AEROCET 3400 Service And Maintenance Manual
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AEROCET 3400 Service And Maintenance Manual

Amphibious floats
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ISSUE DATE:
8/12/03
REVISION
DATE:
2/6/2020
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
AEROCET 3400 AMPHIBIOUS SEAPLANE FLOATS
This ICA must be followed when Aerocet 3400 Floats are installed in
accordance with Supplemental Type Certificate (STC) No. SA01257SE.
The information contained in this document supplements or supersedes the
basic manuals only in those areas listed herein. For limitations, procedures, and
performance information not contained in this manual, consult the basic
aircraft ICA or maintenance manual.
Incorporated
Service & Maintenance Manual
TITLE:
Model 3400 Amphibious Floats
SUBTITLE:
SERVICE MANUAL
AND
FOR
Aerocet, Inc.
P.O. Box 2119
265 Shannon Lane
Priest River, Idaho 83856
Phone: (208) 448-0400
Fax: (208) 448-1644
PAGE
1 of 107
FILE NO.
A-10031
REVISION
8

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  • Page 1 Priest River, Idaho 83856 Phone: (208) 448-0400 Fax: (208) 448-1644 This ICA must be followed when Aerocet 3400 Floats are installed in accordance with Supplemental Type Certificate (STC) No. SA01257SE. The information contained in this document supplements or supersedes the basic manuals only in those areas listed herein.
  • Page 2 ISSUE DATE: PAGE Incorporated 8/12/03 2 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 This page intentionally left blank.

  • Page 3: Log Of Revisions Page

    ISSUE DATE: PAGE Incorporated 8/12/03 3 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Log of Revisions Page REV. PAGES DESCRIPTION DATE AFFECT. Initial Release 8/12/03 2, 15, 22-25...
  • Page 4 & bilge cup subsections. 34 thru 35 Added splash guards to nose gear removal. Added “and Brake” to Aerocet Wheel and Brake. Added 35A-60200 hydraulic power unit. Added “108 Series” to clarify accumulator tube use. Added 6.7 General Service of Hydraulic System.

  • Page 5: Table Of Contents

    Float Installation and Removal to Aircraft ....................63 Repairing Composite Float Hulls ........................77 Recommended Service Schedule, General Practices and Product Listings for Service ........ 85 Tire Pressures ..............................91 Troubleshooting ............................93 Airworthiness Limitations ........................... 103 Installation Drawings for Aerocet Model 3400 Amphibious Floats: ................. 105...
  • Page 6 ISSUE DATE: PAGE Incorporated 8/12/03 6 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 This page intentionally left blank – except this line...

  • Page 7: Introduction And General Float Information

    Amphibious Seaplane Floats should be done according to the FAA approved drawings supporting these different applications. The Aerocet Model 3400 Amphibious Seaplane Floats are twin all composite float hulls separated by spreader bars, which incorporate hydraulically operated retractable landing gear allowing for landing on either water or land. An airplane-mounted electric-hydraulic pump, with a backup hand pump operates the hydraulics.
  • Page 8 2/6/2020 Availability One complete hard (paper) copy of this manual shall be provided with each new set of Model 3400 Twin Amphibian Floats. Additional copies and minor revisions shall be available via email, U.S.P.S. (mail), UPS or FedEx by request. Fees and delivery charges may apply.
  • Page 9 REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Dimensions, Locations and Nomenclature Figure 1.3.1 Showing Model 3400 Amphibious Float installation on a Cessna 180 Aircraft (185 similar). Figure 1.3.2 Showing Model 3400 Amphibious Float installation on a Cessna 206 Aircraft.
  • Page 10 10 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Figure 1.3.3 Showing Model 3400 Amphibious Float installation on a Cessna 182 Aircraft. Figure 1.3.4 Showing Front View of Model 3400 Floats.
  • Page 11 ISSUE DATE: PAGE Incorporated 8/12/03 11 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Figure 1.3.5 Figure 1.3.6...
  • Page 12 12 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Fastener Torque Torque Value Conversion: To convert in.-lb. to ft.-lb: Value (ft.-lb.) x 12 = Value (in-lb.) To convert ft.-lb. to in.-lb: Value (in-lb.) x 0.0833 = Value (ft.-lb.) 1.4.1...
  • Page 13 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Fastener Torque Values Figure 1.5.1 Recommended Torque Values (inch-pounds) (From AC43.13-1B, Table 7-1) (Except where otherwise noted, such as Deck Fitting bolts – see installation drawings) Figure 1.5.2 Minimum Prevailing Torque Values for Re-used Self-Locking Nuts...
  • Page 14 ISSUE DATE: PAGE Incorporated 8/12/03 14 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Figure 1.5.3 Torque Wrench with Various Adapters...
  • Page 15 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.
  • Page 16 ISSUE DATE: PAGE Incorporated 8/12/03 16 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 This page intentionally left blank – except this line...

