SERVICE MANUAL & ICA FOR LYCOMING IO-580-B1A ENGINE INSTALLATION IN CESSNA MODEL 182

WIPLINE FLOATS • SKIS • MODIFICATIONS • AIRCRAFT SALES AVIONICS • INTERIOR • MAINTENANCE • PAINT REFINISHING Revision IR P/N 1006808 Doc. No. W182GW-24-01 SERVICE MANUAL & ICA FOR LYCOMING IO-580-B1A ENGINE INSTALLATION IN CESSNA MODEL 182 SERVICE MANUAL & ICA IO-580-B1A IN CESSNA 182 P/N 1006808 Doc. No. W182GW-24-01 2 Revision IR THIS PAGE INTENTIONALLY LEFT BLANK SERVICE MANUAL & ICA IO-580-B1A IN CESSNA 182 Revision B 3 P/N 1006808 Doc. No. W182GW-24-01 LOG OF REVISIONS REVISION PAGES AFFECTED DESCRIPTION DATE FAA ACCEPTANCE IR ALL INITIAL RELEASE A 14, 15, 20 UPDATED FOR LANDPLANE B 21 Added shear torque chart, and Tef- Gel. Removed warranty claim form. 5/26/2015 View the most current revision of this ICA at www.wipaire.com SERVICE MANUAL & ICA IO-580-B1A IN CESSNA 182 P/N 1006808 Doc. No. W182GW-24-01 4 Revision IR THIS PAGE INTENTIONALLY LEFT BLANK SERVICE MANUAL & ICA IO-580-B1A IN CESSNA 182 Revision B 5 P/N 1006808 Doc. No. W182GW-24-01 LIST OF EFFECTIVE PAGES PAGES REVISION PAGES REVISION PAGES REVISION 1 IR 24 IR 2 IR 3 B 4 IR 5 B 6 IR 7 IR 8 IR 9 IR 10 IR 11 IR 12 A 13 A 14 IR 15 IR 16 IR 17 IR 18 A 19 IR 20 IR 21 B 22 IR 23 IR SERVICE MANUAL & ICA IO-580-B1A IN CESSNA 182 P/N 1006808 Doc. No. W182GW-24-01 6 Revision IR THIS PAGE INTENTIONALLY LEFT BLANK SERVICE MANUAL & ICA IO-580-B1A IN CESSNA 182 Revision IR 7 P/N 1006808 Doc. No. W182GW-24-01 TABLE OF CONTENTS CHAPTER 1 INTRODUCTION AND GENERAL INFORMATION ............................................................................... 11 1.0 INTRODUCTION.............................................................................................................................................................. 11 1.1 GENERAL INFORMATION ON IO-580 ENGINE INSTALLATION ........................................................................ 12 1.2 REFERENCES ................................................................................................................................................................... 13 1.3 SPECIFICATIONS ............................................................................................................................................................ 13 CHAPTER 2 AIRWORTHINESS LIMITATIONS ............................................................................................................. 15 CHAPTER 3 SERVICING AND MAINTENANCE ............................................................................................................ 17 3.0 SERVICING AND MAINTENANCE .............................................................................................................................. 18 3.1 COWL FLAP RIGGING ................................................................................................................................................... 18 3.2 FUEL PRESSURE SETTING ........................................................................................................................................... 18 CHAPTER 4 RECOMMENDED PROCESSES, PRODUCTS AND INSPECTION CHECKLIST ............................... 19 4.0 SERVICING INSTRUCTIONS ........................................................................................................................................ 20 4.1 MAINTENANCE CHECKLIST....................................................................................................................................... 