Page 1 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A WIPLINE FLOATS • SKIS • MODIFICATIONS • AIRCRAFT SALES AVIONICS • INTERIOR • MAINTENANCE • PAINT REFINISHING SERVICE MANUAL AND INSTRUCTIONS FOR CONTINUED AIRWORTHINESS WIPLINE MODEL 10000 AMPHIBIOUS FLOATS AT-802A FIRE BOSS CONVERSION Revision U P/N 1002545...
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Page 3 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A LOG OF REVISIONS Pages Description Date 2, 3, Added info to 10.2; added alternate inst. panel; updated Table of Contents. 5/25/2004 38, 39 39, 46 Added info on AOA system maintenance and figure 9.4A. 11/16/2004 15, 16, Changed some p/n in drawings, added instructions for solenoid valve...
Page 4 Aft Pylon Drag Strut Bolt, Nose Gear Spring, Service Letter 170, and 111, 114 Nose Gear Tracks. Added details about Nose Gear Springs in Inspection Checklist. Added Figure 15.1. View most current revision of this ICA at www.wipaire.com. Page 4 Revision U P/N 1002545...
Page 5: Table Of Contents
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A TABLE OF CONTENTS INTRODUCTION ...............................7 CHAPTER 1 GENERAL INFORMATION ......................9 CHAPTER 2 MAIN GEAR AND NOSE GEAR OPERATION, REMOVAL AND SERVICE ......17 CHAPTER 3 HYDRAULIC PUMP SYSTEM, DISASSEMBLY AND SERVICE ...........37 CHAPTER 4 SCOOP SYSTEM OPERATION, REMOVAL, AND SERVICE ..........43 CHAPTER 5 FOAM DELIVERY SYSTEM OPERATION, REMOVAL AND SERVICE ........49 CHAPTER 6 FLOAT BILGE SYSTEM OPERATION, REMOVAL, AND SERVICE ........53...
Page 6 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A LIST OF FIGURES FIGURE 2.1 SCHEMATIC - HYDRAULIC SYSTEM ................27 FIGURE 2.2 SCHEMATIC - ELECTRICAL SYSTEM ................28 FIGURE 2.3 LAYOUT – MAIN GEAR ......................29 FIGURE 2.4 CARRIAGE ASSEMBLY – MAIN GEAR ................30 FIGURE 2.5 ASSEMBLY –...
Page 7: Introduction
When performing standard repairs for 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.
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Page 9: Chapter 1 General Information
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A CHAPTER 1 GENERAL INFORMATION CONTENTS 1.1 AIRPLANE ..............................10 1.2 FLOATS ..............................10 1.2.1 FLOAT 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...
Page 10: Airplane
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A CHAPTER 1 - GENERAL 1.1 AIRPLANE The airframe of the Fire Boss is adapted from the Air Tractor AT-802A agricultural airplane. It is an all-metal, low cantilever wing design. It is powered by a Pratt and Whitney PT6A-67AG turboprop engine of 1350 SHP or PT6A- 67F of 1600 SHP.
Page 11: Float Hull Maintenance
When towing the amphibian aircraft, tow lugs (2) are provided on underside of the front spreader bar (outboard ends). A rigid “V” frame can be fabricated to attach to these lugs and aircraft towed with a tractor. Wipaire Parts has this tow bar available.
Page 12: Amphibian Landing Gear System
Two points are provided on aft cockpit sides. Two points are the engine mount at the firewall on each side. A lifting beam that will pick up all four points is available at Wipaire Parts Dept. 1.3 AMPHIBIAN LANDING GEAR SYSTEM The landing gear incorporated within the amphibious floats on this airplane is retractable, quadricycle type with two swiveling nose (or bow) wheels and four (4) (two (2) sets of dual) main wheels.
Page 13: Indicator Lights
1.4 SCOOP SYSTEM The Wipaire 802 Fire Boss has two water scoops, one in each float. The scoops are three inches in diameter and are hydraulically operated by the 1000 psi float hydraulic system. The hydraulic system has an accumulator to enhance the speed of scoop deployment and retraction.
