Wipaire, Inc.

1700 Henry Avenue

South St. Paul, MN 55075
Phone (651) 451-1205
Fax (651) 451-1786

AIRCRAFT MAINTENANCE MANUAL SUPPLEMENT

FOR

CONTINUED AIRWORTHINESS

OF THE

DE HAVILLAND MODEL DHC-2 MK I BEAVER

MODIFIED WITH

WIPAIRE STCSA01186CH

TURBINE ENGINE POWERPLANT

Dated May 12, 2000

REG. NO. ____________

SER. NO. ____________

AIRCRAFT MAINTENANCE MANUAL SUPPLEMENT DHC-2 MK I BEAVER

TABLE OF CONTENTS

I. LOG OF REVISIONS ........................................................................................................ 2

II. INTRODUCTION ............................................................................................................... 3

III. DESCRIPTION OF AIRFRAME MODIFICIATIONS – Figure 1........................................ 4

Figure 2-5 - Fuel System ............................................................................................... 5-8

Figure 6 - Heater Installation (Optional) ........................................................................... 9
Figure 7,8 - Fuselage and Wing Reinforcements ...................................................... 10-11
Figure 9 - Horizontal Tailplace Modification ................................................................... 12
Figure 10 - Finlet and Strake Installation ........................................................................ 13
Figure 11 - Engine Installation ........................................................................................ 14
Figure 12 - Battery Box Installation ................................................................................ 15
Figure 13 - Cowling Installation ...................................................................................... 16
Figure 14 - Oil Cooler Installation ................................................................................... 17
Figure 15 - Oil Cooler Duct Installation .......................................................................... 18
Figure 16-18 - Wing Installation ................................................................................ 19-21
Figure 19 - Airspeed Warning System ........................................................................... 22
Figure 20 - Aileron Balancing Weights and Data ........................................................... 23
Figure 21 - Firewall Installation ...................................................................................... 24
Figure 22-23 - Rudder/Aileron Interconnect and Elevator Down Spring Inst............. 25-26
Figure 24 - Flap Limiter Spacer Installation .................................................................... 27
Figure 25 - Auxiliary Rudder Tab Installation ................................................................. 28
Figure 26 - Wing Fence, Flow Energizer, and Aileron Trim System............................... 29
Figure 27 - Checkvalves and Filling Baffles Wing .......................................................... 30
Figure 28-49 - Electrical Schematics ......................................................................... 31-52

IV. TIME LIFE COMPONENTS ............................................................................................ 53

1. Airframe
2. Engine
3. Propeller

V. CONTINUED AIRWORTHINESS INSPECTION CRITERIA ........................................... 54

AIRCRAFT MAINTENANCE MANUAL SUPPLEMENT DHC-2 MK I BEAVER

LOG OF REVISIONS

REV.
NO. PAGES DESCRIPTION DATE

LATEST REVISIONS & SERVICE LETTERS AVAILABLE AT

WWW.WIPAIRE.COM

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INTRODUCTION

This manual is a supplement to the de Havilland Maintenance Manual PSM 1-2-2 and is
made necessary as a result of converting the DHC-2 to turbine power using Wipaire
STC SA0118CH. Maintenance, repairs and modifications accomplished on this airframe
must be compatible not only with the original airframe, but with the modifications as
installed. This supplement is considered a controlled document, and thus revisions must
be kept up to date and are available on our Web site at http://www.wipaire.com or by
calling Wipaire at 651-286-6609.

It will be noted that the modification is accomplished with the use of existing, easy to
obtain parts and accessories. For example, the forward cowling is that of a Beechcraft
90 series aircraft and many of the systems are almost identical to the Cessna 208. This
manual, while not a complete parts manual, does reference most of the parts necessary
for maintenance and continued airworthiness.

