Wipaire WIPLINE 10000 Service Manual Download

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SERVICE MANUAL & ICA

10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A

P/N 1002545

Revision U

Page 1

SERVICE MANUAL AND INSTRUCTIONS FOR

CONTINUED AIRWORTHINESS

WIPLINE MODEL 10000 AMPHIBIOUS FLOATS

AT-802A FIRE BOSS CONVERSION

Revision U

WIPLINE FLOATS • SKIS • MODIFICATIONS • AIRCRAFT SALES

AVIONICS • INTERIOR • MAINTENANCE • PAINT REFINISHING

Summary of Contents for WIPLINE 10000

Page 1: ... P N 1002545 Revision U Page 1 SERVICE MANUAL AND INSTRUCTIONS FOR CONTINUED AIRWORTHINESS WIPLINE MODEL 10000 AMPHIBIOUS FLOATS AT 802A FIRE BOSS CONVERSION Revision U WIPLINE FLOATS SKIS MODIFICATIONS AIRCRAFT SALES AVIONICS INTERIOR MAINTENANCE PAINT REFINISHING ...

Page 2: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A Page 2 Revision U P N 1002545 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 3: ...luding inspection intervals updated numbering in Section 1 and added Means for Leveling Section 1 10 Added green grease as approved grease corrected Hyd fluid level and air pressure Updated maintenance instructions 10 2 Modified finlet inspection requirements and added Visual Inspection 8 21 2014 L 83 89 Added Shear Torque Chart PR 1440 C Sealant and Tef Gel 5 26 2015 M 3 17 83 89 Added Dow Cornin...

Page 4: ...ay to grease 1 23 2020 U 19 100 103 105 108 111 114 Updated Nose Box Track tolerance from 070 to 050 Added info about hardware replacement Added Section 14 2 checklist for hardware retorque and replacement Updated Inspection Time Checklist with details about Aft Pylon Drag Strut Bolt Nose Gear Spring Service Letter 170 and Nose Gear Tracks Added details about Nose Gear Springs in Inspection Checkl...

Page 5: ...AM DELIVERY SYSTEM OPERATION REMOVAL AND SERVICE 49 CHAPTER 6 FLOAT BILGE SYSTEM OPERATION REMOVAL AND SERVICE 53 CHAPTER 7 VENT AND OVERFILL PROTECTION SYSTEM 55 CHAPTER 8 FLOAT STEERING AND RETRACT SYSTEM 57 CHAPTER 9 ANGLE OF ATTACK SYSTEM 61 CHAPTER 10 AIRCRAFT WING AND CONTROL SURFACE MODIFICATIONS 63 CHAPTER 11 AUXILIARY INSTRUMENT PANEL 65 CHAPTER 12 ELECTRICAL 69 CHAPTER 13 REPAIRING FLOAT...

Page 6: ...EL CIRCUIT BREAKER 67 FIGURE 12 0 SCHEMATIC AUXILIARY INSTRUMENT PANEL 71 FIGURE 12 1 SCHEMATIC CIRCUIT BREAKER PANEL 72 FIGURE 12 2 SCHEMATIC INSTALLATION ANGLE OF ATTACK 73 FIGURE 12 3 AOA FLAP CALIBRATION READINGS 74 FIGURE 12 4 SCHEMATIC INSTALLATION FOAM TANKS PUMPS 75 FIGURE 12 5 SCHEMATIC INSTALLATION BILGE PUMPS 76 FIGURE 12 6 SCHEMATIC INSTALLATION SCOOP FILL SYSTEM 77 FIGURE 12 7 SCHEMAT...

Page 7: ...r Wipline Aluminum Floats please refer to the Structural Repair Manual For Wipline Aluminum Floats part number 1008274 It is available free of charge online at www wipaire com The service products referred to throughout this manual are described by their trade name and may be purchased from the Wipaire Parts Department To contact Wipaire for technical support or parts sales call write or email Wip...