  • Page 17: Float Hull And General Maintenance

    17 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Float Hull and General Maintenance The following is a general instruction set to Cleaning Seaplanes operating in saltwater or brackish water should be thoroughly hosed down or flushed with fresh water each day, including the landing gear bays.
  • Page 18 If washing in direct sunlight, it may be advisable to wash in sections. Do not allow soap to dry on the aircraft, or it will become difficult to remove. Bathing Procedure for Aerocet 3400 Amphibian Floats Installations Remove any fairings that cover float gear at least once per week during bathing, or any time the aircraft will sit un- used for more than a week.
  • Page 19 19 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Salt Removal ® We recommend the regular use of Salt-Away to emulsify and remove salt deposits when operating in a marine environment.
  • Page 20 8/12/03 20 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 ® Corrosion Preventatives water-displacing oils (ACF 50 ® Water-displacing, corrosion inhibiting oils like ACF 50 have proven themselves very reliably in marine environments.
  • Page 21 Parker/Cleveland wheels are to be daily greased through fitting. Aerocet grease pack wheels may be greased daily. Aerocet Oil Bath wheels are not greased, but oil level is to be maintained between inspections. External portions of wheel seals may be sprayed with light oil such as LPS 2 or ACF...
  • Page 22 On the 3400 floats, the access panels that lie beneath the trailing edges of the flaps will often gather more water as well.
  • Page 23 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 2.7.1 Float Lockers There is one locker in each float, each having weight allowances for up to 100 lb. of baggage. Float locker latches and seals are to be maintained as needed.
  • Page 24 ISSUE DATE: PAGE Incorporated 8/12/03 24 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Figure 2.7.2 Showing Inboard Hinging Locker with newer latches. Figure 2.7.3 Showing Forward Hinging Locker...
  • Page 25 ISSUE DATE: PAGE Incorporated 8/12/03 25 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Figure 2.7.4 Showing Forward Hinging Locker...
  • Page 26 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 2.7.2 Float Locker Latch adjustments, Inboard Hinging only The latch is held in place by proper tension on the locker panel when closed, with the spring pin seated in the latch ramp detent.
  • Page 27 27 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Figure 2.7.6 Forward Hinging Locker Latch Cut-Away 2.7.3 Float Locker Latch Adjustments, Forward Hinging only With latch closed and door fully pressed against float deck (requires weight on the locker panel), measure the detent gap, assuring that the latch pin remains nested, yet releases by hand.
  • Page 28 2/6/2020 Access Panels Access Panels are installed with stainless threaded fasteners, with either stainless panel u-nuts or Aerocet nutplates. along flanges of panel insets in the float deck. Nut plates are held in place with no. 4 stainless threaded fasteners, available from Aerocet.
  • Page 29 There are two primary versions of the bilge or pump-out cups that Aerocet has used in the 3400 Amphibian Floats. The original design is the fiber glass, molded, integral type, which is closely followed by the fiber glass bonded type.
  • Page 30 30 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Figure 2.9.1 Nylon style Pump-Out Cup (Bilge Cup) Installation 2.10 Storage Leaving the float locker doors and access panels open, when hangered, minimizes condensation in these bays.

  • Page 31: Float Handling And Jacking

    Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Float Handling and Jacking In order to service the landing gear parts and to do retraction tests, the floats are jacked up and blocked using a floor jack with at least 1-ton capacity.
  • Page 32 ISSUE DATE: PAGE Incorporated 8/12/03 32 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 This page intentionally left blank – except this line...