22 SERVICE MANUAL & ICA IO-580-B1A IN CESSNA 182 P/N 1006808 Doc. No. W182GW-24-01 8 Revision IR THIS PAGE INTENTIONALLY LEFT BLANK SERVICE MANUAL & ICA IO-580-B1A IN CESSNA 182 Revision IR 9 P/N 1006808 Doc. No. W182GW-24-01 NEW CUSTOMER INFORMATION Customer Name Billing Address Shipping Address Phone Number Fax Number Purchasing Contact Phone Number E-Mail Fax Number Accounts Payable Contact Phone Number E-Mail Fax Number Type(s) of Aircraft Owned or Maintained Model(s) of Floats and Skis Owned or Maintained FedEx and/or UPS account number (if applicable) Please return to Wipaire Customer Service: Fax 651-306-0666 Phone 651-306-0459 CustomerService@wipaire.com SERVICE MANUAL & ICA IO-580-B1A IN CESSNA 182 P/N 1006808 Doc. No. W182GW-24-01 10 Revision IR THIS PAGE INTENTIONALLY LEFT BLANK SERVICE MANUAL & ICA IO-580-B1A IN CESSNA 182 Revision IR 11 P/N 1006808 Doc. No. W182GW-24-01 CHAPTER 1 INTRODUCTION AND GENERAL INFORMATION 1.0 INTRODUCTION This manual is provided for the owners of a Lycoming IO-580-B1A engine installed on Cessna 182 aircraft. It has two main priorities: To inform owners of the level and amount of servicing required to properly maintain their airplane, and to provide technical data and servicing as specified to maintenance professionals charged with servicing airplanes modified by this STC. The service products referred to throughout this manual are described by their trade names and may be purchased from Wipaire Parts. Department: We, at Wipaire, welcome your purchase and look forward to years of satisfying exchanges with you. Our customer service department, WipCaire, is available for your questions 24 hours a day, 7 days a week, where ever you are in the world. Parts Sales and Technical Support Dept: Wipaire, Inc. 1700 Henry Avenue – Fleming Field South St. Paul, MN 55075 Telephone: (651) 306-0459 Fax: (651)-306-0666 Website: www.wipaire.com Email: CustomerService@wipaire.com When a part of this installation is significantly changed or an additional inspection is recommended or required, often a service letter and/or kit is issued. If a warranty is issued, most commonly it is for an 18 month time period, so it is crucial to check for service letters specific to your float model at each periodic inspection to be eligible. Service Manuals and the installation documents included are also revised periodically and also to be kept updated. Service letters, Service Kits and Service Manuals are available on our web site at no charge, www.wipaire.com. NOTE: IT IS CRITICAL TO CHECK FOR MANUAL UPDATES EACH TIME AN INSPECTION IS EXECUTED. SERVICE MANUAL & ICA IO-580-B1A IN CESSNA 182 P/N 1006808 Doc. No. W182GW-24-01 12 Revision A 1.1 GENERAL INFORMATION ON IO-580 ENGINE INSTALLATION The Lycoming IO-580-B1A is a 315 horsepower engine that replaces the original 230 horsepower IO-540-AB1A5 engine in Cessna models 182S and 182T. This engine installation is very similar to the original IO-540 engine installation and utilizes many of the same parts, however some of the differences are noted below: 1. Side baffles and select other baffles are new. Baffles are made out of 2024-T3 aluminum and painted with high temperature paint. 2. A second oil cooler, identical to the original, is added on the pilot side and is plumbed in parallel with the right side oil cooler. 3. Heating air intake is relocated from the aft left baffle to the lower cowl. 4. Air intake box is modified to accommodate the IO-580 engine. 5. Cowl flap travel is extended and side plates are added to the cowl flaps. 6. New throttle control and mixture control brackets, made out of 4130 steel and painted with high temperature paint. 7. Some hose lengths modified. 8. Cockpit engine instruments changed to reflect proper limits for IO-580 engine. Remaining items are either new on the IO-580 engine or reused from the previous engine installation. These include throttle, mixture, and propeller controls, propeller governor, alternator, and some baffling. The engine cowl is unchanged, as is the fuel system except for some hose length changes in the engine compartment. A modified engine mount is required for the IO- 580 engine installation for floatplanes only, and is covered under a separate STC SA02967CH. Landplanes may use the existing Cessna engine mount. The engine installation on Cessna 182 aircraft is covered in Wipaire installation instructions