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FIGURE 1

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FIGURE 2

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FIGURE 3

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FIGURE 4

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FIGURE 5

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FIGURE 6

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FIGURE 7

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FIGURE 8

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FIGURE 9

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FIGURE 10

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FIGURE 11

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FIGURE 12

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FIGURE 13

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FIGURE 14

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FIGURE 15

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FIGURE 16

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FIGURE 17

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FIGURE 18

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FIGURE 19

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FIGURE 20

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FIGURE 21

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FIGURE 22

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FIGURE 23

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FIGURE 24

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FIGURE 25

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FIGURE 26

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FIGURE 27

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FIGURE 28

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MAIN ELECTRICAL PANEL

FIGURE 29

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SCHEMATIC – GAS GENERATOR SPEED

FIGURE 30

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SCHEMATIC – PROPELLER SPEED

FIGURE 31

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SCHEMATIC – IGNITION SYSTEM

FIGURE 32

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SCHEMATIC – STARTER/GENERATOR SYSTEM

FIGURE 33

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SCHEMATIC – EXTERNAL POWER RECEPTACLE

FIGURE 34

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SCHEMATIC – AUXILARY FUEL PUMP

FIGURE 35

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SCHEMATIC – BATTERY CIRCUIT

FIGURE 36

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SCHEMATIC – LOW OIL PRESSURE WARNING

FIGURE 37

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SCHEMATIC – LOW FUEL LEVEL WARNING - RESERVOIR

FIGURE 38

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SCHEMATIC – LOW FUEL LEVEL WARNING – WING TANKS

FIGURE 39

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SCHEMATIC – ENGINE FUEL HEATER

FIGURE 40

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SCHEMATIC – FUEL QUANTITY

FIGURE 41

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SCHEMATIC – VOLT/AMP METER

FIGURE 42

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SCHEMATIC – FUEL SELECTOR HORN & ANNUNC. PANEL

FIGURE 43

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SCHEMATIC – ELECTRIC TORQUE PRESSURE

FIGURE 44

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SCHEMATIC – STALL WARNING

FIGURE 45

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SCHEMATIC – INLET DE-ICE

FIGURE 46

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SCHEMATIC – ELECTRIC OIL PRESSURE

FIGURE 47
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SCHEMATIC – LOW VOLTAGE WARNING

FIGURE 48
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SCHEMATIC - INSTRUMENTS
FIGURE 49
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TIME LIFE COMPONENTS

1. Airframe – With the C2W 115-1/1115-2 lifetime struts installed, there are no life-
limited components on the airframe.

2. Engine – See Pratt and Whitney service manual for the applicable PT6 engine.

3. Propeller – See the Hartzell service manual for the HC-B3TN-3DY/T10582N.

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AIRCRAFT MAINTENANCE MANUAL SUPPLEMENT DHC-2 MK I BEAVER

CONTINUED AIRWORTHINESS INSPECTION

AIRFRAME

The de Havilland DHC-2 MKI Service Manual and Inspection Schedule is the basic
document for servicing this aircraft. The following pages contain information specific to
the installation of the Turbine Engine per STC SA01186CH and should be used for all
necessary inspections.

Inspected Item
By Date No. Description
1. Check elevator down spring for corrosion, wear and security.
2. Check aileron/rudder interconnect for correct tension.
3. Check aileron/rudder interconnect for proper clearance of
bridal clamps and structure.
4. Perform Cessna A.D. 87-20-03 R2 if applicable. (If aircraft
equipped with STC SA711GL Cessna seats).
5. Check the electric flap hydraulic reservoir for correct level
and inspect for leaks and security.
6. Inspect the following:
a. Inspect stall fences for damage and security.
b. Inspect flow energizers for damage and security.
c. Inspect finlets for cracks, distortion and security
(seaplane/amphibian).
d. Inspect strakes for cracks, distortion and security.

POWER PLANT

NOTE

Refer to Pratt & Whitney PT6A – 27/28 Service Manual for continued airworthiness and
serviceability.

Inspected Item
By Date No. Description
1. Inspect engine cowlings for cracks and damaged or missing
fasteners.
2. Inspect cowling intake for cleanliness.
3. Check particle separator for proper operation and security.
4. Inspect engine mount brackets on engine mount structure
for cracks and security.
5. Inspect vibration isolators for damage, deterioration and
security.