Page 14: Foam System
1.5 FOAM SYSTEM The Wipaire 802A Fire Boss foam system consists of three individual tanks. The original 18-gallon firewall tank is supplemented by an additional 30 U.S. gallon tank in each float (at sta +1) of which approximately 28 U.S. gallons is usable in the automatic mode.
Page 15: Hard And Overgross Landing And Damage Invstigation
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A NOTE: Before opening the main vent door for access, the door bracing turnbuckles (located inside the hopper just below the vent door) need to be disconnected. They are accessible with the drop vent door open (1 on each side).
Page 16: Means For Leveling
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A After removing the corroded area, restore area to original finish (prime and enamel). BOESHIELD T9, Corrosion X, or ACF-50 may also be applied to stop corrosion. Refer to manufacturer’s instructions for application instructions.
Page 17: Chapter 2 Main Gear And Nose Gear Operation, Removal And Service
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A CHAPTER 2 MAIN GEAR AND NOSE GEAR OPERATION, REMOVAL AND SERVICE CONTENTS 2.1 DESCRIPTION AND OPERATION ......................18 2.2 SERVICE – NOSE GEAR .........................19 2.3 NOSE BOX TRACK WEAR ........................19 2.4 SERVICE –...
Page 18: Description And Operation
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A CHAPTER 2 - MAIN GEAR AND NOSE GEAR OPERATION, REMOVAL AND SERVICE 2.1 DESCRIPTION AND OPERATION Retraction and extension of the main and nose landing gear is effected by a hydraulic actuation system shown schematically in figure 2.1.
Page 19: Service - Nose Gear
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A 2.2 SERVICE – NOSE GEAR The nose gear pivot assembly should be cleaned and greased every 25 hours or more frequently whenever in water for extended period of time. Nose gear tracks to be lightly greased. Apply grease to a cloth on a stick or rod and run along tracks inside of the nose box, both sides.
Page 20 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A Shock Strut Servicing WARNING! RELEASE PRESSURE IN STRUT BEFORE DISASSEMBLY 1. Disassemble the strut, removing both end caps. Take apart the gland section and metering tube so the parts can be easily inspected for wear and replacement parts can installed as needed.
Page 21 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A 4. On the other end, install the metering tube with Loctite onto the end-cap and tighten to approx. 30 ft./lbs. 5. Install outer T-seal to end-cap with Vaseline. Also lube the inside of the outer cylinder where the end-cap seats for ease of assembly.
Page 22 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A c. Install the T-seal into the end-cap, again using Vaseline for lube. d. Install the inner cylinder into the end-cap (the end of the tube without holes). 8. For piston install, place the piston onto the metering tube using hydraulic fluid for lube to prevent damage to the threads.
Page 23 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A 12. Re-install the center bolts using gasket 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.
Page 24: Service Nose And Main Gear Rams
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A 15. Fill the strut with nitrogen to 250 psi +/- 10 psi and close the valve and cap. 2.6 SERVICE NOSE AND MAIN GEAR RAMS Lubricate the nose and main gear cylinder mounting flanges with MIL-H-5606 Hydraulic Fluid thru the oilers. The nose has a flip-lip type oiler and the mains have a ball-needle type oiler.
Page 25: Bleeding Hydraulic System After Service
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A The service intervals on the Main Gear Actuators should be every 25 hours if the aircraft is regularly taxiing on sand and gravel. Otherwise they should be cleaned and serviced according to the checklists from the back of this manual.
Page 26: Removal Of Main Gear Drag Link
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A for cylinder removal. Remove cylinder from piston and up through top float inspection cover. To remove the piston, remove top inspection cover on top forward end of gear tunnel, accessible from the top float inspection cover forward of the step.
Page 27: Figure 2.1 Schematic - Hydraulic System
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 2.1 SCHEMATIC - HYDRAULIC SYSTEM P/N 1002545 Revision U Page 27...
Page 28: Figure 2.2 Schematic - Electrical System
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 2.2 SCHEMATIC - ELECTRICAL SYSTEM Page 28 Revision U P/N 1002545...
