landing gear extension and retraction 18 accomplished by two 2 electrically driven hydraulic pumps and four 4 hydraulic maneuverability while the airplane 1s under actuators one 1
73. ver center track 18 about 4 inch from bottomed position while traveling in the up direction Lights should come on about 1 8 inch from the bottomed position while traveling in the down direction The cylinder piston has a magnet that will activate the proximity switches P N 1005723 Doc No W8750 24 01 Page 36 of 104 Revision IR SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 3 2 NOSE GEAR BASIC SERVICING Refer to Figure 3 2 for visual reference The nose gear pivot assembly should be cleaned and The nose wheels contain grease nipples for the inspected every 25 hours or more frequently wheel bearings They should be greased every whenever in water for an extended period of 25 hours time especially saltwater Tracks and blocks Nose tires are standard 5 00 x 5 10 ply inflated should be cleaned and left dry or alternately to 60 5 psi All tires must be approved to cleaned and wiped with a rag with dry silicone TSO C62 type III spray on it e DETAIL B 1 SIDE ONLY FIGURE 3 2 NOSE WHEEL GREASING Revision IR Page 37 of 104 P N 1005723 Doc No W8750 24 01 SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 3 3 NOSE GEAR DISASSEMBLY In float or removed from float Items refer to areas on Figure 3 3 1 Disconnect hydraulic lines Item 1 7 Replace T seals on the Nose Ram Item 9 and Ram Assembly Item 3 if necessary 2 Remove the 4
74. when rotating the Top Arm the rod linkages must also move The geometry is such that the rod linkages are over center on the actuator shaft centerline and thus the rod linkages are trying to rotate the actuator more toward the UP position and in turn force the actuator piston face into the up adjustment setscrew Revision C Revision C SERVICE MANUAL amp ICA 8750 AMPHIBIAN SEAPLANE FLOATS ON CESSNA 208 208B 4 3 ADJUSTING THE GEAR UP POSITION DO NOT adjust the rod linkages Item 3 when setting the over center up adjustment Rotate the actuator rotation arm fully toward the gear up position When the actuators internal piston contacts the UP adjustment setscrew check to make sure all the linkages have rotated past Top Dead Center TDC by pushing and pulling on the Top Arm Assembly The UP adjustment screw Item 10 should not need to be adjusted 1f properly set using Wipaire Tool 1004800 during the actuator maintenance If it 1s found that one can reverse drive the rotary actuator and pull the gear down by hand the rod linkage and the actuator arms have not moved past TDC Re check the position of the stop using Wipaire Tool 1004800 If the UP position is found to be correct look for signs of damage in the floats as something is out of position preventing the stop setting using Tool 1004800 from being correct Call Wipaire s Customer Service Department for specific instructi

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