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Page 9: ...LOAT HULL MAINTENANCE 11 1 3 AMPHIBIAN LANDING GEAR SYSTEM 12 1 3 1 LANDING GEAR HANDLE 12 1 3 2 INDICATOR LIGHTS 13 1 3 3 LANDING GEAR OPERATION 13 1 3 4 EMERGENCY PUMP HANDLE 13 1 4 SCOOP SYSTEM 13 1 5 FOAM SYSTEM 14 1 6 VENT AND OVERFLOW PROTECTION 14 1 7 HARD AND OVERGROSS LANDING AND DAMAGE INVSTIGATION 15 1 8 CLEANING 15 1 9 CORROSION 15 1 10 MEANS FOR LEVELING 16 ...

Page 10: ...trols and indicators 7 A bilge pumping system and a water in floats warning system are incorporated These changes will be briefly discussed in the following paragraphs 1 2 FLOATS The model 10000 amphibious float is an all aluminum constructed float with 12 watertight compartments of approximately 10 000 pounds buoyancy As a part of the float installation the following additional changes are made t...

Page 11: ...e 6061 T6 aluminum keel chine etc Skins are alodined and primed after being cleaned and acid etched Exterior is finished with a urethane color paint or equivalent Float Handling Jacking and Aircraft Towing To jack the floats for servicing tires brakes or doing retraction tests it is recommended that a floor type jack three ton minimum be used These jacks are commonly used for truck repair The jack...

Page 12: ... periodically by viewing the sight glass for fluid level in the upper one third of the range If fluid is low fill with MIL H 5606 or equivalent Filter screens are installed on each pickup tube inside of hydraulic reservoirs and there are also 3 external 10 micron filters as well Clean filter screens and elements every 100 hours Per Service Letter 103 a Spin on Type filter assembly with a Baldwin F...

Page 13: ...ystem and automatically shuts off the hydraulic motors Each gear operates independently of the other and therefore the position lights illuminate at various times 1 3 4 EMERGENCY PUMP HANDLE An emergency hand pump is located on the floor to the left side of the seat for use in the event the normal hydraulic system fails This hand pump may be used to retract or extend the land gear Prior to utilizi...

Page 14: ...eration Tank and floor 50 lbs at 1 0 each float To use fluid stored in the float tanks it is necessary to pump fluid from the float tank to the fuselage firewall tank This transfer can be accomplished manually or automatically by selecting the appropriate position with the left and right foam control switches located on the glare shield panel When manual on is selected fluid will be pumped via the...

Page 15: ...attention to hard to reach places such as seams wheel well etc Alternatively water taxiing in FRESH WATER at step speed with the water scoops in the DOWN position and the fire gates OPEN can help to flush the entire system This method is especially recommended as a daily cleaning for operators scooping in saltwater NOTE Operators scooping saltwater are strongly cautioned rinsing the entire aircraf...

Page 16: ...sion and must be addressed proactively 1 10 MEANS FOR LEVELING The airplane is leveled to level flight attitude See Float Handling Jacking and Aircraft Towing section of this manual The airplane should be in this level position for aircraft weighing and other maintenance installation items that require the aircraft to be in level flight attitude The airplane is in level flight attitude when the to...

Page 17: ...E NOSE AND MAIN GEAR RAMS 24 2 7 ADJUSTMENT TEST 24 2 7 1 NOSE GEAR 24 2 7 2 MAIN GEAR 24 2 7 3 BLEEDING HYDRAULIC SYSTEM AFTER SERVICE 25 2 7 4 HYDRAULIC ACCUMULATOR SERVICE 25 2 8 MAIN AND NOSE GEAR REMOVAL AND DISASSEMBLY 25 2 8 1 REMOVAL OF MAIN GEAR OLEO 25 2 8 2 REMOVAL OF MAIN GEAR RETRACTION CYLINDER 25 2 8 3 REMOVAL OF MAIN GEAR DRAG LINK 26 2 8 4 REMOVAL OF NOSE GEAR TROLLEY ASSEMBLY FRO...

Page 18: ...l amount of lost motion of the actuator rod Retraction takes place when pressure is exerted on the actuator piston driving the collar along the slide tube The lock is tripped when the follower slides up the contoured track in the actuator as shown in figure 2 4 A reverse process affects extension Gear position light proximity switches are closed when the appropriate hook containing the magnetic ma...