Page 29: Figure 2.3 Layout - Main Gear
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 2.3 LAYOUT – MAIN GEAR P/N 1002545 Revision U Page 29...
Page 30: Figure 2.4 Carriage Assembly - Main Gear
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 2.4 CARRIAGE ASSEMBLY – MAIN GEAR Page 30 Revision U P/N 1002545...
Page 31: Figure 2.5 Assembly - Main Gear Shock Strut
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 2.5 ASSEMBLY – MAIN GEAR SHOCK STRUT P/N 1002545 Revision U Page 31...
Page 32: Figure 2.6 Assembly - Main Gear Assembly
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 2.6 ASSEMBLY – MAIN GEAR ASSEMBLY Page 32 Revision U P/N 1002545...
Page 33: Figure 2.7 Assembly - Main Gear Drag Link
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 2.7 ASSEMBLY – MAIN GEAR DRAG LINK P/N 1002545 Revision U Page 33...
Page 34: Figure 2.8 Assembly - Main Gear Wheel And Brake
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 2.8 ASSEMBLY – MAIN GEAR WHEEL AND BRAKE Page 34 Revision U P/N 1002545...
Page 35: Figure 2.9 Assembly - Nose Gear Box And Retraction
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 2.9 ASSEMBLY – NOSE GEAR BOX AND RETRACTION P/N 1002545 Revision U Page 35...
Page 36: Figure 2.10 Assembly - Nose Gear Lower End
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 2.10 ASSEMBLY – NOSE GEAR LOWER END Page 36 Revision U P/N 1002545...
Page 37: Chapter 3 Hydraulic Pump System, Disassembly And Service
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A CHAPTER 3 HYDRAULIC PUMP SYSTEM, DISASSEMBLY AND SERVICE CONTENTS GENERAL ................................38 3.1 OPERATION TROUBLESHOOTING .......................39 P/N 1002545 Revision U Page 37...
Page 38 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A CHAPTER 3 - HYDRAULIC PUMP SYSTEM, DISASSEMBLY AND SERVICE GENERAL The hydraulic pump is factory preset to the following pressures: Pressures switch operates below 525 psi and shuts off at 1250 psi. The pump also has an internal relief valve that opens at 1450 psi and a thermal relief valve that opens at 2000 psi.
Page 39 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A 3.1 OPERATION TROUBLESHOOTING 1. PROBLEM – Powerpack does not run after gear selection. PROBABLE CAUSE a. Circuit breaker has failed b. Pressure switch not pulling in at low cut in. c.
Page 40 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A 3. PROBLEM – Powerpack shuts off before gear reaches position. PROBABLE CAUSE a. Binding or jammed gear retractor, which causes pressure to build up (and stay up), and pressure switch shuts off powerpack.
Page 41 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A b. Poor electrical connection to motor. c. Poor motor. d. Worn pump gears. e. Low ship voltage. REMEDY a. Clean intake screen located 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.
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Page 43: Chapter 4 Scoop System Operation, Removal, And Service
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A 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 –...
Page 44 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A CHAPTER 4 - SCOOP SYSTEM OPERATION, REMOVAL, AND SERVICE 4.1 DESCRIPTION AND OPERATION Full operating information of scooping system is described in Introduction Section 1.4. The scoops (one in each float) are hydraulically operated.
Page 45 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A Fill Tube at Aircraft Tank From inside and outside of tank, remove attaching bolts. Break sealant on inside and outside flanges. Remove from inside tank. On reinstallation, seal completely and reattach. 4.4 SERVICE –...
Page 46: Figure 4.1 Assembly - Scooping System - Complete
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 4.1 ASSEMBLY – SCOOPING SYSTEM - COMPLETE Page 46 Revision U P/N 1002545...
Page 47: Figure 4.1A Assembly - Scooping System
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 4.1A ASSEMBLY – SCOOPING SYSTEM P/N 1002545 Revision U Page 47...
Page 48: Figure 4.2 Assembly - Cylinder Probe Jack
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 4.2 ASSEMBLY – CYLINDER PROBE JACK Page 48 Revision U P/N 1002545...
