Chapter 32 LANDING GEAR

Transcription

1 Chapter 32 LANDING GEAR 32-Title Page 1 January 23, 2012

2 INTENTIONALLY LEFT BLANK 32-Title Page 2 January 23, 2012

3 LIST OF EFFECTIVE PAGES Chapter Section Page Date Title 1 January 23, January 23, LOEP 1 November 27, November 27, November 27, November 27, November 27, November 27, TOC 1 November 27, November 27, November 27, November 27, November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 27, November 27, November 27, November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 21, LOEF Page 1 November 27, 2012

4 LIST OF EFFECTIVE PAGES Chapter Section Page Date November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 27, November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 21, November 21, LOEF Page 2 November 27, 2012

5 LIST OF EFFECTIVE PAGES Chapter Section Page Date July 7, July 7, LOEF Page 3 November 27, 2012

6 LIST OF EFFECTIVE PAGES Chapter Section Page Date LOEF Page 4 November 27, 2012

7 LIST OF EFFECTIVE PAGES Chapter Section Page Date LOEF Page 5 November 27, 2012

8 LIST OF EFFECTIVE PAGES Chapter Section Page Date LOEF Page 6 November 27, 2012

9 TABLE OF CONTENTS Chapter Section Title 32 Environmental Systems 32-Title Title Page 32-LOEP List of Effective Pages 32-TOC Table of Contents General Main Gear Tricycle (2C3) Main Gear Fairings (2C3) Main Gear (2C3) Bearing Replacement Main Wheels & Tires (2C3) Main Wheel Alignment (2C3) Main Gear Tail-Dragger (2C1, 2C2, AND 2C4) Main Gear Fairings (2C1, 2C2 and 2C4) Main Gear Assembly (2C1, 2C2 and 2C4) Main Gear Leg (2C1, 2C2 and 2C4) Main Gear Shock Absorber Puck (2C1, 2C2 and 2C4) Main Wheels & Tires (2C1, 2C2 and 2C4) Over-size Tires - AB Tires (2C1, 2C2 and 2C4) and 29 x Tires (2C1, 2C2 and 2C4) Nose Gear (2C3) Nose Gear Fairings Nose Gear Nose Gear Fork Nose Gear Shock Absorber Puck Replacement Nose Gear Bearings Locations Nose Wheel & Tire Tail Gear (2C1, 2C2, AND 2C4) Tail Gear Trouble Shooting Tail Wheel Problems Tail Wheel Assembly (All Types) Tail Wheel Boom (All Types) Tail Wheel Steering Cables (All Types) Tail Wheel & Tire (All Types) Phenolic Washer Installation in U1009 Tail Wheel Assembly Heavy Duty (HD) Tail Wheel Assembly Wheel and Brakes Main Wheels & Tires Tail Wheels & Tires 32-TOC Page 1 November 27, 2012

10

11 TABLE OF CONTENTS Chapter Section Title Nose Wheel & Tires Tundra Wheels & Tires Brakes Brake Bleeding for Dual Brakes "Pressure Pot Method" Bleeding the Brake - METHOD "A" Removal and Installation of Brake Assembly Brake Wear Limits Series Dual Brake System Aerocet 3500 & 3500L Floats Inspection Before Installation Installation Protection after Removal Aerocet 3400 Floats Inspection Before Installation Float Preparation Floats Installation Brake Line Replacement Controller Electrical Installation Hydraulic Installation Retraction & Extension Tests Protection After Removal Weight & Balance Wipaire 3450 Floats General Inspection Before Installation Float Preparation Floats Installation Brake Line Replacement (Amphibious Floats Only) Controller Removal and Installation (Amphib Floats Only) Electrical Installation (Amphibious Floats Only) Hydraulic Installation (Amphibious Floats Only) Retraction & Extension Tests (Amphibious Floats Only) Protection after Removal Weight & Balance C3200/C3600 Wheel Ski (2C1 & 2C2) Description and Operation Removal and Installation 32-TOC Page 1 January 23, 2012

12 TABLE OF CONTENTS Chapter Section Title Initial Installation of Skis Seasonal Installation of Skis Seasonal Installation of Pump Assembly Seasonal Installation of Hydraulic Lines Purging of Hydraulic System Rigging of Skis Removal of Skis 32-TOC Page 2 January 23, 2012

13 INTENTIONALLY LEFT BLANK 32-TOC Page 3 January 23, 2012

14

15 32 LANDING GEAR GENERAL This chapter contains maintenance information concerning several types of undercarriage and associated components which provide means of supporting, braking, and steering the aircraft. There are 3 main undercarriage categories, wheels, floats, and skis. The 2C1, 2C2, and 2C4 landing gear is arranged in a fixed tail-dragger configuration. The main gear legs are welded steel structures. The legs are pinned to a box beam that spans the fuselage. A stack of elastomer pucks located between the upper end of the leg and the box beam act as shock absorbers. The steer-able tail wheel is attached to a tubular steel stinger/boom mounted to the aft fuselage. The tail wheel is designed to caster when a side load is applied to the wheel. This feature allows the pilot to minimize the turning radius of the airplane. The 2C3 has a tricycle gear arrangement. The design of the 2C3 main landing gear follows the conventional cantilevered spring design used by many airplanes. The main legs are tapered steel tubes of circular cross-section connected to a cross tube spanning the width of the fuselage. The landing loads are transferred from the gear legs into the fuselage via the trunnions that pivot in weldments in the steel tube fuselage. Because the trunnions rotate freely, bending moments from the main legs are transferred directly into the cross tube. The nose gear installation comprises an articulated strut with elastomer compression pucks providing energy absorption and a free castering nose wheel. The carriage structure for the nose gear is a triangulated arrangement of welded steel tubes that transfer the landing and taxiing loads to the steel tube fuselage via the engine mount. Each of the main wheels has a disc type brake which is hydraulically operated by levers mounted on the left hand side (pilot s side) rudder pedals. There is a hydraulic Parking Brake mounted separately from the master cylinder. The 2C1, 2C2, and 2C4 models use tube type main wheel tires as standard equipment. Over-size main gear tires are available as optional equipment for all models. The standard of type tail wheel assembly for the 2C1/2C2 uses a 10 x tube type tire. A heavy-duty tail wheel assembly with an 11.5 diameter tube type tire is used on the 2C4. The heavy duty tail wheel is an option for 2C1/2C2. The 2C3 model aircraft use tube type tires on the main wheels and a tube type tire on the nose wheel. Floats are mounted to the aircraft via 6 struts which mount directly to the forward fuselage frame. There are 2 types of floats available, seaplane floats and amphibious floats. The 2C1, 2C2 and 2C4 models can be equipped with skis mounted to the gear. The wheel skis can be extended or retracted by hydraulic pressure from a dedicated hydraulic system Page 1 November 21, 2011

16 INTENTIONALLY LEFT BLANK Page 2 November 21, 2011

17 32-10 MAIN GEAR - TRICYCLE (2C3) Main Gear Fairings (2C3) Removal & Installation Step 1. Step 2. Remove screws from the lower leg fairing cover and remove cover. See Figure Remove screws securing the leg fairing to the wheel pant. Remove the wheel pant by sliding it outboard approximately 4 to clear the axle extension nut, then lift the wheel pant clear of the tire. See Figure Step 2 Step 1 Figure Fairing Removal and Installation Step 3. Remove the clamp securing the brake line to the leg fairing. Remove the 2 bolts securing the 2 piece collar in the upper portion of the leg fairing. Remove the 2 bolts securing the bottom of the leg fairing to the lower mount. See figure CAUTION: When removing the leg fairing care must be taken to ensure the leg is not scratched or gouged during fairing removal. Step 4. Lift the leg fairing off the gear leg as shown in figure Page 1 November 21, 2011

18 Step 3 Disconnect fairing from leg as shown above Step 4 Figure Fairing Removal and Installation Page 2 November 21, 2011

19 Step 5. Step 6. Remove the screws securing the side gear faring and remove the fairing by spreading the joint and sliding the fairing down the gear leg then upwards as shown in figure Remove the screws securing the center gear panel and remove the panel. See figure Step 5 Step 6 Figure Fairing Removal and Installation Installation can be accomplished by reversing the removal steps Main Gear (2C3) Removal & Installation Step 1. Remove the main gear fairings, see Step 2. Hoist the aircraft as required. See Chapter 7 for instructions. Step 3. Disconnect the brake line at the top end of the gear leg. Cap all lines and fittings. Step 4. Remove the 6 bolts securing the bottom plate and remove the plate. See figure Step 5. Support the cross tube using blocks under the cross tube or straps around the cross tube and the fuse to support the cross tub during leg removal. Step 6. Remove the 8 bolts securing the bearing housings to the fuselage Page 3 November 21, 2011

20 CAUTION: With lowered gear leg, the cross tube and the opposite leg (if unsupported) can rotate suddenly or the cross tube can fall free causing injury and/or damage to the aircraft. Step 7. Step 8. Lower the gear leg from the fuselage mounts and remove the gear leg and cross tube. See figure Repeat steps 3-7 for the opposite leg. Step 4 Figure Bottom Plate Removal & Installation Page 4 November 21, 2011