Page 19: ...r Water heat resistant grease is recommended At brake installation apply STA Lube synthetic brake and caliper grease or equivalent to brake caliper pins The dual piston brakes need no special care other than to maintain the brake disc free of rust which causes premature brake lining wear Bleeding is carried out in the usual manner from the bottom up Although since the line is T ed to the double br...

Page 20: ...ear and security 3 The metering tube does not need to be taken apart from the end cap of the inside cylinder unless extensive cleaning is desired If it is disassembled a To return the metering tube height and condition to factory preset first apply blue Loctite to the threads of the inner end cap threads that hold the metering tube for added security until next removal b The metering tube is threa...

Page 21: ...e Vaseline or equivalent as it dissolves in hydraulic fluid 6 Install the end cap bolts with gasket sealer on the threads for added security Tighten to 25 30 in lbs making sure not to over tighten damaging the T seal Set this part of the unit aside and move on to next steps 7 To assemble the gland assembly insert the inside T seal and wiper again using Vaseline on the T seal a The gland must be in...

Page 22: ... damage to the threads e Using a spanner wrench tighten the piston to the inner cylinder f Install the jam nut onto the piston end of the metering tube and stake for security g Install the 2 T seals onto the exterior of the piston and gland and lube with Vaseline 9 Gently clamp the outer tube end in a vise and add 1900 ml of hyd fluid 5606 or equivalent 10 Lube the inside of the outer cylinder whe...

Page 23: ...sealer 13 Install the O ring onto the fill drain plug before installing the plug onto the end cap 14 Install the O ring onto the Schrader valve and install onto the outside of the end cap NOTE Align Schrader valve 180 degrees from the Placard NOTE Double check the plugs and bolts for proper Installation and security before adding gas charge ...

Page 24: ...p stop bolt See figure 2 9 and 2 10 for locations and assembly Nose gear proximity switches are located on clips that are mounted on the outer cylinder body one on each end The most forward switch is for the gear down lights and most aft is for the gear up position lights Set the proximity switch mounting clip along outer cylinder body to a position such that the light goes out when the over cente...

Page 25: ...rsely when opening a connection in the system a discharge of fluid under pressure will occur as the accumulator empties itself Once the accumulator is full the fluid level should be maintained in the upper one third 1 3 of the sight glass If the reservoir empties i e fluid disappears in sight glass stop the cycle by pulling the circuit breaker on the control panel Fill the reservoir again and comp...

Page 26: ... of cylinder ram at rod end Turn piston from aft side of nose box out of rod end Push on trolley assembly to unlock and remove the bottom thru bolts Slide out of nose box Note On installation adjust piston so it bottoms out on aft flange at the same time as the bearings when nose gear is in locked position Also note orientation of trolley blocks The side with the most edge distance from hole is to...

Page 27: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 27 FIGURE 2 1 SCHEMATIC HYDRAULIC SYSTEM ...

Page 28: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A Page 28 Revision U P N 1002545 FIGURE 2 2 SCHEMATIC ELECTRICAL SYSTEM ...

Page 29: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 29 FIGURE 2 3 LAYOUT MAIN GEAR ...

Page 30: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A Page 30 Revision U P N 1002545 FIGURE 2 4 CARRIAGE ASSEMBLY MAIN GEAR ...

Page 31: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 31 FIGURE 2 5 ASSEMBLY MAIN GEAR SHOCK STRUT ...

Page 32: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A Page 32 Revision U P N 1002545 FIGURE 2 6 ASSEMBLY MAIN GEAR ASSEMBLY ...

Page 33: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 33 FIGURE 2 7 ASSEMBLY MAIN GEAR DRAG LINK ...

Page 34: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A Page 34 Revision U P N 1002545 FIGURE 2 8 ASSEMBLY MAIN GEAR WHEEL AND BRAKE ...

Page 35: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 35 FIGURE 2 9 ASSEMBLY NOSE GEAR BOX AND RETRACTION ...

