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Priest River, Idaho 83856 Phone: (208) 448-0400 Fax: (208) 448-1644 This ICA must be followed when Aerocet 5850 Floats are installed in accordance with Supplemental Type Certificate (STC) No. SA01722SE . The information contained in this document supplements or supercedes the basic manuals only in those areas listed herein.
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ISSUE Incorporated PAGE 10/17/06 2 of 81 DATE: FILE NO. ICA Maintenance Manual for A-10034 TITLE: REVISION REVISION 5850 Floats on a SUBTITLE: DATE: DHC-2, Beaver 9/10/12 This page intentionally left blank...
1. INTRODUCTION Thank you for choosing Aerocet Floats. This manual covers the installation and maintenance of the 5850 floats as installed on the DHC-2 Beaver airplane, including instructions for installing the struts, steps, water rigging, and float structure. An IPC is also provided.
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OEM and other approved cockpit handles, is installed in the standard manner. Figure 1.1.2 Side View of Model 5850 Floats on a DeHavilland DHC-2 "Beaver" Each float is attached to the airplane by forward, mid, and aft struts. An attachment block is bolted to the upper end of the forward strut.
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DATE: FILE NO. ICA Maintenance Manual for A-10034 TITLE: REVISION REVISION 5850 Floats on a SUBTITLE: DATE: DHC-2, Beaver 9/10/12 Figure 1.1.3 General Float Terms Figure 1.1.4 Front View of Floats and Rigging Figure 1.1.5 Model 5850 Float, Side View...
This manual is organized as follows: Maintenance Manual. Instructions and information necessary to maintain, install, and remove the Aerocet Model 5850 Twin Seaplane Floats on a DeHavilland DHC-2 Beaver airplane. This dovetails into existing sections of the DeHavilland Maintenance Manual, PSM 1-2-2.
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PAGE 10/17/06 11 of 81 DATE: FILE NO. ICA Maintenance Manual for A-10034 TITLE: REVISION REVISION 5850 Floats on a SUBTITLE: DATE: DHC-2, Beaver 9/10/12 certification, mandatory inspection times for type certification and inspection procedures for those approved mandatory times.
9/10/12 1.3. Availability: One complete copy of this manual shall be provided with each new set of Aerocet Model 5850 floats. Additional copies and minor revisions shall be available via email, U.S.P.S (Mail), UPS or FedEx by request. Fees and delivery charges may apply.
13 of 81 DATE: FILE NO. ICA Maintenance Manual for A-10034 TITLE: REVISION REVISION 5850 Floats on a SUBTITLE: DATE: DHC-2, Beaver 9/10/12 2. MAINTENANCE MANUAL 2.1. Lubrication Replaces paragraph 1.29 of the DeHavilland Maintenance Manual, PSM 1-2-2. None required. Corrosion protection covered in the Instructions for Continued Airworthiness (ICA).
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FILE NO. ICA Maintenance Manual for A-10034 TITLE: REVISION REVISION 5850 Floats on a SUBTITLE: DATE: DHC-2, Beaver 9/10/12 Access panels should be torqued only to "hand tight", the fiberglass should exhibit only mild deformation. A portable hand drill could be used, provided that the clutch is set properly.
Washers may be rearranged if necessary to accommodate proper fit, up to two washers beneath the nut and one beneath the fastener head. Typically, Aerocet intends to put one thin washer beneath the fastener head and one thicker washer beneath the nut.
The Aerocet Model 5850 Twin Seaplane Floats are all-composite float hulls. The float hulls are separated by spreader bars that slide into the float assemblies. The float design uses a double fluted bottom contour from the step forward, and has a flat top deck design with built-in antiskid.
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FILE NO. ICA Maintenance Manual for A-10034 TITLE: REVISION REVISION 5850 Floats on a SUBTITLE: DATE: DHC-2, Beaver 9/10/12 Each float is attached to the airplane by forward, mid, and aft struts. Bolted to the upper end of the forward strut is an attachment block, and to the upper end of the mid and aft struts, a forked attachment fitting, each of which is in turn bolted to a landing gear attachment lug on the side of the fuselage.