21 Step 6 Step 7 Figure Gear Leg Removal and Installation Page 5 November 21, 2011

22 Bearing Replacement Main Gear Pivot Bearings Reference Figure Note: Care must be taken during bushing replacement to ensure that the bearing housing does not get damaged during the pressing operation. See figure Step 1. With the bearing housings removed as described in section Step 2. Press the existing bushing out of the bearing housing and press the new bushing in. Cross Tube Bearing The cross tube bearing is a shrink fit installation. Contact for instructions. Thrust washer Bearing Cross tube bearing Trunnion Bearing Housing Main gear leg assembly Figure Bearing Locations Page 6 November 21, 2011

23 Main Wheels & Tires (2C3) The following wheel is used on the 2C3: Parker Hannifin P/N 40-75T Bolt Pattern Wheel Assembly The standard tires on the 2C3 aircraft are tube type with a 6 ply rating. The tire pressure is 40 to 44 PSI. Tires should preferably be serviced with nitrogen which is an inert, moisture free gas which prevents water condensation. Dry air may be used if nitrogen is not available. Main Wheel Removal and Installation Step 9. Remove the wheel fairings per Section Step 10. Jack or trestle aircraft as required. See Chapter 7 for instructions. Step 11. Deflate the tire. Step 12. Ensure parking brake is released. Remove bolts holding brake and swing brake unit clear. WARNING THE TIRE MUST BE DEFLATED BEFORE REMOVING THE AXLE NUT. FAILURE TO DO SO COULD RESULT IN PERSONNEL INJURY OR EVEN DEATH Step 13. Step 14. Remove cotter pin from axle nut, remove axle nut. Slowly slide wheel off axle taking care to not drop the wheel onto the axle during removal. Do not let the outboard bearing fall to ground. Wheel is now free. Note: Bearings should be cleaned, inspected and re-lubricated at each wheel removal as well as regularly scheduled maintenance. To install main wheel reverse above steps. Carry out brakes function check. Main Wheel Disassembly and Assembly WARNING THE TIRE MUST BE DEFLATED BEFORE BEGINNING TO DISASSEMBLE. FAILURE TO DO SO COULD RESULT IN PERSONNEL INJURY OR EVEN DEATH. Disassembly Step 1. Loosen the six nuts on the O/B side of the wheel assembly. Step 2. Remove the bolts from the wheel assembly Page 7 November 27, 20112

24 Step 3. The two wheel halves are now free to be separated. Some light tapping with a wooden mallet or soft faced dead blow hammer may be required to free the two halves. The wheel halves, when separated, allows removal of the tire and inner tube. Assembly Step 1. Lightly coat the entire surface of the inner tube with talcum powder. Step 2. Place the inner tube inside the tire. Step 3. Place the O/B half of the wheel face down on a clean surface. Step 4. Place the tire & tube over the O/B wheel half, and guide the inner tube valve stem through the valve stem hole in the rim. Step 5. Place the I/B half of the wheel on O/B wheel half, then place the brake rotor on top of the stacked assembly. Step 6. Install the bolts through the holes with the heads to the I/B side of the assembly. Step 7. Initial torque all nuts to 125 in - lbs. Final torque all nuts to 150 in - lbs. Step 8. Inflate tires Main Wheel Alignment (2C3) It is acceptable to adjust the main wheel alignment by installing shims between the axle and the gear leg. Both camber and toe-in/toe-out may be adjusted in this manner. The airplane is delivered from the factory with zero toe-in/toe-out. Shims may be used to correct tracking problems that may occur as the aircraft ages. Camber will vary with aircraft weight. Shims may be installed to adjust the camber to improve tire wear. Shim Installation Step 1. Remove the wheel fairings per Section Step 2. Jack or trestle aircraft as required. See Chapter 7 for instructions. Step 3. Remove the wheel per Section Step 4. Remove the 4 bolts holding the axle to the leg. Refer to Figure Step 5. Remove flat shim and replace with tapered shim Step 6. Complete the installation by reversing the removal steps Page 8 November 27, 20112

25 SHIM AXLE Figure Shim Installation Page 9 November 27, 20112

26

27 32-15 MAIN GEAR TAIL-DRAGGER (2C1, 2C2, AND 2C4) Main Gear Fairings (2C1, 2C2 and 2C4) Removal & Installation Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. Step 7. Step 8. Step 9. Step 10. Remove the screws securing the blister fairing to the belly pan. Holding the collar portion open, slide the fairing forward, off of the leg fairing. Remove the screws securing the brake fairing to the lower end of the leg fairing. While spreading the fairing, slide it forward off of the leg fairing. Remove the screws securing the leg fairing cover to the bottom of the leg fairing and remove the cover. Remove the bolt securing the step assembly to the main gear leg and remove the step by sliding it aft until it is clear of both the gear leg and the fairing. Remove the foam dam material from the upper portion of the leg fairing. Remove the screws securing the leg fairing to the main landing gear leg and lift the fairing off from the top. Remove the screws securing the aluminum main gear side cover between the forward and rear belly pans and remove the cover. Remove the screws securing the main gear access panel to the belly pans and remove the panel. Installation can be accomplished by reversing the removal steps Main Gear Assembly (2C1, 2C2 and 2C4) The main gear cross beam assembly is attached directly to the forward fuselage steel frame. It is made from two upper caps, two lower caps and a web, with several fittings attached. Removal and Installation Reference Figure (2C1 & 2C2) and (2C4) Note: The cross beam assembly may be removed with the gear legs installed or removed. If the gear legs are to be removed, this must be done prior to gear beam removal. The steps below outline removal of the cross beam with the gear legs installed. See for gear leg removal, if required. Step 1. Hoist the aircraft as applicable. See Chapter 7 for instructions. Aircraft should be in a level position to ease removal and installation. Step 2. Remove main gear leg to fuselage fairings. See section Step 3. Disconnect the brake lines at the fuselage fittings. Cap all lines and fittings Page 1 November 21, 2011

28 CAUTION: Do not remove the pivot pin as it can result in serous injury or damage to the aircraft. Step 4. Step 5. Step 6. Step 7. Remove the drag stay hardware at forward end at both locations. Remove the pivot retaining pin and drive the main gear pivot pin forward just enough for the drag stay to clear the pillow block for removal. Remove the drag stay hardware at the aft end and remove the drag stay. Tap the pivot pin back in position and secure with the retaining pin. Serial Number 28 through 31 only Step 8B Remove the Pilot s seat from the cabin. See Chapter Step 8C Remove the Pilot s side floorboard to gain access to the heat ducts. See Chapter Step 8D Remove clamp on aft end of heater duct, at the rear heater distribution box and clear duct from the cross beam. Serial Number 32 onwards Step 8A Step 9. Step 10. Step 11. Remove clamp on either end of heater duct splice tube and clear duct from the cross beam. Support cross beam assembly in such a manner that further disassembly will not cause damage. Remove four 5/16 bolts located at the outboard top corners of the cross beam assembly. Lower cross beam assembly until it clears fuselage structure. Cross beam assembly is now free. To install the cross beam assembly reverse the above steps Main Gear Leg (2C1, 2C2 and 2C4) The main gear leg is a steel three piece assembly which is welded together. Removal and Installation See Figure (2C1 & 2C2) and (2C4) Step 1. Remove gear fairings, see Step 2. Disconnect the brake lines at the fuselage fittings Cap all lines and fittings. WARNING WHEN REMOVING THE NUT FROM THE SHOCK ABSORBER TIE BOLT THE AIRCRAFT WEIGHT MUST BE ON THE LANDING GEAR TO RELIEVE THE PRELOAD. FAILURE TO DO SO MAY RESULT IN DAMAGE TO THE AIRCRAFT OR SERIOUS INJURY Page 2 November 21, 2011

29 Step 3. With the full weight of the aircraft on the landing gear there should be free play in the bushings at the bottom end of the tie bolts as shown in figure If this is not the case more weight must be added to the aircraft until the bushings are free. Note: Do not proceed to step 4 until step 3 has been satisfied. As shown in figure Step 4. Remove the cotter pin, nut and spacer from the shock absorber tie bolt. Step 5. Remove the tie bolt, rebound elastomer and cap. Step 6. Hoist the aircraft slowly (See Chapter 7 for instructions), until the primary elastomer pucks and separator plates can be removed. Step 7. Remove the drag strut hardware at forward end at both locations. Step 8. Remove the pivot retaining pin and drive the main gear pivot pin forward to clear the drag stay fitting. Step 9. Remove the drag strut hardware at aft end. Drag strut is now free. Step 10. Support gear leg in such a manner that further disassembly will not cause damage. Step 11. Remove the Pivot pin. Main gear leg is now free. To install main gear leg reverse above steps. Note: For reloading the puck stack 2 pieces of plywood or similar under each wheel as shown in figure The plywood allows the wheels to spread as the aircraft weight is lowered on to the gear. Note: It may be necessary to apply some grease between the 2 pieces of wood to allow them to slide more freely. Bleed brakes (Ref. Chapter 32-42) and carry out an operational check of wheels and brakes Page 3 November 21, 2011