Page 36: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A Page 36 Revision U P N 1002545 FIGURE 2 10 ASSEMBLY NOSE GEAR LOWER END ...

Page 37: ...ERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 37 CHAPTER 3 HYDRAULIC PUMP SYSTEM DISASSEMBLY AND SERVICE CONTENTS GENERAL 38 3 1 OPERATION TROUBLESHOOTING 39 ...

Page 38: ...power pack installation the power pack will need to be lifted up and supported with a ratchet strap or something similar while loosening up the clamps that will attach it to the aircraft tubing This will lift the assembly up far enough to remove the reservoir 3 Remove the 4 screws on each tank 2 on upper side of the reservoir 4 Dump out remaining oil and clean reservoir 5 Unscrew stand pipe with t...

Page 39: ...re switch leads and see if motor runs If motor operates replace pressure switch c Short across solenoid pressure switch leads and see if motor runs If motor operates replace solenoid pressure switch d If c above does not produce results and it is verified that voltage was actually applied to motor it can be assumed motor is bad or not properly grounded e Check motor ground 2 PROBLEM Powerpack does...

Page 40: ...ng fluid level in reservoir and looking at couplings for oil leaks If no external leaks are found disconnect and cap off the hydraulic actuators one at a time and find the leaky one by process of elimination If isolating entire system still indicates internal leak powerpack check valve located in pressure port of pump is bad and needs replacement or reseating b Visually inspect lines cylinders and...

Page 41: ...d inside reservoir tank b Connect motor direct to 24 volt source and note its operation if good wire connection is bad if operation poor motor needs overhaul c Covered in b above d Replace pump 7 PROBLEM Circuit breaker pops during cycle PROBABLE CAUSE a Wire connections bad or corroded b Bad motor brushes c Bad circuit breaker REMEDY a Clean and protect terminal with grease b Overhaul motor c Rep...

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Page 43: ... 43 CHAPTER 4 SCOOP SYSTEM OPERATION REMOVAL AND SERVICE CONTENTS 4 1 DESCRIPTION AND OPERATION 44 4 2 ADJUSTMENT AND TEST 44 4 3 REMOVAL OF SCOOP AND FILL SYSTEM 44 4 4 SERVICE SCOOP SYSTEM 45 4 5 SERVICE OF SELONOID VALVE SCOOP RETRACTION 45 4 6 SERVICE OF IN LINE FILTERS SCOOP RETRACTION 45 ...

Page 44: ...he scoop is above the lower most part of the main keel by approximately 1 8 After adjustment reconnect hydraulic lines and cycle probe for proper operation Check if probe up and down position lights are operating properly 4 2 ADJUSTMENT AND TEST Lower Scoop Assembly and Scoop Cylinder Remove attaching bolt for scoop assembly accessible from outside of the float Drop down and disconnect the rod end...

Page 45: ... Remove nut and spring and gently remove the valve spring Remove the electrical box cover the one with the amber light by loosening the two center round knobs Pull off electrical box Remove solenoid block from the manifold by removing the four Allen hex head bolts Remove the solenoid valve from the manifold and clean by carefully blowing air through the ports Reinstall the block with the four Alle...

Page 46: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A Page 46 Revision U P N 1002545 FIGURE 4 1 ASSEMBLY SCOOPING SYSTEM COMPLETE ...

Page 47: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 47 FIGURE 4 1A ASSEMBLY SCOOPING SYSTEM ...

Page 48: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A Page 48 Revision U P N 1002545 FIGURE 4 2 ASSEMBLY CYLINDER PROBE JACK ...

Page 49: ...S ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 49 CHAPTER 5 FOAM DELIVERY SYSTEM OPERATION REMOVAL AND SERVICE CONTENTS 5 1 DESCRIPTION AND OPERATION 50 5 2 ADJUSTMENT AND TEST 50 5 3 REMOVAL OF FOAM SYSTEM 50 5 4 SERVICE FOAM SYSTEM 50 ...