  • Page 33: Nose Gear

    FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Nose Gear General Description The nose gear utilizes a composite fiberglass strut to absorb energy on landing along with the deflection of the nose tire.
  • Page 34 Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Reassembly of the Nose Gear to the Nose Gear Box – Reference 35A-CPL-42000, Sheets 1 & 2; 35A-CPL-42100, Sheets 1-3; 35A-CPL-42300, Sheet 1; and 35A-CPL-42400.
  • Page 35 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Figure 4.5.1 Use a knife or razor blade to sever bonding sealant between float components and splash guards. Work loose and be careful to avoid damage to gel coat or aluminum components. (Splash guards will likely be damaged during removal.)
  • Page 36 The heat-treated pivot pin, part 35A-42110, is heat shrunk into the nose block. The nose block and pivot pin are supplied from Aerocet, Inc. assembled. If the pivot pin is pressed out, the anodized surface is opened causing dissimilar metal contact between the two components when reassembled.

  • Page 37: Main Gear

    Main Wheel Removal & Assembly – Reference 35A-CPL-45700. Consult Parker/Cleveland Maintenance Manual and Parts Catalog or Aerocet Component Maintenance Manual A-10036 for wheel and brake maintenance and repair. Make sure gear is in the down position and hydraulic gear motor circuit breaker is pulled.
  • Page 38 ISSUE DATE: PAGE Incorporated 8/12/03 38 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Figure 5.2.1...
  • Page 39 35A-CPL-45000, Sheets 2,6,7; 35A-CPL-45200, Sheets 1 & 2. (Oleo Bleeder Assembly 35A-T45200 may be available from Aerocet upon request. See Figure 5.3.1) Make sure gear is in the down position and hydraulic gear motor circuit breaker is pulled. Block and jack the airplane according to Section 3 Float Handling and Jacking.
  • Page 40 ISSUE DATE: PAGE Incorporated 8/12/03 40 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Figure 5.3.1...
  • Page 41 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Oleo Assembly – Reference 35A-CPL-45000, Sheets 2, 6, 7; and 35A-CPL-45200, Sheets 1 & 2. In general, reverse disassembly procedures. Lube all seals before putting them into place. Assure that all Polypak seals face correctly for keeping the pressure in the oleo.
  • Page 42 When installing the main gear hydraulic actuator back into the bulkhead, note that there is a Stat-O-Seal washer on the head side of the bolt and a Thred-Seal washer on the thread side of the bolt. (Aerocet also recommends use of a one-part, urethane, marine-grade sealant here as well, such as Sika-Flex 292 – Do not use silicone.)
  • Page 43 The newer version has a stainless barrel and is somewhat longer. Both hook up electrically in the same manner. The newer does require an additional threaded mount from Aerocet, 35A-45071. (See Figure 5.6.2 and Figure 5.6.3 for an illustration of the two sensors.) Ni8U-S12-AN6X-H1141 Sensor (Originally supplied): With proper hook up, this sensor will activate red lights in the upper barrel when the target (main gear drag link) is in range.
  • Page 44 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Figure 5.6.2 Ni8U-EM12E-AN6X-H1141 Sensor (Supplied as original or as replacements after 12/08): With proper hook up, sensor will activate green lights in the upper barrel. These lights will become amber when target (main gear drag link) is in range.