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AIRCRAFT MAINTENANCE MANUAL SUPPLEMENT DHC-2 MK I BEAVER

Inspected Item
By Date No. Description
6. Inspect firewalls and fireseals for damage and security.
7. Inspect exhaust stacks for cracks, distortion and security.
8. Check power, propeller feather and standby-throttle controls
for full and free movement, wear, correct travel at engine
and control quadrant, and security. Friction dampers for
proper operation.

NOTE

Do not attempt to put power lever into reverse range unless engine is running.

9. Check combustion, turbine and exhaust sections for the

following:
a. Gas generator case, fire seals and combustion chamber
for cracks, warping, distortion, burning, fretting, wear and
hot spots.
b. Turbine inlet ducts for cracks and distortion.
c. Check thermocouple system for cracks, security, wiring
and functional checks.
d. Check engine fuel nozzles for evidence of leakage.
10. Check turbine exhaust vanes for cracks, distortion,
looseness and erosion.
11. Inspect turbine exhaust case and duct for cracks and
distortion.
12. Replace engine fuel filter.

FUEL SYSTEM

Inspected Item
By Date No. Description
1. Check header tank drain valve for damage, leaks and positive
shut-off.
2. Check wing fuel tank drain valves for damage, leaks, and
positive shut-off.
3. Check fuel system strainer for cleanliness and damage.
4. Check rubber “swing valves” (check valve) located at wing
station 123.5 for security and operation. These valves are
inspected through the aluminum plugs located on each lower
wing panel leading edge at station 121.5. Check valve for
security and operation. Valve may not seat 100% with no fuel
in tank.
CAUTION
DRAIN FUEL BEFORE REMOVING PLUG FOR INSPECTION

Rubber valve is Cessna part number 9912071-2. Reinstall

plug, “O” ring (p/n MS29513-116), and safety wire

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Inspected Item
By Date No. Description
5. Check engine driven fuel pump filter for foreign matter.
Replace element.
6. Fuel Selector Valves and Linkages (Wing Area) – Inspect
shut-off valves, controls and linkage for condition, security and
evidence of damage. Inspect all fuel selector valve arms for
proper contact with the off stop pins. Rerig if necessary.
7. Check auxiliary fuel pump, ejector pump, swing check valves
and fuel shut-off valve screens for damage and security of
installation. (Access cover on top of reservoir.)
8. Check engine fuel shut-off control for damaged conduit,
security and freedom of movement; spring lock for sufficient
compression.
9. Inspect header tank for damage, security and leaks.
10. Inspect fuel transfer and vent lines from wings for damage,
security and leaks.
11. Inspect fuel caps for leakage, deterioration, and proper
operation.
12. Inspect wing fuel tanks for leaks in leading edge and aft of
forward spar.
13. Inspect fuel transmitters and wiring for security.
14. Inspect all fuel lines for leaks with engine fuel shut-off lever
OFF and fuel booster pump switched to ON. Check low fuel
pressure light goes out. Check pump runs in “normal”
position.
15. Drain sufficient fuel from header tank and check that low fuel
level light comes on. Approximately 7.5 gallons will be
remaining. (Header tank capacity is 12.5 gallons.)
16. Drain sufficient fuel from wings and check that low fuel level
light comes on. Approximately 15 gallons of fuel will be
remaining in each wing.
17. Check that audible hom and annunciator are operational with
both fuel selectors in the OFF position.

OIL SYSTEM

Inspected Item
By Date No. Description
1. Remove oil filter and caps, check for foreign matter.
2. Inspect oil cooler for leaks and security; and air passages for
cleanliness.
3. Inspect oil cooler shroud for damage, corrosion, and
security.

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IGNITION SYSTEM

Inspected Item
By Date No. Description
1. Check igniters for cleanliness and corrosion.

NOTE

Refer to PT6A –27/28 Service Manual for serviceability limits.

PROPELLER

Inspected Item
By Date No. Description
1. Remove spinner and check for grease and oil leaks.
Reinstall spinner after operations 2 through 6 have been
completed.
2. Inspect blades for nicks and cracks. Remove nicks at
leading edge.
3. Inspect hub for cracks.
4. Check all visible parts for wear and safety.
5. Grease blade clamps through zerk fittings. Care should be
taken to avoid blowing out clamp gaskets. Remove one zerk
fitting and pump grease into the remaining fitting until grease
appears through the hole where the zerk was.