Page 50: ... is necessary for this system When pumps are running a pump on light is located on the auxiliary instrument panel 5 2 ADJUSTMENT AND TEST To remove tank from float disconnect electrical plug and hose coupling from tank edges Lift from center handle and the tank from the float through top deck Tank should have small amount of foam in for ease of removal The tank floor may now be removed through top...

Page 51: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 51 FIGURE 5 SCHEMATIC PLUMBING FOAM SYSTEM ...

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Page 53: ...TS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 53 CHAPTER 6 FLOAT BILGE SYSTEM OPERATION REMOVAL AND SERVICE CONTENTS 6 1 DESCRIPTION AND OPERATION 54 6 2 ADJUSTMENT AND TEST 54 6 3 REMOVAL OF THE SYSTEM 54 6 4 SERVICE BILGE SYSTEM 54 ...

Page 54: ...HAPTER 6 FLOAT BILGE SYSTEM OPERATION REMOVAL AND SERVICE No adjustment is necessary for this system When pumps are operating A light for the right float and left float will illuminate on the auxiliary instrument panel When water is present in the float compartment forward of the step the sensor will illuminate a light on the auxiliary instrument panel 6 2 ADJUSTMENT AND TEST To remove pumps from ...

Page 55: ...00 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 55 CHAPTER 7 VENT AND OVERFILL PROTECTION SYSTEM CONTENTS 7 1 DESCRIPTION AND OPERATION 56 7 2 ADJUSTMENT AND TEST 56 7 3 SERVICE OVERFILL VENT SYSTEM 56 ...

Page 56: ...ull forward to release the stop from its holder and let the cable go slack The door is now free to hinge To reattach pull cable forward so cable ball is in its holder and stow handle 7 1 DESCRIPTION AND OPERATION CHAPTER 7 VENT AND OVERFILL PROTECTION SYSTEM No adjustment is necessary for this system The cable lengths determine the pressure on the spring It should unseat at approximately 40 pounds...

Page 57: ...FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 57 CHAPTER 8 FLOAT STEERING AND RETRACT SYSTEM CONTENTS 8 1 DESCRIPTION AND OPERATION 58 8 2 ADJUSTMENT 58 8 3 REMOVAL AND ACCESS 58 8 4 SERVICE OF STEERING AND RETRACT SYSTEM 58 ...

Page 58: ...the aircraft rudder and adjusting the turnbuckles such that both rudders trail with the float centerline Set steering and balance cable tension to 10 lbs 5 0 Retraction cables should be rigged such that the rudder blade is in the up position and that the cables are just slack in the down position and lightly resting on the stops 8 2 ADJUSTMENT Cables can be accessed through the fuselage side panel...

Page 59: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 59 FIGURE 8 WATER RUDDER STEERING AND RETRACTION SYSTEM ...

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Page 61: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 61 CHAPTER 9 ANGLE OF ATTACK SYSTEM CONTENTS 9 1 GENERAL 62 9 2 MAINTENANCE 62 ...

Page 62: ... the AT 802A aircraft on 10000 floats The wiring schematic is on figure 9 4 The manual for all other instructions is in the manufacturer s manual The vane setting should be 7 8 nose up from aircraft leveling point when 1st green light just comes on Measurements were taken from flat section of vane Figure 9 4A shows resistances in ohms Ω across the P 12 connection on the J6 module box These reading...

Page 63: ...MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 63 CHAPTER 10 AIRCRAFT WING AND CONTROL SURFACE MODIFICATIONS CONTENTS 10 1 DESCRIPTION AND OPERATION 64 10 2 MAINTENANCE 64 ...

Page 64: ...replaced as soon as possible FINLETS 50 hrs Perform a visual inspection of auxiliary finlets and struts if installed Clean the area inspect auxiliary finlet installation for missing gaskets and loose bolts or cracks in attach fittings if struts are installed inspect the strut and attach fittings for loose bolts or cracks inspect the area of the stabilizer around mounting holes and doublers for cra...

Page 65: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 65 CHAPTER 11 AUXILIARY INSTRUMENT PANEL CONTENTS 11 1 DESCRIPTION AND OPERATION 66 ...