  • Page 45: Landing Gear Retraction System

    45 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Landing Gear Retraction System General Description Normal landing gear extension and retraction is accomplished by hydraulic actuators for each gear. The hydraulic system is powered by a reversible, electrically driven hydraulic pump.
  • Page 46 ISSUE DATE: PAGE Incorporated 8/12/03 46 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Figure 6.2.1 Hydraulic lines for 182, 206 similar, see drawings. Figure 6.2.2...
  • Page 47 A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Figure 6.2.3 CESSNA 182 INSTALLATION SHOWN NOTE: “UP” OR RETRACT LINES ARE ALWAYS INSTALLED INBOARD; AND “DOWN” OR DEPLOY LINES ARE ALWAYS INSTALLED OUTBOARD, ON ALL MODEL 3400 FLOATS.
  • Page 48 Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Figure 6.2.4 Showing Cessna 180 or 185 or 206, FWD Deck Fitting, Hydraulic Fittings and conductor cable installation. Figure 6.2.5 Showing Available Aerocet -3 Brake Line Conversion...
  • Page 49 49 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Hydraulic Actuators – Reference 35A-CPL-42400, Sheet 1, 35A-CPL-45300, Sheet 1, and 35A-CPL-45400. Both the nose and main gear actuators can be rebuilt.
  • Page 50 108 Series Oildyne with versions for the 12V or 24V aircraft systems. This has become unavailable after 12/2019. Aerocet has developed its own system, 35A-60200, which replaces the 108 Series pumps in the Model 3400 installations. The figure below compares the external features as installed in a Cessna 180 or 185.
  • Page 51 Reference the Power Unit Drawings for adjustment if necessary. NOTE: These settings are very fine, and Aerocet does not recommend making adjustments unless it is necessary. It should be noted that the Pressure switches (electrical), which turn the pump on and off, are at a lower setting.
  • Page 52 Backup Hand Hydraulic Pump – Normal operation - the Hand Pump selector handle should be in the “OFF” position. 10. Hand Pump operation should be according to the Pilots Operating Handbook. 11. If pump should leak, contact Aerocet, Inc. for replacement.
  • Page 53 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 General Service of Hydraulic System The landing gear hydraulics system is self-bleeding by cycling the gear. Maintain the reservoir fluid level while cycling the gear until the fluid level stabilizes. (Note that the fluid level will fluctuate between gear up and gear down positions.
  • Page 54 K-65-CPL. General For all information regarding the Aerocet Model GC600 Gear Advisory, please refer to CMM A-10037. (See illustration for comparison between the K-65 and GC600 units) The newer GC600 is designed to be a direct replacement for the K-65. Both fit the same panel opening and accept the same wiring connector and hook-up. The K-65 will not be readily available after 11/09.
  • Page 55 The Gear Advisory unit is a sealed unit and it should be returned to Aerocet, Inc. for any servicing. Aerocet, Inc. endeavors to have exchange units available to minimize down time.
  • Page 56 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Spot Mirror Assembly 35A-59430 Spot Mirror and Bracket Assembly is intended to provide a visual verification of landing gear position. It is designed to install on an inspection panel under the aircraft wings, both port and starboard.
  • Page 57 Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Installation (Ref Drawing No. 35A-59402 and Figure 6.9.1, Figure 6.9.2) Locate an inspection cover on the underside of the wing just inboard or outboard of the wing strut.
  • Page 58 ISSUE DATE: PAGE Incorporated 8/12/03 58 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 This page intentionally left blank.

  • Page 59: Water Rudder Retraction And Steering System

    FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Water Rudder Retraction and Steering System General Description The water rudders are used for steering when taxiing on the water. They are steered through 3/32” stainless cables that connect to the airplanes rudder system and are retracted manually through a lever in the cockpit again using 3/32”...
  • Page 60 ISSUE DATE: PAGE Incorporated 8/12/03 60 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 This page intentionally left blank – except this line...

  • Page 61: Anodic Systems

    Anodic systems are part of a multi-pronged approach to fighting corrosion of metal components. The first defense is in the design. Aerocet has gone to great lengths to minimize corrosion by anodizing aluminum components, avoiding or minimizing dissimilar metals where possible, and eliminating contact where possible. Other portions of this manual point out the necessity of freshwater rinsing, cleaning, and mechanical removal of residues and deposits from the seaplane or amphibian assembly.
  • Page 62 2/6/2020 Anode Locations There are a number of anode installations (See Figure 8.2.1) on Aerocet 3400 floats, designed to protect isolated portions of the metal floats and/or the aircraft as well. Figure 8.2.1 Showing Zinc Anode Locations on the 3400 Amphibian Floats ZINC ANODE ○...