30 Main Gear Shock Absorber Puck (2C1, 2C2 and 2C4) Removal and Installation Step 1. Remove gear fairings, see WARNING WHEN REMOVING THE NUT FROM THE SHOCK ABSORBER TIE BOLT THE AIRCRAFT WEIGHT MUST BE ON THE LANDING GEAR TO RELIEVE THE PRELOAD. FAILURE TO DO SO MAY RESULT IN DAMAGE TO THE AIRCRAFT OR SERIOUS INJURY. Step 2. Step 3. Step 4. Step 5. With the full weight of the aircraft on the landing gear there should be free play in the bushings at the bottom end of the tie bolts as shown in figure If this is not the case more weight must be added to the aircraft until the bushings are free. Note: Do not proceed to step 4 until step 3 has been satisfied. As shown in figure Remove the cotter pin, nut and spacer from the shock absorber tie bolt. Remove the tie bolt, rebound elastomer and cap. Hoist the aircraft slowly (See Chapter 7 for instructions), until the primary elastomer pucks and separator plates can be removed. To install Main Gear Shock Absorber Pucks reverse above steps. Note: For reloading the puck stack 2 pieces of plywood or similar under each wheel as shown in figure The plywood allows the wheels to spread as the aircraft weight is lowered on to the gear. Note: It may be necessary to apply some grease between the 2 pieces of wood to allow them to slide more freely. Bleed brakes (Ref. Chapter 32-42) and carry out an operational check of wheels and brakes Page 4 November 21, 2011

31 Figure : Main Landing Gear (2C1 and 2C2) Page 5 November 21, 2011

32 17,19, ,26,25,35 18 Figure : Main Landing Gear (Standard on 2C4, optional mod for the 2C1/2C2) Page 6 November 21, 2011

33 Free space between the bushing and the puck pad Puck pad cut away for clarity Figure : Main Landing Gear Page 7 November 21, 2011

34 Tie Bolt Cap Washer Rebound Puck Bushing Top of Leg Alignment Sleeve Primary Puck Isolator Plate Bushing Puck pad Bracket Nut and Washer Spacer Figure : Shock Absorber Puck Stack Page 8 November 21, 2011

35 Figure : Plywood Under The Wheel Page 9 November 21, 2011

36 Main Wheels & Tires (2C1, 2C2 and 2C4) The following wheels are used on the 2C1, 2C2, and 2C4: Parker Hannifin P/N 40-84A Bolt Pattern Wheel Assembly (2C1 and 2C2 only) Parker Hannifin P/N 40-75T Bolt Pattern Wheel Assembly (2C1, 2C2, and 2C4) Alaskan Bushwheel P/N ABI x10 Wheel Assembly (2C1, 2C2, and 2C4) It should be noted that the wheels listed above may be converted to 10 wheels using the Alaska Tundra Tires (formerly Gar Aero) wheel adapters. The standard tires on the 2C1, 2C2 and 2C4 aircraft are tube type with a 6 ply rating and are mounted on the wheels listed above. The tire pressure is 33 to 35 PSI. The 2C1, 2C2 and 2C4 aircraft may be equipped with the following over-size tires: Tire Diameter (in) Wheel Alaskan Bushwheel Tire P/N R Alaskan Bushwheel Tire P/N R Ply 26 Alaskan Bushwheel 10 Wheel P/N ABI-1010 or Alaska Tundra Tires Wheel Adapters 29 x Ply 29 Alaskan Bushwheel 10 Wheel P/N ABI-1010 or Alaska Tundra Tires Wheel Adapters Tires should preferably be serviced with nitrogen which is an inert, moisture free gas which prevents water condensation. Dry air may be used if nitrogen is not available. Main Wheel Removal and Installation Step 15. Step 16. Step 17. Jack or trestle aircraft as required. See Chapter 7 for instructions. Deflate the tire. Ensure parking brake is released. Remove bolts holding brake and swing brake unit clear. WARNING THE TIRE MUST BE DEFLATED BEFORE REMOVING THE AXLE NUT. FAILURE TO DO SO COULD RESULT IN PERSONNEL INJURY OR EVEN DEATH Page 10 November 21, 2011

37 Step 18. Remove cotter pin from axle nut, remove axle nut. Step 19. Slowly slide wheel off axle taking care to not drop the wheel onto the axle during removal. Do not let the outboard bearing fall to ground. Wheel is now free. See Figure Note: Bearings should be cleaned, inspected and re-lubricated at each wheel removal as well as regularly scheduled maintenance. To install main wheel reverse above steps. Carry out brakes function check. Figure Wheel Removal & Installation Main Wheel Disassembly and Assembly WARNING THE TIRE MUST BE DEFLATED BEFORE BEGINNING TO DISASSEMBLE. FAILURE TO DO SO COULD RESULT IN PERSONNEL INJURY OR EVEN DEATH. Disassembly Step 4. Step 5. Step 6. Loosen the three nuts (for standard wheels) or six nuts (for heavy duty wheels) on the O/B side of the wheel assembly. Remove the bolts from the wheel assembly. The two wheel halves are now free to be separated. Some light tapping with a wooden mallet or soft faced dead blow hammer may be required to free the Page 11 November 21, 2011

38 two halves. The wheel halves, when separated, allows removal of the tire and inner tube. Assembly Step 9. Step 10. Step 11. Step 12. Step 13. Step 14. Step 15. Step 16. Lightly coat the entire surface of the inner tube with talcum powder. Place the inner tube inside the tire. Place the O/B half of the wheel face down on a clean surface. Place the tire & tube over the O/B wheel half, and guide the inner tube valve stem through the valve stem hole in the rim. Place the I/B half of the wheel on O/B wheel half, then place the brake rotor on top of the stacked assembly. Install the bolts through the holes with the heads to the I/B side of the assembly. Initial torque all nuts to 125 in - lbs. Final torque all nuts to 150 in - lbs. Inflate tires Wheel Adapters ( wheels that have been converted to 10 wheels using adapters) Removal and Installation Removal of these wheels shall be done the in the same manner as standard wheels. Installation of these wheels shall be done the in the same manner as standard wheels. Adapter Separation If a wheel adapter becomes separated from the wheel at any time, both the adapter and the wheel must have Eddy Current or Fluorescent Penetrant Inspection (NDT) carried out on them. If no Non Destructive Testing is carried out, then both parts are to be scrapped. Any nuts which are used to hold these wheel assemblies together shall be used a maximum of two times. After the second installation the nuts shall be discarded and new nuts shall be used. This is to ensure the nylon lock integrity is not compromised through multiple usages Page 12 November 21, 2011

39 Over-size Tires - Alaskan Bushwheel Tires (2C1, 2C2 and 2C4) 26 Diameter P/N R 29 Diameter P/N R Tire Pressure Tire pressure is 15 to 20 PSI CAUTION DO NOT PUT MORE THAN 1 PSIG OF AIR PRESSURE IN AN UNMOUNTED TIRE This can cause irreparable damage to the tire and/or split the core Preventive Maintenance Keeping aircraft tires at their correct inflation pressure is the most important factor in any tire preventive maintenance program. Air pressure enables a tire to properly support the load, which is why it is so critical. Under-inflation can be particularly severe, producing uneven tread wear and shortening tire life because of excessive flex heating. Over-inflation can cause uneven tread wear, reduce traction, make the tread more susceptible to cutting and increase stress on aircraft wheels. An important fact to remember is that for every 5 o F change (increase) in temperature will result in a corresponding 1% change (increase) in tire pressure. It is common for Mounted Tubeless Tires to have a slight amount of gas diffusion through the liner material and casing. A tire/wheel assembly can lose as much as 5% of the inflation pressure in a 24hr period and still be considered normal. The initial stretch or growth of a tire results in a pressure drop after mounting. Consequently, tires should not be placed in service until they have been inflated a minimum of 12 hours, pressures rechecked, and tires re-inflated if necessary. Bias tires, left stationary for any length of time can develop temporary flat spots. The degree of this flat spotting depends upon the load, tire deflection, and temperature. Flat spotting is most severe and more difficult to work out during cold weather. Under normal conditions, a flat spot will disappear by the end of the taxi run. Rotation Alaskan Bushwheel Inc recommends rotation of the tires not only from one side of the plane to the other, but also rotation of the tire on the wheel. This is especially important when the tires are exposed to frequent, long taxiing. Rotating should be done as frequently as determined by use and/or visible wear. (EX: every 100 long taxi s, 100 hours or annually) Protecting Tires from Chemicals and Exposure Tires should be kept clean and free of contaminants such as oil, hydraulic fluids, grease, tar and degreasing agents which have a deteriorating effect on rubber. Contaminants should be wiped off with denatured alcohol, and then the tire should be washed immediately with soap and water Page 13 November 21, 2011