CAUTION
ENSURE THAT THE SAME AMOUNT OF GREASE IS APPLIED TO EACH BLADE CLAMP,
OTHERWISE BALANCE OF PROPELLER MAY BE AFFECTED.

UTILITY SYSTEMS

Inspected Item
By Date No. Description
1. Check heat control for full and free movement, correct
operation and security.
2. Check heat exchanger for cracks and security.
3. Check distributor duct for damage and security, and
adjustable outlets for freedom of movement.
4. Inspect cabin-heating ducts for damage, cracks, and
security.
5. Inspect bleed air lines for damage and security.

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ELECTRICAL

Inspected Item
By Date No. Description
1. Remove battery for capacity check. Check electrolyte level
before reinstallation.
2. Inspect the battery area for evidence of electrolyte leakage or
overflow; terminals for pitting and corrosion.
3. Check momentary toggle switches for sticking in “ON”
position.
4. Inspect the generator control unit externally for cleanliness
and security; electrical connections for security.
5. Inspect inverters externally for cleanliness and security.
6. Inspect the starter – generator for cracked or broken mounting
flange and security; electrical connections for security.

NOTE

Refer to starter/gen manufacturers for proper servicing guidelines.

7. Check the starter – generator brushes for specified minimum

length, even wear and freedom of movement in brush
holders; inspect the commutator for evidence of excessive
arcing.
8. Inspect the tachometer generators for security.
9. Inspect the external power receptacle for cleanliness and
contacts for cleanliness.
10. Inspect all relays for security of mounting, connections and
serviceability of wires.
11. Inspect all electrical systems for the following:
a. Wiring for deterioration, chafing, fraying, evidence of
overheating and security.
b. Connector plugs for corrosion, cracks, evidence of
overheating and security.
c. Wire shielding for fraying, crimping and corrosion.
d. Junction boxes for cracks, cleanliness and corrosion.
e. Bonding for damage, corrosion and security.

INSTRUMENTS

Inspected Item
By Date No. Description
1. Inspect all instrument wiring for deterioration, chafing, fraying,
overheating and a proper support. Shielding for fraying,
corrosion and damage. Terminal strips, connections and
bonding for damage, corrosion and security.

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CABLE TENSIONS AT OPERATING TEMPERATURES

FOR STC SA01186CH

Cable Cable Tension (lbs.)

Elevator 85

Rudder 45

Aileron (Fuselage) 28

Elevator & Rudder Trim 9

Notes: 1. Aileron tension should be checked with rudder/aileron interconnect tension relieved.

Rudder/Aileron Interconnect: With right rudder pedal depressed to stop and left aileron to stop,
adjust bridal clamp to remove cable slack plus 1 inch. Reverse
controls to set opposite side.

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FLIGHT CONTROL TRAVELS

FOR STC SA01186CH

CONTROL ANGULAR TOLERANCE TRAVEL DISTANCE

TOLERANCE

SURFACE DISPLACEMENT + OR - FROM NEUTRAL – IN. + OR – IN.

Ailerons Up 18 2 4.20 0.40

Down 11 2 2.50 0.40
Droop 15 1 1/2 3.50 0.30
(wing flap fully down)

Elevator Up 28 2 0 10.60 0.75

0.00
Down 23 2 0 8.75 0.75
0.00

Up 18 1 1/2 1.10 0.1

Elevator Down 26 1 1/2 1.60 0.1
Trim Tab Droop 4 (screw
jack and cables at
center of travel) 0.25

Rudder Left 25 2 11.40 0.90

Right 25 2 11.40 0.90

Rudder Left 18 2 1.125 0.125

Trim Tab Right 18 2 1.125 0.125

Wing Flaps Down 35 2 12.30 0.70

Reference Points:
Wing Flap Settings -0 Ailerons – at outboard end.
-15 1 Flaps – at inboard flap hinge.
-35 1 Elevators and tabs – at Station 8.00from CL of
aircraft.
Rudder – at bottom aft end or bottom of trim tab in
neutral.

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