  • Page 63: Float Installation And Removal To Aircraft

    The appendices are intended to provide aircraft specific installation drawings or instructions necessary to install Aerocet Model 3400 Amphibious Floats. Some approvals (by way of Supplemental STC, or via field approval (“Form 337”) are not the property of Aerocet and may require other documentation.
  • Page 64 Apply grease or oil to main gear wheels per applicable component maintenance manual(s). (See 1.2) If installing used floats, disassemble, clean, inspect, lubricate and reassemble. It may be desirable to do this before mounting the aircraft. (Nose Gear wheels are pre-packed. Disassemble, inspect and re-pack if installing a used set of 3400’s.) 9.1.3 Float Assembly: You will need the help of at least four people to align the floats and install the spreaders.
  • Page 65 65 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 WARNING: DO NOT INSERT THE SPREADERS TOO DEEPLY INTO THE SOCKETS OR YOU MAY DAMAGE THE OUTER SKINS OF THE FLOATS.
  • Page 66 Remove landing gear per Cessna Manuals. As shown in the Installation Drawings, Aerocet intends the use of washers beneath the head of the fastener (preferably a thin washer) and beneath the nut. This helps to isolate the steel of the fasteners from the aluminum of the struts.
  • Page 67 Aerocet floats are supplied with stainless 3/32” Wire Rope per MIL-DTL-83420, Type I, Composition B, which is to say, non-jacketed, stainless steel. Aerocet supplies stainless, 7 X 7, but allows steel 7 X 7 as well. 7 X 19 is acceptable if preferred.
  • Page 68 8/12/03 68 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 9.1.6 Boarding Step Installation For Cessna 180/185 Installation: 35A-59100 For Cessna 206 or T206H Installation: 36-15300 Boarding Steps are installed to the outboard sides of the struts as shown in the drawings, creating a ladder for loading and boarding of the aircraft.
  • Page 69 8/12/03 69 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 9.1.9 Hydraulic Pump Installation For Cessna 180/185 Installation: 35A-60000, 35A-60001, 35A-60010, 35A-60015, 35A-61000, 35A-62000, 35A-64000. For Cessna 206 Installation: 35A-60015, 36-15400, 36-15410, 36-15460, 36-15480, 36-15490.
  • Page 70 70 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 9.1.10 Wire Routing: Assure clearances to all control cables, pulleys, and structural members. Plastic ties must not be used where their failure could result in interference with moveable controls, equipment or chafing damage.
  • Page 71 PAGE Incorporated 8/12/03 71 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Figure 9.1.4 (FROM AC43.13-1B, PAR 11-188) 9.1.11 Checklist NOTE: Check all work before proceeding. (minimum checklist) Torque for all bolts: (See Tables in Section 1.4 ff – Except where otherwise noted) Spreaders and Deck Fittings –...
  • Page 72 72 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 9.1.12 System Activation With the aircraft and floats securely hoisted or lifted and all precautions taken to prevent an engine start: Note the position of the float gear and place the Gear Position switch to match.
  • Page 73 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Conversion from Floats to Wheels Hoist and secure aircraft using lifting rings installed with the Cessna float kit and other tie down rings as necessary.
  • Page 74 Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 18. Disconnect the mid and aft struts at the aircraft fittings, hydraulic lines as applicable. 19. Disconnect the remaining struts for complete disassembly, with the floats sitting on the floor.
  • Page 75 An inaccurate CG may lead to exceeding the CG range resulting in inadequate control. Modify the equipment list to include the 3400 float installation and verify the remaining items. On level scales with each wheel on the scales, aircraft empty – no fuel.
  • Page 76 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 9.3.1 Weights for components left installed For temporary float removals, such as for winter flight on skis, it may be desirable to leave certain float equipment on board, such as hydraulic lines and fittings, float gear wiring and hydraulic pumps.