Page 66: ... panel This panel houses all the switches lights and displays for the water scooping portion of this installation This panel also houses the ITT and Torque gauges for easier viewing Figure 11 1 and 11 2 shows the panel layout along with the circuit breaker panel layout 11 1 DESCRIPTION AND OPERATION CHAPTER 11 AUXILIARY INSTRUMENT PANEL FIGURE 11 1 INSTRUMENT PANEL ...

Page 67: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 67 FIGURE 11 2 INSTRUMENT PANEL CIRCUIT BREAKER ...

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Page 69: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 69 CHAPTER 12 ELECTRICAL CONTENTS 12 1 GENERAL 70 ...

Page 70: ... ON AIR TRACTOR AT 802A Page 70 Revision U P N 1002545 Figures 12 0 through figure 12 10 show the electrical schematic for the auxiliary instrument panel along with electrical schematics for each noted system 12 1 GENERAL CHAPTER 12 ELECTRICAL ...

Page 71: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 71 FIGURE 12 0 SCHEMATIC AUXILIARY INSTRUMENT PANEL ...

Page 72: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A Page 72 Revision U P N 1002545 FIGURE 12 1 SCHEMATIC CIRCUIT BREAKER PANEL ...

Page 73: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 73 FIGURE 12 2 SCHEMATIC INSTALLATION ANGLE OF ATTACK ...

Page 74: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A Page 74 Revision U P N 1002545 FIGURE 12 3 AOA FLAP CALIBRATION READINGS ...

Page 75: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 75 FIGURE 12 4 SCHEMATIC INSTALLATION FOAM TANKS PUMPS ...

Page 76: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A Page 76 Revision U P N 1002545 FIGURE 12 5 SCHEMATIC INSTALLATION BILGE PUMPS ...

Page 77: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 77 FIGURE 12 6 SCHEMATIC INSTALLATION SCOOP FILL SYSTEM ...

Page 78: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A Page 78 Revision U P N 1002545 FIGURE 12 7 SCHEMATIC INSTALLATION PROBE POSITION ...

Page 79: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 79 FIGURE 12 8 SCHEMATIC INSTALLATION PDR 60 AUDIO ...

Page 80: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A Page 80 Revision U P N 1002545 FIGURE 12 9 SCHEMATIC INSTALLATION ITT EXCESS POWER LIGHT ...

Page 81: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 81 FIGURE 12 10 SCHEMATIC INSTALLATION WATER IN FLOAT SENSORS ...

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Page 83: ...CTOR AT 802A P N 1002545 Revision U Page 83 CHAPTER 13 REPAIRING FLOAT HULL SHEET METAL BULKHEADS AND OTHER AREAS CONTENTS 13 1 DESCRIPTION 84 13 2 RIVET REPLACEMENT 84 13 3 BULKHEAD ACCESS HOLES 89 13 4 REPAIRING FLOAT HULL EXTRUSIONS KEEL CHINE ETC 90 ...

Page 84: ...1 through 10 3 or any acceptable repair method listed in FAA Advisory Circular 43 13 1A Any float hull sheet metal or part thereof can be purchased from Wipaire to aid in repair To simplify repairs the skins may be ordered precut Skins may be reattached to extrusions by method shown in figures 10 1 through 10 3 NOTE There are many ways to repair Wipline floats and each method depends on the degree...

Page 85: ...fasteners edge distance and rivet spacing guidelines per AC43 13 1B should be followed at all times 2 In areas where solid rivets are smoking or missing blind rivets are an acceptable short term solution but should be replaced with solid rivets or Hi Lok fasteners or equivalent 3 Follow fastener manufacturer guidelines for installation ...

Page 86: ... TRACTOR AT 802A Page 86 Revision U P N 1002545 FIGURE 13 1 TYPICAL SKIN REPAIRS 1 Trim hole as shown by dotted line 2 Patch material to at least same thickness as original skin 3 Prime all bare surfaces 4 Seal between patch and skin 5 Rivet in place ...