40 Aircraft tires, like other rubber products, are affected to some degree by sunlight and extremes of weather. Weather checking does not impair performance; it can be reduced by protective covers. Covers, ideally with a reflective outside surface, should be placed over tires when an aircraft is tied down outside. It is also recommended to store tires away from fluorescent lights, electric motors, battery chargers, electric welding equipment & electric generators, since they create ozone which has a deteriorating effect on rubber. Inspection Systematic inspection of mounted tires is strongly recommended for safety and tire economy. The frequency of the inspection should be determined by the use and normal tire wear of the particular aircraft involved. If there is any doubt that a tire is un-airworthy or is classified as unserviceable, it must not be used until it is properly repaired or otherwise inspected by qualified/authorized individuals. Call Alaskan Bushwheel Inc for assistance in an airworthiness determination to continue the tires in service. Alaskan Bushwheel Inc requires that all repairs be done at the factory by the people best trained and equipped for this work. Tread Wear Inspect tread wear visually. Tires should be removed when any cording is showing regardless of the amount of tread remaining elsewhere. If tread wear is excessive on one side, the tire can be demounted and turned around, providing there is no exposed fabric. Gear misalignment causing this condition should be corrected. Sidewall Damage Remove tire from service if weather-checking, cracking, cuts and snags extend down to the casing ply in the sidewall bead areas or if fabric is exposed. Cuts and cracks deeper than one ply require factory inspection. Bulges Bulges in any part of the tire tread, sidewall or bead area indicate a separation or damaged tire. Please contact factory. Checking Random patterns of shallow sidewall cracks usually caused by age deterioration, prolonged exposure to weather, or improper storage. Remove if fabric is exposed. Contact the factory. Tire Storage Ideally, new tires should be stored in a cool, dry place out of direct sunlight. Particular care should be taken to store tires away from fluorescent lights, electric motors, battery chargers, electric welding equipment, electric generators and similar equipment. These items create ozone, which has a deteriorating effect on rubber Page 14 November 21, 2011

41 and 29 x Tires (2C1, 2C2 and 2C4) Ply Tire 29 x Ply Tire Tire Pressure Tire pressure is 15 to 20 PSI WARNING FOR TIRES MOUNTED ON WHEEL ADAPTERS THE TIRE PRESSURE SHALL NEVER EXCEED 25 PSI UNDER ANY CIRCUMSTANCES FAILURE TO DO SO COULD RESULT IN PERSONNEL INJURY OR EVEN DEATH Page 15 November 21, 2011

42 INTENTIONALLY LEFT BLANK Page 16 November 21, 2011

43 32-20 NOSE GEAR (2C3) Nose Gear Fairings Removal & Installation Step 1. Step 2. Remove the screws (2 per side) securing the nose pant to the main pant and remove the nose pant. Remove the screws (4 per side) securing the main pant to nose gear fork and remove the main pant by sliding it aft to clear the wheel. CAUTION: When removing the leg fairing care must be taken to ensure the leg is not scratched or gouged during fairing removal. Step 3. Remove the screws (2 per side) securing the leg fairing to the leg and remove the fairing by spreading the fairing and sliding it forward off of the leg. See figure Step 3 Step 2 Step 1 Figure Nose Gear Fairings Removal & Installation Page 1 November 21, 2011

44 Nose Gear Removal and installation Step 1. Remove cowling per chapter Step 2. Remove the nose gear fairings per section WARNING THE AIRCRAFT WEIGHT MUST BE ON THE GEAR WHEN THE NUT SECURING THE PUCK STACK IS REMOVED FROM THE TOP OF THE SHOCK ABSORBER ASSEMBLY. FAILURE TO DO SO MAY CAUSE SERIOUS INJURY OR DAMMAGE TO THE AIRCRAFT. Step 3. Step 4. Step 5. Step 6. Step 7. Remove the cotter pin, nut, cap and rebound puck from the top end of the shock absorber assembly. Jack, trestle or hoist aircraft as required. See Chapter 7 for instructions. Lower the nose gear until the tire rests on the ground and the top of the puck pad assembly is clear of the engine mount. Remove the 2 bolts securing the A-arm to the engine mount and remove the nose gear assembly from the aircraft. The nose gear is now free. For installation reverse step above. Step 3 Step 5 Step 6 Figure Nose Gear Removal & Installation Page 2 November 21, 2011

45 Nose Gear Fork Removal and Installation Step 1. Step 2. Step 3. Remove cotter pin, nut and washer from the bottom of the spindle. Remove the 4 Bellville washers and the steel penny washer. Rock the fork and pull downward to remove it from the spindle cup. Note: The Bellville washers must be oriented as shown in figure For installation reverse the removal steps. Adjust shimmy damper, see following. Step 3 Step 2 Step 1 Figure Fork Removal & Installation Page 3 November 21, 2011

46 Shimmy Damper Adjustment Note: Tire must be off the ground to perform adjustment. Step 1. Attach spring scale to axle. See figure Step 2. Torque castellated nut so that a constant force of more than 50 lb is required to rotate wheel and fork assembly. Step 3. Loosen nut and re-torque so that constant force of lb is required to rotate wheel and fork assembly. Step 4. Install cotter pin Steps 2 to 4 Figure Shimmy Damper Adjustment Page 4 November 21, 2011

47 Nose Gear Shock Absorber Puck Replacement Bushing is pressed into the engine mount Cotter pin Nut Washer Cap Rebound Puck Engine mount puck pad rest of mount not shown 4 alignment sleeves 4 Primary pucks 4 Separator plates Figure Shock Absorber Assembly Page 5 November 21, 2011

48 Nose Gear Bearings Locations All bearings are of the press fit variety and as such will need to be pressed out/in for replacement as required. See figure for bearing locations. Figure Bearing Locations Page 6 November 21, 2011

49 Nose Wheel & Tire The tires are tube type with a 6 of 10 ply rating. The nose gear tire pressure is 52 (+2, -0) PSI. Wheel Removal WARNING THE TIRE MUST BE DEFLATED BEFORE REMOVING THE AXLE NUT. FAILURE TO DO SO COULD RESULT IN PERSONNEL INJURY OR EVEN DEATH Step 1. Jack aircraft as required. See Chapter 7 for instructions. Step 2. Deflate the tire. Step 3. Remove the cotter pin, nut and washer from the axle bolt. Step 4. Remove the axle bolt and wheel assembly. See figure Fork Axle spacer Shim Ring Wheel assembly Axle bolt Axle plug Axle tube Figure Nose Wheel Removal & Installation Page 7 November 27, 2012

50 Nose Wheel Disassembly and Assembly WARNING THE TIRE MUST BE DEFLATED BEFORE BEGINNING TO DISASSEMBLE. FAILURE TO DO SO COULD RESULT IN PERSONNEL INJURY OR EVEN DEATH. Disassembly Step 1. Step 2. Step 3. Loosen the three nuts on the wheel assembly. Remove the bolts from the wheel assembly. The two wheel halves are now free to be separated. Some light tapping with a wooden mallet or soft faced dead blow hammer may be required to free the two halves. The wheel halves, when separated, allows removal of the tire and inner tube. Assembly Step 17. Step 18. Step 19. Step 20. Step 21. Step 22. Step 23. Step 24. Lightly coat the entire surface of the inner tube with talcum powder. Place the inner tube inside the tire. Place the O/B half of the wheel face down on a clean surface. Place the tire & tube over the O/B wheel half, and guide the inner tube valve stem through the valve stem hole in the rim. Place the I/B half of the wheel on O/B wheel half. Install the three bolts through the holes with the heads to the I/B side of the assembly. Initial torque all nuts to 125 in - lbs. Final torque all nuts to 150 in - lbs. Inflate tire Page 8 November 21, 2011

51 32-25 TAIL GEAR (2C1, 2C2, AND 2C4) Tail Gear - General 2C1 and 2C2 The tail wheel assembly may be one of the following configurations: Avox/Scott XP Mods XPM1-7-8NLK U1009 (Avox/Scott unit modified by Found Aircraft) U4049 The U4049 is a heavy duty tail wheel assembly designed and manufactured by Found Aircraft for the 2C4 and offered as a mod for the 2C1 and 2C2. All are 360 castoring, steerable type mounted on a tail boom. 2C4 The 2C4 is equipped with the heavy duty U4049 tail wheel assembly. It is a 360 castoring, steerable-type mounted on the same tail boom as the 2C1 and 2C2. Tires The Avox/Scott , XP Mods XPM1-7-8NLK, and U1009 tail wheel assemblies are equipped with a 10 diameter ply tube type tires. The tire pressure is 50 PSI. The U4049 tail wheel assembly is equipped with a ply tube type tire. The tire pressure is 60 psi Page 1 November 21, 2011

52 Fwd. Bolt Washer Nut Bolt Washer Nut Cotter Pin Bolt Washer Nut Cotter Pin Figure Tail Gear Page 2 November 21, 2011

53 Trouble Shooting Tail Wheel Problems All Types Trouble Probable Cause Remedy Hard landing, Collision with foreign objects Tail wheel will not break loose to full swivel Tail wheel will not track straight Tail wheel will not turn when taxi Tail wheel sticks in position Excessive rate of decent Uneven or extremely rough landing surface. Bearing pre-load set too tight. Steering cables too tight. Broken or worn internal parts. Loose or worn vertical shaft. Remove tail wheel. Disassemble tail wheel; visually inspect hub, fork and wheel for cracks with 4X or greater magnifying glass. Replace any broken parts. Check to make sure steering cables are not too tight. Hook up cables to 0 lbs. tension, ½ slack at low point is permissible. Loosen vertical nut one pin hole. If this does not remedy; disassemble tail wheel. Make sure internal parts are not broken or worn to the point they do not provide consistent operation of the lock-out or brake over to full swivel motion. Complete and proper assembly / reassembly is critical to the proper function and safety of the tail wheel. We urge you to contact Found Aircraft Canada with any questions relating to the tail wheel. Tail wheel shimmy during landing or take off Tire out of balance. Tire for out of round. Abnormal or uneven tread wear. Low tire pressure. Boom to fuselage connection loose. Rudder and tail wheel misaligned. Bearing pre-load set too low. Replace tire. Replace tire. Replace tire. Set tire pressure to 50 p.s.i. Replace rubber grommet at forward end and tightened main bolt. Correct steering cable rigging. Set torque to 15 in-lbs min then, if required, continue clockwise to access cotter pin hole Page 3 November 21, 2011