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FILE NO. ICA Maintenance Manual for A-10034 TITLE: REVISION REVISION 5850 Floats on a SUBTITLE: DATE: DHC-2, Beaver 9/10/12 which in turn is connected to a lengthened torque tube arm that replaces the landplane arm on the rudder. The purpose of the spring is to ensure air rudder operation if the water rudders become inoperative due to icing or other failure.
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FILE NO. ICA Maintenance Manual for A-10034 TITLE: REVISION REVISION 5850 Floats on a SUBTITLE: DATE: DHC-2, Beaver 9/10/12 The water rudder retract cables should be rigged so that the rudders are tucked neatly behind the float transoms when retracted and the cables are just becoming slack in the down position.
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FILE NO. ICA Maintenance Manual for A-10034 TITLE: REVISION REVISION 5850 Floats on a SUBTITLE: DATE: DHC-2, Beaver 9/10/12 All float access panels are to be removed upon annual inspection to detect any hidden damage and to comply with the maintenance and water rudder sections of this supplemental manual.
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FILE NO. ICA Maintenance Manual for A-10034 TITLE: REVISION REVISION 5850 Floats on a SUBTITLE: DATE: DHC-2, Beaver 9/10/12 For optional, newer, forward hinging locker covers, orient the arrow-shaped handle pointing forward (toward the hash mark in the “CLOSE” position shown on the placard) and in the detent.
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FILE NO. ICA Maintenance Manual for A-10034 TITLE: REVISION REVISION 5850 Floats on a SUBTITLE: DATE: DHC-2, Beaver 9/10/12 Investigation should be prompted if excessive water is pumped from any of the pump-out cups during pre flight. Water can leak through the pump-out plugs where the nylon pull line (on some styles of plugs) penetrates and may also seep through the access panel seals.
FILE NO. ICA Maintenance Manual for A-10034 TITLE: REVISION REVISION 5850 Floats on a SUBTITLE: DATE: DHC-2, Beaver 9/10/12 Bare steel parts such as cross-wire terminals, wire pulls, bolt heads, nuts, and other hardware items should be protected with a coating of Paralketone rust preventive or heavy grease.
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FILE NO. ICA Maintenance Manual for A-10034 TITLE: REVISION REVISION 5850 Floats on a SUBTITLE: DATE: DHC-2, Beaver 9/10/12 3. Attach balance cable to inboard end of left water rudder lever, and thread it through fairlead on left hand float. Remove balance pulley and from brackets and on rear spreader bar, position balance cable in brackets, and refit pulleys and.
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DATE: FILE NO. ICA Maintenance Manual for A-10034 TITLE: REVISION REVISION 5850 Floats on a SUBTITLE: DATE: DHC-2, Beaver 9/10/12 2. Place forked fittings, one between the top fork of each mid strut. Note The mid struts are identified by their length, which is intermediate between the longest (forward) struts, and the shortest (aft) struts.
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FILE NO. ICA Maintenance Manual for A-10034 TITLE: REVISION REVISION 5850 Floats on a SUBTITLE: DATE: DHC-2, Beaver 9/10/12 through each forked fitting and lug. Fit washer and nut to bolts and tighten finger tight. Place forked fitting, located at bottom of each aft strut, over each lug on the float deck.
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DATE: FILE NO. ICA Maintenance Manual for A-10034 TITLE: REVISION REVISION 5850 Floats on a SUBTITLE: DATE: DHC-2, Beaver 9/10/12 2.7.5. Installing Float Unit on Airplane See Figures 1 through 7, and proceed as follows: 1. With the airplane hoisted, position fuselage over float unit, lower airplane, and align fittings at top of struts, with attachment lugs, and on one side of fuselage.
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FILE NO. ICA Maintenance Manual for A-10034 TITLE: REVISION REVISION 5850 Floats on a SUBTITLE: DATE: DHC-2, Beaver 9/10/12 2. Install right hand threaded fork ends as marked with “R” on wire pulls at top of mid and aft struts. Install left hand threaded fork ends and marked with “L” on the float wire pulls and.
FILE NO. ICA Maintenance Manual for A-10034 TITLE: REVISION REVISION 5850 Floats on a SUBTITLE: DATE: DHC-2, Beaver 9/10/12 2. With retraction control system installed and rudders in neutral position, retract the rudders, locate position of retraction ring attachment spool on door frame, and fit spool.