  • Page 77: Repairing Composite Float Hulls

    Damage larger than 4” in size require consulting Aerocet, Inc. for proper laminate orientation and assuring number of laminates in the damaged area.
  • Page 78 (ex. lead shot bags with a release film to keep from sticking to any excess). Larger areas require core bonding using a vacuum bag. Consult Aerocet, Inc. for this procedure. Fill any seam voids with a resin/glass bubble mixture. Apply the final laminates accordingly to finish the repair.
  • Page 79 Keel & Wear Strip Bonding (UHMW plastic style) *UHMW Style keel and wear strips are no longer offered on new Aerocet floats, being replaced with aluminum keel strips and fiberglass wear strips. These instructions are still applicable to re-bond existing strips, otherwise, contact Aerocet to order replacements of the new styles.
  • Page 80 80 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Figure 10.7.1 10.8 Keel Strip Replacement (Aluminum Style) 1) Remove any existing, worn or damaged keel strip. Use a thin metal scraper or similar device beneath the strip to avoid peeling off excessive gelcoat or resin.
  • Page 81 8) Position the rub strips and firmly push them onto the floats so that there is a consistent bead of squeeze-out. Aerocet uses a three foot 2” x 2” with a ½” 90-degree notch near the middle to apply heavy pressure with a rocking motion to work out any air pockets in the adhesive.
  • Page 82 1) Excessive wear around the attachment bolt of the main gear actuator will result in elongation of the hole and excessive water leakage in the locker bay. Figure 10.11.1 2) Aerocet offers a reinforcement kit, 35A-K45025 which increases the bearing area around the hole by bonding a reinforcement to the affected area. (Drawing 35A-K-45025 included in kit.)
  • Page 83 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Figure 10.11.2 3) Clean and degrease affected area using acetone, abrade lightly, allow to ventilate and to dry completely. 4) Abrade area with emery cloth or 80gr. Sandpaper, lightly re-clean with acetone and allow to ventilate and to dry completely.
  • Page 84 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Figure 10.11.3 10) Apply thoroughly mixed paste to 35A-K45025 parts, orienting them as shown, and securing with old or disposable hardware that has been waxed (not greased) to avoid bonding to it. Remove excess paste.

  • Page 85: Recommended Service Schedule, General Practices And Product Listings For Service

    PAGE Incorporated 8/12/03 85 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Recommended Service Schedule, General Practices and Product Listings for Service TABLE 11.1 HOURS (MONTHS) INSPECTION TIME INTERVALS...
  • Page 86 ISSUE DATE: PAGE Incorporated 8/12/03 86 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 HOURS (MONTHS) INSPECTION TIME INTERVALS (Whichever occurs first) Notes (12) (24) Nose Landing Gear, Inspect travel & extra side play (Cont’d)
  • Page 87 ISSUE DATE: PAGE Incorporated 8/12/03 87 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 HOURS (MONTHS) INSPECTION TIME INTERVALS (Whichever occurs first) Notes (12) (24) Main Landing Gear Actuator Mount, Lower (Cont’d)
  • Page 88 ISSUE DATE: PAGE Incorporated 8/12/03 88 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 HOURS (MONTHS) INSPECTION TIME INTERVALS (Whichever occurs first) Notes (12) (24) Hulls & Struts Inspect for damage, surface...
  • Page 89 89 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 11.1 “Exceptional” Inspections: In a variety of circumstances, it is necessary to perform prompt inspections for damage. Details relating to these investigations are addressed in Section 2, Section 11 of this manual and Table 1 above.
  • Page 90 5029NS, EZ Turn Lubricant United-Erie, DuBois Chemical ACG-2 Polymer-fortified, Aluminum Complex Grease Composite Materials for Hull Repair – Contact Aerocet, Inc. for resin, cloth, gelcoat, resin thickeners 10. Electrically Conductive Sealants for Anode Installation – Parker CHO-Bond 1038, 1121 or PRC-Desoto PR-2200 11.

  • Page 91: Tire Pressures

    8/12/03 91 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Tire Pressures NOSE WHEEL TIRE PRESSURE: 70 PSI on 10-3.50, 4-Ply Rated Tires MAIN WHEEL TIRE PRESSURE: 55 PSI on 6.00-6, 8-Ply Rated Tires. – Gross Weight above 2950 lb.
  • Page 92 ISSUE DATE: PAGE Incorporated 8/12/03 92 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 This page intentionally left blank – except this line...