54 Tail Wheel Assembly (All Types) Removal and Installation Step 1. Step 2. Step 3. Step 4. Jack or trestle the tail of aircraft as required. See Chapter 7 for instructions. Disconnect the tail wheel steering cables at the tail wheel. Disconnect the tail wheel lock cable, if equipped. Disconnect and remove the two bolts which hold the tail wheel assembly to the tail wheel boom. The tail wheel assembly is now free. See Figure To install the tail wheel assembly, reverse above steps. An anti-seize compound or thick grease is recommended at installation on the tail boom to preclude corrosion Tail Wheel Boom (All Types) Removal and Installation Step 1. Step 2. Step 3. Step 4. Step 5. Lift the tail of aircraft. See Chapter 7 for instructions. Disconnect the tail wheel steering cables at the tail wheel. Gain access to the forward end of the tail boom through the interior of the aft fuselage and remove the cotter pin. See Figure Support the tail boom in such a manner that further disassembly will not cause damage to the tail boom assembly. Remove the bolt from the tail boom support bracket, slide tail boom aft about two inches. The tail boom is now free. To install the tail boom reverse the above steps. Ensure that the rubber grommet at the forward end of the boom is not displaced during reinstallation Tail Wheel Steering Cables (All Types) Removal and Installation Step 1. Remove the inspection covers FP1 and FS1, (see figure or ). Step 2. Disconnect the tail wheel steering cables by removing the clevis bolts from the steering arms of the tail wheel, (see Figure ). Replace the cotter pins upon reassemble. Step 3. Referencing Figure , remove the bolts securing the pulley wheels to the fuselage, (this will allow the cable thimbles to pass through the fuselage) Page 4 November 21, 2011

55 Step 4. Disconnect the bolts securing the springs to the rear quadrant and remove the cables with the springs and links, (see Figure ). The cables may now be removed from the springs. To install the cables reverse the above steps. Keep in mind the following points; Always install new cotter pins. Reference Figure for cable tension specifications. When installing new factory cables the technician will need a nicopress tool. The thimble is not installed to allow the tension to be hand set to 0 lbs with limited slack Tail Wheel & Tire (All Types) Removal and Installation Step 1. Step 2. Step 3. Lift the tail of aircraft as required. See Chapter 7 for instructions. Deflate the tire. Remove axle bolt from tail wheel assembly. Note: There are spacers and washers installed which may fall free when the bolt is removed, so note location of hardware before removing the bolt. Tail wheel is free. To install tail wheel reverse above steps Page 5 November 21, 2011

56 Figure Tail Wheel Steering Cable Attachment Figure Tail Wheel Steering Cables Tension Specification Page 6 November 21, 2011

57 Figure Tail Wheel Steering Cables Fuselage Connections Page 7 November 21, 2011

58 Phenolic Washer Installation in U1009 Tail Wheel Assembly Figure shows the general arrangement of the U1009 Tail Wheel Assembly in an exploded format. Step 1. With reference to Chapter Lifting the Tail, lift and secure the aircraft s tail. Step 2. Removal of the tail wheel assembly from the tail boom, see section Step 3. Remove the tail wheel see section Step 4. Next remove the bracket assembly, (1); reference Figure First remove the cotter pin, (3). Next, remove the castle nut and washer, (17) & (16). The bracket assembly may now be removed. Step 5. Figures & -07 show a method for the removal of the cone bearing, (4). Figure shows the location of the two thru holes on the bottom of the fork assembly thru which a 5/32 drift is to be inserted and shows the correct placement of the drift and socket for the bearing removal. This step is best accomplished with the help of a second person to hold the assembly and socket while the first person taps gently on the drift, alternating between the thru holes until the cone bearing is completely free as indicated by Figure Note: The removal of the bearing will damage the spacer, (5), requiring that it be replaced during reassembly. Step 6. Step 7. Step 8. It is necessary to degrease/clean certain parts to be bonded. Note, with regard to the fork assembly clean only the indicated surfaces as seen in Figure Do not use excessive solvent/cleaner as the fork assembly contains other greased parts which would require re-greasing if diluted. Bond the steel washer, (7), to the phenolic washer, (8). Use a quality two part epoxy. Be certain to read and follow the directions given with the epoxy, including the requirement to rough the bonding surfaces. Do not use an excessive amount of epoxy. Any excess epoxy must be cleaned/removed. Next step is to bond the phenolic washer (10) to its mating surface on the fork assembly. Again, use a quality two part epoxy. Be certain to read and follow the directions given with the epoxy, including the requirement to roughen the bonding surfaces. An exception to this procedure is to not sand or abrade the surface of the fork assembly. Do not use an excessive amount of epoxy. Any excess epoxy must be cleaned/removed Page 8 November 21, 2011

59 Step 9. Reassembly the tail wheel in the reverse order to the aforementioned procedures with the following points in mind. Install the pawl, (12) per Figure with the long side down. If an appropriate bearing press is not available a 1 1/8 socket can be used to gently reseat the bearing per Figure Again, the spacer, (5), must be replaced. Replace the two cotter pins removed during disassembly with new ones. Torque castle nuts, (both wheel and bracket), 15 in-lbs minimum. Then if required continue clockwise to access cotter pin hole Page 9 November 21, 2011

60 Figure General Arrangement Page 10 November 21, 2011

61 Figure Setup Cone Bearing Removal Page 11 November 21, 2011

62 Figure Bearing Removal Figure Fork Assembly - Bonding Surface Page 12 November 21, 2011

63 Figure Pawl Installation Detail Figure Cone Bearing Installation Page 13 November 21, 2011

64 Figure Cotter Pin Installation Preferred Method Page 14 November 21, 2011

65 Heavy Duty (HD) Tail Wheel Assembly 1. CAP ASSEMBLY 2. STEERING ARM ASSY. 3. DAMPER 4. DAMPER HOLD DOWN 5. SCREW 6. PRESSURE PLATE 7. ROLL PIN 8. STOP 9. SPRING 10. LOCK PIN ASSY 11. CAM 12. FORK 13. SCREW 14. TIRE 15. BOLT 16. WASHER, FLAT 17. AXLE SPACER 18. AXLE 19. NUT 20. COTTER PIN 21. WHEEL 22. BUSHING 23. BELVILLE WASHER 24. NUT 25. COTTER PIN 26. BOLT 27. WASHER, CSK. 28. BUSHING 29. TAIL WHEEL LOCK 30. WASHER, FLAT 31. NUT A ,9, OPTIONAL LUBRICATE WITH GENERAL PURPOSE GREASE DETAIL A Figure HD Tail Wheel Assembly Page 15 November 21, 2011

66 INTENTIONALLY LEFT BLANK Page 16 November 21, 2011

67 32-42 BRAKES Each of the main wheel brakes is independently operated by brake pedals mounted on the left hand side rudder pedals. Each brake pedal is connected by a simple linkage system to an actuator, which has a line that is routed directly to its respective brake unit Brake Bleeding for Dual Brakes Pressure Pot Method Note: The Pressure Pot must be at least 4 l (1U.S. Gal). Description is given for starboard side brake, port side bleeding is identical by using left brake assembly and left brake pedals. Step 1. Remove filler cap from reservoir and install a V8 NPT nipple. Install a hose on the nipple leading to a suitable container of at least 4 l capacity. Step 2. Loosen the bleed screw on the brake assembly (1 to 3 turns) and place the hose line from pressure pot on bleed screw. Step 3. Pump until the fluid pumps from the reservoir. CAUTION: Ensure that the pressure pot fluid does not drop below ¼ full or air may be introduced into the brake system. Step 4. With the pressure pot still connected, press the Co-pilot s right pedal and release, continue pumping fluid until satisfied that no air entrapment remains and fluid pumps freely. Step 5. With the pressure pot still connected, repeat with the Pilot s right pedal until satisfied that no air entrapment remains and fluid pumps freely. Step 6. Release pressure from the pressure pot and tighten bleed screw, remove the hose line from the bleed screw. Step 7. Repeat for the port side. Step 8. Check pedal height and pressure, repeat procedure if necessary Bleeding the Brake METHOD A Step 1. Step 2. Step 3. Step 4. Step 5. Note : Ensure that the aircraft is chocked. Release the parking brake. Ensure that the hydraulic reservoir located on the forward side of the engine firewall is full. Fully depress the brake pedal and hold in this position. Release the Bleed screw on the brake unit until all pressure is released then tighten. Repeat steps 3 and 4 until there is no evidence of air left in the system. Check level of the fluid in the hydraulic reservoir. If steps 3 and 4 are done more than twice check the level of the fluid in the hydraulic reservoir after step Page 1