document 1005680. Additional details specific to the engine can be found in “IO-580-B1A Operation and Installation Manual”, Lycoming part number 60297-28. Operational information is detailed in the Airplane Flight Manual Supplement. See the list of applicable supplements in 1005680. SERVICE MANUAL & ICA IO-580-B1A IN CESSNA 182 Revision A 13 P/N 1006808 Doc. No. W182GW-24-01 1.2 REFERENCES A list of important references is given below. In addition to this document, these will aid in the maintenance and continued airworthiness of this engine installation. Lycoming document LMO-580-B, IO-580-B1A Maintenance and Overhaul Manual Lycoming Specification 2655, Detail Specification for Engine Model IO-580-B1A Lycoming document 60297-28, IO-580-B1A Operation and Installation Manual Wipaire document 1005680, Installation Instructions for IO-580-B1A Installation in Cessna 182S and 182T Aircraft Cessna Service Manual for 182S and 182T Aircraft The aircraft and engine service manuals should be the primary references in the servicing and continued airworthiness of this installation. Any necessary subject matter relating to this installation that is not covered in those manuals will be covered in this manual. 1.3 SPECIFICATIONS Engine limitations are shown below. Tachometer Red line: 2700 RPM Green arc: 2000 – 2700 RPM Manifold Pressure Green arc: 15 – 30 in.Hg Fuel Flow Green arc: 5 – 20 GPH Cylinder Head Temperature Redline: 465 °F Green arc: 200 – 465 °F Oil Temperature Redline: 235 °F Green arc: 100 – 235 °F Oil Pressure Redline: 115 psi Green arc: 50 – 90 psi Redline: 20 psi SERVICE MANUAL & ICA IO-580-B1A IN CESSNA 182 P/N 1006808 Doc. No. W182GW-24-01 14 Revision IR THIS PAGE INTENTIONALLY LEFT BLANK SERVICE MANUAL & ICA IO-580-B1A IN CESSNA 182 Revision IR 15 P/N 1006808 Doc. No. W182GW-24-01 CHAPTER 2 AIRWORTHINESS LIMITATIONS SERVICE MANUAL & ICA IO-580-B1A IN CESSNA 182 P/N 1006808 Doc. No. W182GW-24-01 16 Revision IR AIRWORTHINESS LIMITATIONS This Airworthiness Limitations section is FAA approved and specifies maintenance required under paragraphs 43.16 and 91.403(c) of the Federal Aviation Regulations unless an alternative program has been FAA approved. The aircraft Airworthiness Limitations are unchanged as a result of installation of the Lycoming IO-580- B1A engine addressed by this STC. FAA APPROVED_________________________ DATE_________________________ SERVICE MANUAL & ICA IO-580-B1A IN CESSNA 182 Revision IR 17 P/N 1006808 Doc. No. W182GW-24-01 CHAPTER 3 SERVICING AND MAINTENANCE SERVICE MANUAL & ICA IO-580-B1A IN CESSNA 182 P/N 1006808 Doc. No. W182GW-24-01 18 Revision A 3.0 SERVICING AND MAINTENANCE The IO-580 engine installation on the Cessna 182S/T is very similar to the original IO-540 engine installation. Therefore, many of the existing maintenance items, servicing procedures, inspection intervals, etc. that are contained in the Cessna service manual should be followed. This section describes any items that deviate or are not included in either the Cessna service manual or the Lycoming IO-580 service manual. 3.1 COWL FLAP RIGGING Cowl flap travel is extended for this engine installation to give the engine greater cooling capability. Side plates are also added to the cowl flaps to control airflow. Extensions consist of standoffs added to the cowl flap push rods. Cowl flaps should be rigged to obtain the following open and closed angles. Angles are measured with respect to the fixed part of the cowl just inboard of the cowl flap. Cowl flap angle is measured by placing an inclinometer on the inboard bottom side of cowl flap. Open: 42° ± 1° Closed: 8.5° ± 1° 3.2 FUEL PRESSURE SETTING Connect a pressure gauge capable of reading up to 50 psi to the pressure port of the fuel servo. Alternatively the pressure gauge can be tee’d into the output from the engine fuel pump. This measures unmetered fuel pressure. Run engine and ensure unmetered fuel pressure reads at least 12 psi at