  • Page 93: Troubleshooting

    There are a number of troubleshooting instructions given throughout this manual in relevant areas. This section is intended to compile these instructions and additionally provide any additional instructions that have become evident since the original writing. Table 13.1 Troubleshooting Model 3400 Amphibious Floats5 Float Hull Assemblies (Excluding Amphibian Gear) Detected Problem...
  • Page 94 Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Table 13.1 Troubleshooting Model 3400 Amphibious Floats5 Float Hull Assemblies (Excluding Amphibian Gear) Detected Problem Possible Cause Corrective Action Reduced water rudder Broken cable Replace as necessary. steering Debris caught in the tiller Remove debris.
  • Page 95 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Table 13.1 Troubleshooting Model 3400 Amphibious Floats (Cont’d) Hydraulic System Detected Problem Possible Cause Corrective Action Electric Hydraulic Hydraulic system is compromised - Check all lines for damage. Replace as...
  • Page 96 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Table 13.1 Troubleshooting Model 3400 Amphibious Floats (Cont’d) Hydraulic System Detected Problem Possible Cause Corrective Action Gear Advisory Unit has failed. Check 1 Amp circuit breakers. (One is for the Gear Advisory Internal Relays;...
  • Page 97 A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Table 13.1 Troubleshooting Model 3400 Amphibious Floats (Cont’d) Hydraulic System Detected Problem Possible Cause Corrective Action Slow Gear Operation Mechanical Obstructions Check gear and hydraulic systems for mechanical damage, debris or other obstructions.
  • Page 98 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Table 13.1 Troubleshooting Model 3400 Amphibious Floats (Cont’d) Hydraulic System Detected Problem Possible Cause Corrective Action Gear position activates Hydraulics lines are not correctly Trace the hydraulic lines to the installation...
  • Page 99 A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Table 13.1 Troubleshooting Model 3400 Amphibious Floats (Cont’d) Electrical Circuit Breakers Detected Problem Possible Cause Corrective Action 1-amp Circuit Breaker Hook up wiring is compromised. (CB Check for faults with installation wiring. This on bus bar opens.
  • Page 100 REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Table 13.1 Troubleshooting Model 3400 Amphibious Floats (Cont’d) Gear Advisory** (Includes K-65 Models; See A-10037 for additional details applicable to GC600 Models.) Gear Advisory Indicator Lights Detected Problem Possible Cause Corrective Action Internal Gear Advisory Components Return the Gear Advisory Unit to Aerocet, Inc.
  • Page 101 REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Table 13.1 Troubleshooting Model 3400 Amphibious Floats (Cont’d) Gear Advisory** (Includes K-65 Models; See A-10037 for additional details applicable to GC600 Models.) Gear Advisory Audio Detected Problem Possible Cause Corrective Action...
  • Page 102 REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 Table 13.1 Troubleshooting Model 3400 Amphibious Floats (Cont’d) Gear Advisory** (Includes K-65 Models; See A-10037 for additional details applicable to GC600 Models.) Gear Advisory Audio Detected Problem Possible Cause Corrective Action Factory presets are not desirable.

  • Page 103: Airworthiness Limitations

    §§43.16 and 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA approved. 14.2 DESCRIPTION TIME LIMITED ITEMS. None. REQUIRED INSPECTIONS INTERVAL. None. Scheduled Maintenance: for Aerocet recommended Inspection or Replacement are located in Section 11.
  • Page 104 ISSUE DATE: PAGE Incorporated 8/12/03 104 of 107 FILE NO. Service & Maintenance Manual A-10031 TITLE: REVISION REVISION Model 3400 Amphibious Floats SUBTITLE: DATE: 2/6/2020 This page intentionally left blank – except this line...

  • Page 105: Installation Drawings For Aerocet Model 3400 Amphibious Floats

    Drawing List. The appendices are bound separately. Appendix A: Cessna 180 or Cessna 185 Per STC SA01257SE Aerocet Document A-18, Part Application Listing Weight Affidavit for Cessna 180 or 185 Seaplanes on Aerocet Model 3400 Amphibious Floats 35-24001 [TSO] Rudder Assembly – also in CPL...
  • Page 106 Weight Affidavit for Cessna 206 Seaplanes on Aerocet Model 3400 Amphibious Floats 35-24001 [TSO] Rudder Assembly – also in CPL 35A-46010 [TSO] Float Wiring Schematic 36-15000 Master Drawing List, Aerocet Model 3400 Amphibious Float Installation on Cessna 206 Aircraft 35-11052 Tie Rod Assembly 35-24011 Water Rudder Retract Handle 35A-60001 Wire Assembly, Relay to Terminal Block, Model 3400 Float STC’s...
  • Page 107 Appendix C: Cessna T206H per STC SA01257SE 35-24001 [TSO] Rudder Assembly – also in CPL 35A-46010 [TSO] Float Wiring Schematic 36-15000 Master Drawing List, Aerocet Model 3400 Amphibious Float Installation on Cessna 206 Aircraft 35-11052 Tie Rod Assembly 35-24011 Water Rudder Retract Handle 35A-60001 Wire Assembly, Relay to Terminal Block, Model 3400 Float STC’s...

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