68 Step 6. Step 7. Function test toe brakes for sponginess. Apply parking brake and attempt to move aircraft. Brakes should hold. METHOD B This method is preferred over METHOD A. Note: Ensure the Brake reservoir is at least ¾ empty before carrying out this procedure for each brake that is bled. Step 1. Step 2. Step 3. Step 4. Ensure that the aircraft is chocked. Release the parking brake. Place a rubber hose, attached to a pressure pot, over the brake bleed valve. Pressurize the pressure pot, and then slowly loosen the bleed valve until fluid begins to flow into the brake unit. Pump fluid into the brake unit until the brake reservoir is between ½ full and ¾ full. CAUTION: Do not over fill the reservoir or it will spill into the engine compartment. Step 5. Step 6. Step 7. Step 8. Tighten the bleed valve. Remove hose. Function test toe brakes for sponginess. Apply parking brake and attempt to move aircraft. Brakes should hold. Check fluid level in brake reservoir Removal and Installation of Brake Assembly Step 1. Step 2. Step 3. Step 4. Ensure that the aircraft is chocked. Ensure that the Parking Brake is released. Remove the hydraulic line from the brake assembly taking care to catch spilled fluid. Cap all lines and fittings. If desired the brake can be removed without removing the brake line. Remove the four fasteners which hold the brake pads to the brake unit, pads will fall free. Brake assembly is now free. To install brake assemble reverse the above steps and bleed the brake(s) per Chapter or Page 2

69 Brake Wear Limits The minimum thickness of the brake disk is The minimum thickness of the brake pads is If the brake pad attachment rivets are exposed before the minimum thickness is attained the brake pads must be replaced before the aircraft is taxied Page 3

70 Coupling Nut Socket Adapter Typ. Flex Line Figure : Brake Lines Installation (2C1 & 2C2) Page 4

71 BRAKE FLUID RESERVOIR PARKING BRAKE VALVE L/H BRAKE PEDAL R/H BRAKE PEDAL PORT WHEEL = FLUID FLOW DIRECTION STBD. WHEEL Figure : Single Brakes Schematic (2C1 & 2C2) Page 5

72 BRAKE FLUID RESERVOIR T T PILOT'S L/H BRAKE PEDAL PARKING BRAKE VALVE PILOT'S R/H BRAKE PEDAL CO-PILOT'S L/H BRAKE PEDAL CO-PILOT'S R/H BRAKE PEDAL SHUTTLE VALVE SHUTTLE VALVE = FLUID FLOW DIRECTION PORT WHEEL STBD. WHEEL Figure : Dual Brakes Schematic (2C1 & 2C2) Page 6

73 Series Dual Brake System This section is applicable to A/C serial #57 and on with dual brakes installed or any A/C with SI implemented and all 2C3 and 2C4 aircraft. This brake system arrangement uses the same basic components as previous configurations. The general arrangement is shown in Figure The brake fluid reservoir feeds a brake manifold which connects to the reservoir side of the co-pilot s master brake cylinders. The pressure side of these cylinders are then routed over to the corresponding pilot s master brake cylinders reservoir inputs. The output lines from the pilot s side master cylinders are then connected to the park valve. Finally, the output lines from the park brake valve are routed to the brake callipers of the landing gear system installed on the aircraft, (wheels, skis, amphibian floats) Page 7

74 Figure : Series Dual Brake System, Hydraulic Schematic Page 8

75 32-71 AEROCET 3500 & 3500L FLOATS Inspection before Installation Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. Step 7. Step 8. Ensure that all water has been removed from the floats. Carry out a visual inspection of each float compartment for obvious damage and cleanliness. Inspect the bottoms of floats for cracks, chips, crazing of the Gel coat. Inspect all deck fittings for evidence of corrosion and general condition. Inspect all strut fittings for evidence of corrosion and general condition. Inspect all water rudder cables for fraying and corrosion. Inspect all cable pulleys and fairleads for freedom of movement and condition. Inspect water rudders for freedom of movement and general condition of hinges, springs and stops. All hardware used for float installation must be free of defects and corrosion Installation Step 1. All bolts and clevis pins must have a light coating of grease applied to them before installation. Step 2. Do not tighten hardware until the correct rigging of the floats has been established. Step 3. It may be required to rock the floats, or to raise or lower the aircraft in order to install strut bolts. Ensure that floats, aircraft and personnel are not endangered while doing this. Step 4. Depending on aircraft attitude while suspended, either the forward or aft strut may be installed first, but the centre strut must be installed last. Step 5. Remove the main landing gear assembly per Chapter Step 6. The belly of aircraft should be about 55 to 58 above floor level. Step 7. Position the floats under the aircraft about 10 feet apart. Step 8. The forward spreader bar is marked with an F in the center of the lower surface. The back spreader bar is marked with a B in the center of the lower surface. Step 9. Spread a thin film of grease both on the inside of the spreader bar sockets (forward and back on both floats) and the unpainted ends of the spreader bars. CAUTION: Be very careful not to slide the spreader bars past the bolt holes otherwise damage could result to the outside of the float. Step 10. Step 11. Slide both the forward and back spreader bars into the sockets on one float until you can drop the two ½ bolts into position. Support the opposite end of the spreader bars so that the spreader bars are roughly level Page 1

76 Step 12. Step 13. With one person on each of the spreader bars, and at least one person on each end of the remaining float, introduce the spreader bars into the spreader bar sockets taking great care to keep the spreader bars and the deck parallel to each other. It may be necessary to rock or tilt the floats gently a bit to insert the spreader bars fully into the sockets. CAUTION: Be very careful not to slide the spreader bars past the bolt holes otherwise damage could result to the outside of the float. Step 14. Spread a thin film of grease on the bolts before installing them. Step 15. Mask off as required around the spreader bars and apply a polyurethane sealant. Step 16. Place the floats in their approximate position under the aircraft. Step 17. Position the forward float strut (on either side) on the forward strut fuselage fitting and install the upper bolt. Do not tighten. Step 18. Position the forward float strut on the forward deck fitting and install the lower bolt. Do not tighten. Step 19. Position the forward float strut (on other side) on the forward strut fuselage fitting and install the upper bolt. Do not tighten. Step 20. Position the forward float strut on the forward deck fitting and install the lower bolt. Do not tighten. Step 21. Repeat the struts installation for the aft struts. Step 22. Repeat the struts installation for the centre struts. Step 23. Attach the forward flying wires to the forward fly wire fuselage pickup and the forward float fitting. Step 24. Attach the aft flying wires to the aft fly wire fuselage pickup and the aft float fitting. Step 25. Adjust the flying wires to achieve dimensions shown in Figure Step 26. Tighten all spreader bars and strut hardware, install safety devices as required. Step 27. Install one step on each outboard side of float struts. Step 28. Attach the Port float water rudder steering cable to the Starboard rudder steering cable (See Figure ). Install safety devices as required. Step 29. Attach the Starboard float water rudder steering cable to the Port rudder steering cable (See Figure ). Install safety devices as required. Step 30. Attach the water rudder balance cable to both water rudders (See Figure ). Step 31. Move the rudder pedals in the cockpit and ensure both of the water rudders move in the same direction as each other AND the same direction as the air rudder. Ensure that water rudders hit turn stops, but do not restrict the travel of the air rudder. Step 32. Install the water rudder lift mechanism on the cabin floor between the forward cabin seats. (See Figure ). Step 33. Attach the water rudder lift cable to the lift mechanism, adjust for correct travel, and install safety devices as required Page 2

77 Step 34. Remove the tail wheel and tail boom assembly per Chapter Step 35. Install ventral fin by placing under the belly of the aircraft and aligning holes in ventral fin with holes in belly. Secure with screws (See Figure ). Step 36. Install finlets on top of horizontal stabilizer by placing finlets on top of the horizontal stabilizer and aligning the holes in the three brackets on the bottom of each finlet with the holes on the top of the horizontal stabilizer (See Figure ). Step 37. Reinstall the main landing gear beam panel B1 (Reference Figure ). Step 38. Install the float strut to fuselage fairings. Step 39. Change rudder deflection limits per Table or Page 3 July 7, 2011

78 1. FLYING WIRE ASSY. 2. PORT LINK 3. STBD. LINK 4. STRAIGHT PIN 5. WASHER 6. COTTER PIN 7. WIRE PULL Figure A: Flying Wires Page 4

79 1. FORWARD STRUT ASSY. 2. DIAGONAL STRUT ASSY. 3. AFT STRUT ASSY. 4. EYE BOLT 5. NAS BOLT 6. CSK. WASHER 7. WASHER 8. LOCK NUT 9. SPACER * CSK. WASHER UNDER BOLT HEAD Figure B: Struts Installation Page 5

80 Figure : Control Cables Installation Page 6

81 Figure : Balance Cable Installation Page 7

82 Figure : Water Rudder Lifting Mechanism Page 8

83 Figure A: Ventral Fin Installation (2C1 & 2C2) Page 9

84 Ventral fin mount Secured 3 Places each side Ventral fin Figure B: Ventral Fin Installation (2C3 & 2C4) Page 10

85 Figure A: Finlets Installation (2C1 & 2C2) Page 11

86 Horizontal stabilizer Finlet mounts Figure B: Finlet Installation (2C3 & 2C4) Protection after Removal All deck fittings, cables; strut fittings shall have a thin coat of grease applied to prevent corrosion. If the struts and/or floats are to be stored outdoors, ensure that upper ends of struts and spreader bar sockets (if spreader bars are removed) are covered in such a manner that water can not enter and be trapped thereby causing damage Page 12