Do not tighten plug knob with a wrench, as this may lead to destruction of the plug and socket assembly. securing ring to cockpit side wall. 2.9. Testing Floats If a float compartment fills with water, and the damage is not apparent by inspection, contact Aerocet using the contact information on the cover of this supplemental manual.
ISSUE Incorporated PAGE 10/17/06 33 of 81 DATE: FILE NO. ICA Maintenance Manual for A-10034 TITLE: REVISION REVISION 5850 Floats on a SUBTITLE: DATE: DHC-2, Beaver 9/10/12 2.10. Troubleshooting Problem Possible Cause Corrective Action Water in floats Missing plug Install plug...
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ISSUE Incorporated PAGE 10/17/06 34 of 81 DATE: FILE NO. ICA Maintenance Manual for A-10034 TITLE: REVISION REVISION 5850 Floats on a SUBTITLE: DATE: DHC-2, Beaver 9/10/12 This Page intentionally left blank.
The materials used for original construction and repair are conventional to the industry. Any damage on the bottom of the float should be repaired immediately because of the tremendous water pressures encountered. Contact Aerocet, Inc. prior to beginning a repair to obtain correct materials, including resin (resins have shelf lives),...
Damage larger than 4.0 inches in size requires consulting Aerocet, Inc. for proper laminate orientation and assuring correct number of laminates in the damaged area.
Larger areas require the use of a vacuum bag for core bonding. Consult Aerocet, Inc. for this procedure. Fill any seam voids with a resin/glass bubble mixture. Apply the final laminates according to the ply schedule to finish the repair.
FILE NO. ICA Maintenance Manual for A-10034 TITLE: REVISION REVISION 5850 Floats on a SUBTITLE: DATE: DHC-2, Beaver 9/10/12 3.5. Resin Mixing Gel times or pot life is the time it takes the resin to set up in the container after proper and thorough mixing with accelerators and catalysts.
FILE NO. ICA Maintenance Manual for A-10034 TITLE: REVISION REVISION 5850 Floats on a SUBTITLE: DATE: DHC-2, Beaver 9/10/12 2. When laps are necessary, lap widths of at least 0.5 inch shall be maintained for fiberglass pieces in any given ply and no more than one of the component plies shall be lapped at any one place.
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4. Keel Strips only: Hold the keel strip in place using an abundance of masking tape. Remove tape after the urethane cures and clean up excess material. Aerocet recommends carefully scoring the squeeze-out along the edges of the keel strips, then...
§§43.16 and 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA approved. 4.2.DESCRIPTION TIME LIMITED ITEMS. None. REQUIRED INSPECTIONS INTERVAL. None. Scheduled Maintenance: for Aerocet recommended Inspection or Replacement are located in Section 4.
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3. Bolt Protection: PUR-AL-KETONE, which is distributed by Lake and Air; LPS Industries LPS 3; Zip Chemical Company Zip D-5029NS. 4. United EZ Turn Lubricant: Produced by United Erie 1-800-377-7561, and available through distributors. 5. Composite Materials for Hull Repair: Contact Aerocet, Inc., for resin, cloth, gel-coat, resin thickeners.
DATE: FILE NO. ICA Maintenance Manual for A-10034 TITLE: REVISION REVISION 5850 Floats on a SUBTITLE: DATE: DHC-2, Beaver 9/10/12 5.3. Part 1, Preflight Conduct Preflight inspections according to existing DeHavilland maintenance manual, and add the following to the Airframe group: Check Float lockers secured.
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PAGE 10/17/06 45 of 81 DATE: FILE NO. ICA Maintenance Manual for A-10034 TITLE: REVISION REVISION 5850 Floats on a SUBTITLE: DATE: DHC-2, Beaver 9/10/12 5.5.1. Continued Airworthiness Service Schedule TABLE 4.5 Service Schedule HOURS (MONTHS) INSPECTION TIME INTERVALS (Whichever occurs first)
46 of 81 DATE: FILE NO. ICA Maintenance Manual for A-10034 TITLE: REVISION REVISION 5850 Floats on a SUBTITLE: DATE: DHC-2, Beaver 9/10/12 5.6. Special Inspections Conduct Special inspections per existing DeHavilland maintenance manual, and add the following to the Airframe group: In a variety of circumstances, it is necessary to perform prompt inspections for damage.
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