idle. Increase power to at least 75% power and ensure pressure reads 32 psi ± 2 psi. If pressure is not within range, adjust using set screw on fuel pump. Turning the set screw in will increase pressure with 1/4 turn = 1 psi. SERVICE MANUAL & ICA IO-580-B1A IN CESSNA 182 Revision IR 19 P/N 1006808 Doc. No. W182GW-24-01 CHAPTER 4 RECOMMENDED PROCESSES, PRODUCTS AND INSPECTION CHECKLIST SERVICE MANUAL & ICA IO-580-B1A IN CESSNA 182 P/N 1006808 Doc. No. W182GW-24-01 20 Revision IR 4.0 SERVICING INSTRUCTIONS As coded in the Inspection Time Limits chart in this section, there are items to be checked each 25, 50, 100, and 200 hours. Also, there are notes on special items which may require servicing at more frequent intervals. *When conducting an inspection at 25 hours, all items marked for 25 hours would be accomplished. *at 50 hours, the 25 and 50-hour items would be accomplished. *at 100 hours, the 25, 50, and 100-hour items would be accomplished. *at 200 hours, the 25, 50, 100 and 200-hour items would be accomplished. *A complete inspection (Annual Inspection) would include all 25, 50, 100, 200 hour items. Below is a list of recommended lubricants and “protection”. This lists products used by Wipaire during installation. There may be equivalent products just as satisfactory for protection. However, it is recommended if trying different products, to inspect them frequently so as to determine their effectiveness. Protection of nuts, bolts, hydraulic lines, metal surfaces, or electrical connections. Dinitrol AV30 Dinol Group CRC – SP400 Soft Seal CRC Industries General Lubricants LPS 1, LPS 2 and LPS 3 LPS Industries SERVICE MANUAL & ICA IO-580-B1A IN CESSNA 182 Revision B 21 P/N 1006808 Doc. No. W182GW-24-01 Metal Corrosion Protection Boeshield T9 Rust Protection Boeing Company Corrosion X ACF-50 Rust Protection Tef-Gel Ultra Safety Systems, Inc. RTV Silicones General Electric SIKAFLEX 201 or 252 Sika Manufacturing Teflon Spray 6P-730A Comet Industries Bolt Torque Bolts in Critical Areas - For common, correct torque when installed, or when visual inspection indicates a need for a torque check. **Tension Nut Nut-Bolt Size Torque Limits (in-lbs) Min. Max. 8-36 12 15 10-32 20 25 1/4-28 50 70 5/16-24 100 140 3/8-24 160 190 7/16-20 450 500 1/2-20 480 690 9/16-18 800 1,000 5/8-18 1,100 1,300 3/4-16 2,300 2,500 7/8-14 2,500 3,000 1-14 3,700 4,500 1 1/8-12 5,000 7,000 1 1/4-12 9,000 11,000 **Shear Nut Nut-Bolt Size Torque Limits (in-lbs) Min. Max. 8-36 7 9 10-32 12 15 1/4-28 30 40 5/16-24 60 85 3/8-24 95 110 7/16-20 270 300 1/2-20 290 410 9/16-18 480 600 5/8-18 600 780 3/4-16 1,300 1,500 7/8-14 1,500 1,800 1-14 2,200 3,300 1 1/8-12 3,000 4,200 1 1/4-12 5,400 6,600 ** A Torque of 80% should be used when Tef-Gel is applied to the bolt SERVICE MANUAL & ICA IO-580-B1A IN CESSNA 182 P/N 1006808 Doc. No. W182GW-24-01 22 Revision IR 4.1 MAINTENANCE CHECKLIST SERVICE MANUAL & ICA IO-580-B1A IN CESSNA 182 Revision IR 23 P/N 1006808 Doc. No. W182GW-24-01 INSP MECHANIC HOURLY LIMITS Annual X X X X X X X 200 100 X X X X X 50 25 X INSTRUCTIONS / PROCEDURES Details Inspect baffling for cracks and security. Ensure there are no leaks and no cha ffing. Ensure all fittings are tight and hoses are secured. Ensure fasteners are secure Inspect urethane induction elbow for any signs of wear or deterioration. Wipe off any oil or grease. Check cowl flap rigging matches specifications given in this manual . Ensure cowl flaps operate properly. General Check installed placards against the AFM/POH Supplement Section 2, and installation drawings. Engine Baffling Inspect fuel lines and oil hoses. Examine airbox assembly for security Inspect and clean inducti on elbow Verify cowl flap rigging . Check Cessna and Lycoming Service Manuals for additional required maintenance items. General Baffles Hoses Airbox Cowl Flaps Service Documents SERVICE MANUAL & ICA IO-580-B1A IN CESSNA 182 P/N 1006808 Doc. No. W182GW-24-01 24 Revision IR END