87 32-72 AEROCET 3400 FLOATS The Aerocet 3400 Amphibious Floats are an all composite hulls separated by spreader bars which incorporate hydraulically operated retractable landing gear allowing for landing on either water or land. An airframe mounted electric-hydraulic pump, with a backup hand pump operates the hydraulics. Each float has a single large storage locker. Including the locker, there are a total of 6 compartments in each float. The storage locker is accessed through a quick release hatch cover. The remaining 5 compartments are accessed through screw on covers. Water rudders are mounted to the stern of each float for water taxi operation. The floats incorporate pump locations into each compartment and these are used to remove any excess water which may accumulate through condensation. The main landing gear utilizes a trailing arm link design using a 6.00 X 6 tire and oleo shock strut. The nose gear is full swivelling, has a centring device, and uses a composite strut for absorbing the landing loads. On land, 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 positions, a pump operation light, and an audio output to advise the pilot of gear position when triggered at a set speed. The parts to retro fit the Aerocet 3400 amphibious floats may be acquired locally, or from Found Aircraft Canada Inc., but a list of the parts must be obtained from Inc. The Aerocet Document A Service Manual and Instructions for Continued Airworthiness for Aerocet 3400 Amphibious Seaplane Floats is required for instructions on component inspection, removal, installation, maintenance, and continued airworthiness. For reference purposes in this document it shall be referred to as Aerocet Manual Inspection before Installation Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. Step 7. Step 8. Ensure that all water has been removed from the floats. Carry out a visual inspection of each float compartment for obvious damage and cleanliness. Inspect the bottoms of floats for cracks, chips, crazing of the Gel coat. Inspect all deck fittings for evidence of corrosion and general condition. Inspect all strut fittings for evidence of corrosion and general condition. Inspect all water rudder cables for fraying and corrosion. Inspect all cable pulleys and fairleads for freedom of movement and condition. Inspect water rudders for freedom of movement and general condition of hinges, springs and stops. All hardware used for float installation must be free of defects and corrosion Page 1

88 Step 9. Step 10. Step 11. Step 12. All lines, hoses and wires for general condition and security. All rubber hoses for date of manufacture. Tires for general condition and wear. Lubricate landing gear pivot points. Clean, inspect and repack all wheel bearings Float Preparation Note: Float preparation may already be accomplished if the floats have been previously installed and removed from the aircraft. If floats are already assembled, proceed to Float Installation. Step 1. Step 2. Position the floats about 10 feet apart. Spread a thin film of grease both on the inside of the spreader bar sockets (forward and back on both floats) and the ends of the spreader bars. CAUTION: Be very careful not to slide the spreader bars past the bolt holes otherwise damage could result to the float. Step 3. Step 4. Step 5. Step 6. Slide both the forward and back spreader bars into the sockets on one float until you can drop the three bolts into position. Support the opposite end of the spreader bars so that the spreader bars are roughly level. With one person on each of the spreader bars, and at least one person on each end of the remaining float, introduce the spreader bars into the spreader bar sockets taking great care to keep the spreader bars and the deck parallel to each other. It may be necessary to rock or tilt the floats gently a bit to insert the spreader bars fully into the sockets. CAUTION: Be very careful not to slide the spreader bars past the bolt holes otherwise damage could result to the float. Step 7. Step 8. Step 9. Place the deck fittings in the correct position. Spread a thin film of grease on the spreader bar bolts before installing them through the deck fittings into the spreader bars. Install the brake lines inside of the forward struts. Install the actuator lines inside of the aft struts Page 2

89 Floats Installation Note: All bolts and clevis pins must have a light coating of grease applied to them before installation. Do not tighten hardware until the correct rigging of the floats has been established. It may be required to rock the floats, or to raise or lower the aircraft in order to install strut bolts. Ensure that floats, aircraft and personnel are not endangered while doing this. Step 1. Remove the main landing gear assembly per Chapter Step 2. The belly of aircraft should be about 58 to 62 above floor level. Step 3. Position the forward float strut (on either side) on the fuselage fitting and install upper eye bolt, Figure Step 4. Install the lower bolt in the forward strut through the forward deck fitting. Step 5. Position the forward float strut (on other side) on the fuselage fitting and install upper eye bolt. Step 6. Install the lower bolt in the forward strut through the forward deck fitting. Step 7. Repeat the struts installation for the centre struts. Step 8. Repeat the struts installation for the aft struts. Step 9. Attach the forward flying wires to the forward fly wire fuselage pickup eye bolt and the forward float fitting. Step 10. Attach the aft flying wires to the aft fly wire fuselage pickup and the aft float fitting. Step 11. Adjust the flying wires to achieve dimensions shown in drawing, Figure Note: Measure from the rear of one of the floats to a position on the aft fuselage (position can be a lower corner, or centreline). Measure from the same position on the opposite float to a corresponding location on the other side of the fuselage. Both of these measurements should be similar to each other. Adjust the flying wires to obtain similar measurements. Step 12. Torque spreader bar bolts to 25 foot pounds. Tighten all strut hardware, install safety devices as required. Step 13. Attach the Port float water rudder steering cable to the Starboard rudder steering cable (See Figure ). Install safety devices as required. Step 14. Attach the Starboard float water rudder steering cable to the Port rudder steering cable (See Figure ). Install safety devices as required. Step 15. Attach the water rudder balance cable to both water rudders (See Figure ). Step 16. Move the rudder pedals in the cockpit and ensure both of the water rudders move in the same direction as each other AND the same direction as the air rudder. Ensure that water rudders hit turn stops, but do not restrict the travel of the air rudder Page 3

90 Step 17. Install the water rudder lift mechanism on the cabin floor between the forward cabin seats. (See Figure ). Step 18. Attach the water rudder lift cable to the lift mechanism, adjust for correct travel, and install safety devices as required. Step 19. Remove the tail wheel and tail boom assembly per Chapter Step 20. Install ventral fin (See Figure ). Step 21. Install the water stops while installing the ventral fin. (See Figure ). Step 22. Install finlets on top of the Horizontal stabilizer (See Figure ). Step 23. Install one step on each outboard side of float struts. (See Figure ). Step 24. Install the main landing gear close out panels. Step 25. Install the float strut to fuselage fairings. Step 26. Check tire inflation pressure. Step 27. Change rudder deflection limits per Table or Page 4

91 1. FORWARD STRUT ASSY. 2. DIAGONAL STRUT ASSY. 3. AFT STRUT ASSY. 4. EYE BOLT 5. NAS BOLT 6. CSK. WASHER 7. WASHER 8. LOCK NUT 9. SPACER * CSK. WASHER UNDER BOLT HEAD Figure : Struts Installation Page 5

92 1. FLYING WIRE ASSY. 2. PORT LINK 3. STBD. LINK 4. STRAIGHT PIN 5. WASHER 6. COTTER PIN 7. WIRE PULL Figure : Flying Wires Page 6

93 Figure : Control Cables Page 7

94 Figure : Balance Cable Page 8

95 Figure : Water Rudder Lifting Mechanism Page 9

96 Figure A: Ventral Fin Installation (2C1 & 2C2) Page 10

97 Ventral fin mount Secured 3 Places ea side Ventral fin Figure B: Ventral Fin Installation (2C3 & 2C4) Page 11

98 1. FWD. WATER STOP 2. AFT WATER STOP 3. BOLT 4, WASHER 5. LOCK NUT Figure : Water Stop Installation Page 12

99 Figure : Finlet Installation (2C1 & 2C2) Page 13

100 Horizontal stabilizer Finlet mounts Finlet Figure B: Finlet Installation (2C3 & 2C4) Page 14

101 1. STEP 2. STEP STRUT 3. LUG AT FUSELAGE 4. STRUT LUG 5. SPACER 6. BOLT 7. WASHER 8. NUT Figure A: Step Installation 1 (2C1 & 2C2) Page 15

102 Figure B: Step Installation 2 (All models) Page 16

103 Brake Line Replacement The brake system utilizes the same system as the landplane with the exception of running the brake lines down the inside of the forward strut instead of down the gear leg. Internal lines in the strut are connected to fittings on the float at the forward strut. Internal float brake lines are provided by Aerocet Inc. The brake system reservoir is located on the forward face of the firewall on the left hand side. Reference Maintenance Manual Chapter for brake system information. One port and one starboard brake line must be removed and a new part brake line installed. This does not have to be done at a specific point in the installation and is left to the installer to determine the best time to accomplish. Instructions are applicable to single and dual brakes. Step 1. Remove the pilots side Kydex panel in front of the rudder pedals. Remove the header tank cover from the right hand side. Step 2. Remove both of the cockpit floors. Reference Chapter Aircraft s/n Step 3a (Single Brake System) Disconnect the Port brake line, P/N B25-2 from the bulkhead fitting on the belly pan and the parking brake valve. Reference Figure , Item 1. Step 3b (Dual Brake System) Disconnect the Port brake line, P/N B81 from the bulkhead fitting on the belly pan and the T fitting below the parking brake valve. Reference Figure , Item 1. Step 4a (Single Brake System) Install new Port brake line, P/N B109 from the parking brake valve to the brake line fitting located in the port firewall corner box. Reference Figure , Item 1. Step 4b (Dual Brake System) Install new Port brake line, P/N B67 from the T fitting below the parking brake valve to the brake line fitting located in the port firewall corner box. Reference Figure , Item 1. Aircraft s/n 55 and on Step 3. Remove the cap from the T on the Port brake line. Reference Figure A and A, Item 1. Step 4. Install B127 brake line. Reference Figure A and A, Item 1. Step 5a (Single Brake System) Remove the cap from the T on the Starboard brake line. Reference Figure and A Item Page 17