Page 87: ... TRACTOR AT 802A P N 1002545 Revision U Page 87 1 Trim hole as shown by dotted line 2 Patch material to at least same thickness as original skin 3 Prime all bare surfaces 4 Seal between patch and skin 5 Rivet in place FIGURE 13 2 TYPICAL SKIN REPAIRS ...

Page 88: ... TRACTOR AT 802A Page 88 Revision U P N 1002545 1 Trim hole as shown by dotted line 2 Patch material to at least same thickness as original skin 3 Prime all bare surfaces 4 Seal between patch and skin 5 Rivet in place FIGURE 13 3 TYPICAL SKIN REPAIRS ...

Page 89: ...age 89 During extensive float maintenance it may be desirable to cut an access hole in a solid bulkhead to enable replacement of neighboring float structure This type of access hole can be cut and then repaired according to figure 13 3 BULKHEAD ACCESS HOLES FIGURE 13 4 BULKHEAD ACCESS HOLES ...

Page 90: ...through 11 5 Sections of extrusion for splicing may be purchased from Wipaire in any length needed Skins may be purchased pre cut to simplify repairs There are many ways to repair Wipline floats and each method depends on the degree and location of the damage The following figures are examples of some repairs For additional help contact the Wipline float factory at 651 451 1205 13 4 REPAIRING FLOA...

Page 91: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 91 FIGURE 13 5 GUNWALL EXTRUSION REPAIR ...

Page 92: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A Page 92 Revision U P N 1002545 FIGURE 13 6 FORWARD CHINE EXTRUSION REPAIR ...

Page 93: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 93 FIGURE 13 7 MAIN KEEL EXTRUSION REPAIR ...

Page 94: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A Page 94 Revision U P N 1002545 FIGURE 13 8 AFT KEEL EXTRUSION REPAIR ...

Page 95: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 95 FIGURE 13 9 AFT CHINE EXTRUSION REPAIR ...

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Page 97: ...A 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 97 CHAPTER 14 CONTINUED AIRWORTHINESS CONTENTS 14 1 SERVICE SCHEDULE 98 14 2 FLOAT HARDWARE RECOMMENDED RETORQUE AND REPLACEMENT CHECKLIST 103 ...

Page 98: ... protection products when servicing float hull amphibious components and firebombing equipment This lists products used by Wipaire during assembly of the floats 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 or metal...

Page 99: ...u cannot determine existing grease in wheel bearings completely clean and repack bearings with new grease As general inspection guidelines each of the following areas should be inspected for their own unique attributes Movable Parts For lubrication servicing security of attachment binding excessive wear safetying proper operation proper adjustment correct travel cracked fittings security of hinges...

Page 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 Nut Bolt Size Torque Limits In lbs Minimum Torque Limits In lbs Maximum 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...

Page 101: ...S ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 101 Electrical Connections Apply SP 400 SOFT SEAL or LPS 500 to all electrical connections to prevent corrosion Hydraulic Fluid For use in all hydraulic systems including brakes MIL H 5606 ...

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Page 103: ...es 1 Recommended RETORQUE of all items below 100 hrs 25 hrs 2 Recommended REPLACEMENT of all items below 750 hrs 250 hrs 3 Inspection signoff is optional 4 Torque values shown are for clean non lubricated parts Threads should be free of dust metal filings etc 5 Tef Gel is recommended to be applied to the bolt shank Torque values should be reduced by 20 if Tef Gel is coating the bolt threads 6 May ...

Page 104: ...loat fitting AN10 30A 2 5 8 15 16 55 ft lbs 44 ft lbs NAS1149F1063P 4 MS21044N10 6 Fwd spreader bar Internal float fitting to spreader bar fitting AN10 30A 2 5 8 15 16 55 ft lbs 44 ft lbs NAS1149F1063P 4 MS21044N10 7 Fwd spreader bar Spreader bar fitting tow lug through bolts AN5 40A 8 5 16 1 2 6 ft lbs 5 ft lbs NAS1149F0563P 16 MS21044N5 8 Center bolt flywires to fwd kicker struts AN10 37A 1 5 8 ...