104 Step 5b (Dual Brake System) Remove the B79 aluminium line on the Starboard brake line. Reference Figure and A, Item 2. Step 6. Install new Starboard brake line, P/N B69 from the T fitting to the brake line fitting located on the starboard firewall corner box. Reference Figure , A, , A, Item 2. Step 7. Bleed the brake system. Reference Maintenance Manual Chapter Page 18

105 Figure : Single Brake System (Aircraft S/N 28-54) Page 19

106 Figure A: Single Brake System (Aircraft S/N 55 and On) Page 20

107 Figure : Dual Brake System (Aircraft S/N 28 54) Page 21

108 Figure A: Dual Brake System (Aircraft S/N 55 and On) (2C1 & 2C2) Page 22

109 brake line connection to float brake line connection to float Figure B: Dual Brake System (2C3 & 2C4) Controller When working on the pitot-static system, care must be taken to ensure that no undue force is placed on any of the lines so as not to kink a line or to change its routing to chafe against other lines or structure. Failure to do so may cause failure of the pitot system. Controller Removal Step 1. Step 2. Step 3. Step 4. Remove the four #6 screws that hold the controller to the instrument panel. With the screws removed, the controller can be lowered below the instrument panel. Disconnect the Pitot line from the rear of the controller. Cap the line and fitting. Disconnect the Static line from the rear of the controller. Cap the line and fitting. Disconnect the electrical D connector from the rear of the controller. The controller is now free. Controller Installation Step 1. Step 2. Step 3. To install the controller, reverse the removal Steps. Carry out a Pitot Static leak test. During the Pitot Static test verify that the audio warning comes on at 75 knots. The speed may be adjusted by means of a small slotted set screw in the face of the controller located just above the gear selector handle. Turning the screw clockwise will increase the speed. The allowable limits for the audio warning is 75 to 80 knots. Carry out an extension/retraction test Page 23

110 PITOT STATIC Figure : Controller Installation Page 24

111 Electrical Installation At any time the floats are being worked on ensure that the aircraft is electrically safe. This may require the battery to be disconnected to prevent inadvertent activation of the gear. If electrical power is required to carry out troubleshooting or function checks, ensure that the aircraft is blocked or jacked (reference the Aerocet Manual) and that all personnel are clear. Refer to Section for retraction and extension tests after any electrical work is carried out. The electrical system consists of a controller, electric hydraulic pump, gear position sensors, circuit breakers, and a fuse. Circuit Breakers & Fuses There are 3 circuit breakers and 1 fuse in the electrical system. The Gear Motor circuit breaker is located on the right hand instrument panel. This circuit breaker is rated at 25 amps and provides power to the motor via two motor control relays in the aft fuselage. If this breaker trips the electric hydraulic pump will not operate, the audio warnings will still operate, and gear indication is still available. The gear can be raised or lowered using the hand pump. The Gear Control circuit breaker is located on the top row, 4 th from the left. This circuit breaker is rated at 1 amp and provides power to the two motor control relays in the aft fuselage. If this breaker trips gear position indication lights will still operate, the audio warnings will still operate, but the electric hydraulic pump will not operate. The gear can be raised or lowered using the hand pump. The Gear Advisory circuit breaker is located on the right hand instrument panel. This circuit breaker is rated at 1 amp and provides power to the position sensors in the floats, the lights in the controller and the audio portion of the controller. If this breaker trips the electric hydraulic pump will still operate, there will be no gear position indication lights, the audio warnings will not operate. The gear can be raised or lowered using the hydraulic pump or the hand pump. There is a 1 amp fuse located on the relay panel in the aft fuselage. This fuse provides power to illuminate the Pump ON light on the controller. If this fuse blows there will be no indication that the pump is on Page 25

112 Motor Control Relays The motor control relays are located in the aft fuselage on the right side of Former The motor control relays provide power to the electric hydraulic pump. To replace a relay, simply pull it straight up. The new relay may be installed by pushing it firmly in place. When a motor control relay is changed carry out a retraction & extension test (reference Section ) Page 26

113 RIGHT FLOAT ASS'Y 85 87a a UP DN To Air Frame Gnd (Control Consol) 2 3 To Air Frame Gnd 1 Orange 2 3 Black M A I N B U S Hydraulic Ports (Frt Of Pump) "UP" "DN" PRESSURE SWITCH Hydraulic Pump (Top View) 1 PRESSURE SWITCH 3 3 LEFT FLOAT ASS'Y (Ref. Pump Mounting Boss) To Air Frame Gnd (Control Consol) a Figure : Airframe Electrical Schematic Page 27

114 INTENTIONALLY LEFT BLANK Page 28

115 Figure : TSO Wiring Schematic (Aerocet Dwg No. 35A-46010) Page 29

116 INTENTIONALLY LEFT BLANK Page 30

117 Hydraulic Installation At any time the floats are being worked on ensure that the aircraft is electrically safe. This may require the battery to be disconnected to prevent inadvertent activation of the gear. If electrical power is required to carry out troubleshooting or function checks, ensure that the aircraft is blocked or jacked (reference the Aerocet Manual) and that all personnel are clear. Ensure that residual hydraulic pressure is bled off before loosening any fitting. Refer to Section for retraction and extension tests after any hydraulic work is carried out. Bleeding The Actuation System The reservoir must be filled with MIL-H-5606 hydraulic fluid. Start with the gear in the full down position. Step 1. Step 2. Fill the reservoir to ¾ full as indicated by the sight glass on the reservoir. Select gear UP on the hand pump selector and begin hand pumping. This will result in the gear retracting on each of the four positions. If the gear does not begin to retract, the hydraulic connections on the floats should be reversed. CAUTION: Place the hand pump selector in the neutral position to relieve system pressure before disconnecting hydraulic lines. Step 3. Step 4. Step 5. Place the hand pump selector in the UP position and hand pump the gear to the full retract position. Monitor the sight glass while operating the pump - the fluid level must remain visible in the sight glass at all times - replenish as required. Place the hand pump selector in the DOWN position and hand pump the gear to the full extend position. Monitor the sight glass while operating the pump - the fluid level must remain visible in the sight glass at all times - replenish as required. Complete the DOWN cycle. Repeat Steps 3 and 4 one more time. The system is now bled Page 31

118 Electric Pump The hydraulic pump is located in the aft fuselage on the right hand side at about Station 129. It is attached to a mounting bracket with two bolts. The mounting bracket is mounted to the side of the fuselage with four screws. Hydraulic Pump Removal Step 1A. Gain access to the pump by removing the aft wall of the interior. The aft wall is attached with screws. Step 1B. For aircraft that have a baggage shelf installed, remove the aft wall of the baggage compartment. The aft wall is attached with screws. Step 1. Disconnect the return line at the bottom of the unit. Have a cap ready as hydraulic fluid will come out of the fitting when the line is removed. Step 2. Disconnect the Pressure UP and DOWN lines from the T fittings. Cap and plug all lines and fittings. Step 3. Locate the Terminal Block on the bottom of Former Disconnect the 2 wires from each of the two pressure sensor and the grounding wire (total of 5 wires). Step 4. Locate the four screws which attach the bracket to the aircraft structure and remove them. The pump assembly is now free Page 32

119 LOCKWIRE FOR SAFETY Figure : Hydraulic Pump Installation Page 33

120 Hydraulic Pump Installation Step 1. To install the pump reverse the removal Steps. Step 2. Locate the slot head filler plug at the top of the reservoir and remove it. Fill the reservoir with MIL-H-5606 hydraulic fluid until the level in the sight glass is about 1 from the bottom. Step 3. Ensure the aircraft is blocked or jacked per Aerocet Manual. Step 4. Carry out a retraction and extension test, Reference Section Hand Pump The hand pump is located in the cockpit on the floor between the two forward seats on the hand pump console. The hand pump assembly has a selector valve to allow up or down gear selection and a lever to pump the gear to the desired position. Hand Pump Removal Step 1. Step 2. Step 3. Step 4. Remove the pump console aft cover. Remove the pump console forward cover. Remove the pump console side cover. Remove the forward right hand floor. Reference Maintenance Manual Chapter Disconnect the three hydraulic lines from the system one at a time. Reference Figure CAUTION: Hydraulic fluid will flow freely from the fitting as soon as the line is removed. Have caps ready to install as soon as each line is removed. Step 5. Disconnect the three hydraulic lines from the hand pump. Cap and plug all lines and fittings. Step 6. Remove the two bolts which secure the hand pump to the pump attach bracket. The pump is now free. Step 7. Remove the water rudder lifting handle by removing the eight screws which secure it to the pump console. The water rudder lifting cable must be cut at close to the nico press fitting as possible. The water rudder lifting handle can now be lifted free. Step 8. Remove the water rudder lifting cable pulley cover and install cover. Step 9. Reinstall the right hand forward floor. Reference Maintenance Manual Step 10. Install pump console forward cover, aft cover and side cover Page 34

121 Figure A: Hand Pump Installation (2C1 & 2C2) Page 35

122 Mount angle Pump Mount clip Resivior line Deployment line Retraction line Figure B Hand Pump Installation (2C3 & 2C4) Page 36