Page 105: ...6J 16 MS21044N6 16 Rear spreader bar Center spreader bar fitting to rear kicker struts NAS6209 29 2 9 16 7 8 45 ft lbs 36 ft lbs NAS1149F0932P 2 MS21083N9 17 Upper rear fuselage fitting to rear kicker struts NAS6209 26 2 9 16 7 8 45 ft lbs 36 ft lbs NAS1149F0932P 2 MS21083N9 18 Nose gear spring Upper spring bolts to trolley AN8 33A AN7 31A 4 4 1 2 7 16 1 2 5 8 Note 6 57 ft lbs 41 ft lbs 46 ft lbs ...

Page 106: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A Page 106 Revision U P N 1002545 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 107: ...NUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 107 CHAPTER 15 INSPECTION CHECKLISTS CONTENTS 15 1 INSPECTION TIME CHECKLIST 108 15 2 OVERGROSS LANDING INSPECTION CHECKLIST 112 ...

Page 108: ... Systems Inspect the following cables for broken wire cable fittings for cable slippage cracks and distortion Inspect cable pulleys for freedom of rotation cable guard pins for presence rigging Retract for operations check X Water Rudder Blades and Posts Inspect for damage security of attachment corrosion paint rigging Inspect water rudder bulkhead boots for cracks and wear X Electrical System Gea...

Page 109: ...draulic Fluid Screen inside Hydraulic Reservoir Clean and inspect Note If floats sit for extended periods of time i e if removed during winter months screen should be cleaned before putting floats back into service Hydraulic fluid in reservoir should be checked for moisture or other contaminates and changed if necessary X 3 External Hydraulic 10 micron filter elements Clean and inspect replace if ...

Page 110: ...exceed 1 25 in total length X Retorque Nose Gear Spring attach hardware Reference Tension Application Torque Chart X Main Gear Drag Link Inspect for condition lubrication corrosion check attach bolts for wear Grease the pivot points X Main Gear Shock Strut Inspect for evidence of corrosion pitting cleanliness and security Check lower attach bolt for wear and lubrication X Main Landing Gear Lower A...

Page 111: ...s of front float strut and the main float pylon attach X Comply with Service Letter 170 X Water Pickup Probes Perform Retraction Test For probe down position inspect for proper seating and alignment of tubes X Inspect for speed of retraction approximately one second X Inspect for any leaks in probe jack cylinder X Inspect float area around probe opening for any damage X Inspect scoop probe for dam...

Page 112: ...ction for deformation and hole elongation Nose gear Trolley Inspect for evidence of impact damage near attach points and all attached linkages to include over center down lock mechanism to include trolley block and or trolley axles When damage is found accomplish gear swing looking for nose gear binding due to component damage and replace as needed Nose gear ram assy and Rod End Inspect for eviden...

Page 113: ...ion Inspect Carriage for evidence of damage and proper functionality See Service Manual for how to properly perform retraction extension test Inspect Slide Tube attach points for damage and loose sheared hardware to include Slide Tube concentricity Float Hulls Inspect float exterior for evidence of wrinkled metal smoking rivets and popped fasteners Inspect keel for any evidence of contact with run...

Page 114: ...ng locations Fuselage float fitting attach points Inspect area for bending cracking or distortion Detailed Inspection of all strut attach on bulkheads for signs of fatigue surrounding strut attach points Fwd Aft kicker strut attach points Inspect for component distortion Loose or damaged hardware Loose attaching hardware will require further inspection for deformation and hole elongation FIGURE 15...

Page 115: ...SERVICE MANUAL ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT 802A P N 1002545 Revision U Page 115 CHAPTER 16 WEIGHT AND BALANCE CONTENTS 16 1 WEIGHING PROCEDURES FOR THE AT 802A FIREBOSS AMPHIBIAN 116 ...

Page 116: ...ing leading edge on either side of the plane to the floor and mark This is the datum line station 0 0 Draw another line between the nose wheel centers and a 3rd line between the main wheel centers Measure the distance from 0 0 to the nose wheel line This is X Measure the distance from 0 0 to the main wheel line This is Y Use this table for the calculations 16 1 WEIGHING PROCEDURES FOR THE AT 802A ...

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