Page 49: Chapter 5 Foam Delivery System Operation, Removal And Service
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A 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 P/N 1002545 Revision U Page 49...
Page 50 Tank should have small amount of foam in for ease of removal. The tank floor may now be removed through top deck. The 18 gallon firewall tank is a standard Air Tractor installation with a Wipaire liquid level sensor added and line routed to the float tank. 5.4 SERVICE – FOAM SYSTEM The foam pump on each float tank is not serviceable and cannot be overhauled.
Page 51: Figure 5 Schematic - Plumbing - Foam System
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 5 SCHEMATIC – PLUMBING – FOAM SYSTEM P/N 1002545 Revision U Page 51...
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Page 53: Chapter 6 Float Bilge System Operation, Removal, And Service
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A 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 P/N 1002545 Revision U Page 53...
Page 54 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A CHAPTER 6 - FLOAT BILGE SYSTEM OPERATION, REMOVAL, AND SERVICE 6.1 DESCRIPTION AND OPERATION Each float is equipped with (2) bilge pumps. These pumps are located in float compartments just forward of the step.
Page 55: Chapter 7 Vent And Overfill Protection System
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A 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 P/N 1002545 Revision U Page 55...
Page 56 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A CHAPTER 7 - VENT AND OVERFILL PROTECTION SYSTEM 7.1 DESCRIPTION AND OPERATION On the top aircraft hopper door, aft side, is a domed shaped overfill relief door. This door is hinged and spring loaded to blow open in the event of a tank overfill.
Page 57: Chapter 8 Float Steering And Retract System
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A 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 P/N 1002545 Revision U Page 57...
Page 58 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A CHAPTER 8 - FLOAT STEERING AND RETRACT SYSTEM 8.1 DESCRIPTION AND OPERATION The water rudder retract system is manually operated by a lever in the cockpit. The water rudder is then operated by a system of cables and pulleys.
Page 59: Figure 8 Water Rudder Steering And Retraction System
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 8 WATER RUDDER STEERING AND RETRACTION SYSTEM P/N 1002545 Revision U Page 59...
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Page 61: Chapter 9 Angle Of Attack System
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A CHAPTER 9 ANGLE OF ATTACK SYSTEM CONTENTS 9.1 GENERAL ..............................62 9.2 MAINTENANCE ............................62 P/N 1002545 Revision U Page 61...
Page 62 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A CHAPTER 9 – ANGLE OF ATTACK SYSTEM 9.1 GENERAL The Rite Angle 111b AOA system is installed in this aircraft. A separate manual is provided for installation and operation of this system. This system is not a primary aircraft instrument and is for advisory only. 9.2 MAINTENANCE The AOA system is pre-programmed for the AT-802A aircraft on 10000 floats.
Page 63: Chapter 10 Aircraft Wing And Control Surface Modifications
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A CHAPTER 10 AIRCRAFT WING AND CONTROL SURFACE MODIFICATIONS CONTENTS 10.1 DESCRIPTION AND OPERATION ......................64 10.2 MAINTENANCE ............................64 P/N 1002545 Revision U Page 63...
Page 64 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A CHAPTER 10 - AIRCRAFT WING AND CONTROL SURFACE MODIFICATIONS 10.1 DESCRIPTION AND OPERATION The wing leading edge and the leading edge of the horizontal stabilizers have vortex generators installed. Each wing leading edge has 63 generators and each horizontal stabilizer has 21 generators.
Page 65: Chapter 11 Auxiliary Instrument Panel
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A CHAPTER 11 AUXILIARY INSTRUMENT PANEL CONTENTS 11.1 DESCRIPTION AND OPERATION ......................66 P/N 1002545 Revision U Page 65...
Page 66: Figure 11.1 Instrument Panel
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A CHAPTER 11 - AUXILIARY INSTRUMENT PANEL 11.1 DESCRIPTION AND OPERATION An auxiliary instrument is mounted on top of the landplane instrument 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.
Page 67: Figure 11.2 Instrument Panel (Circuit Breaker)
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 11.2 INSTRUMENT PANEL (CIRCUIT BREAKER) P/N 1002545 Revision U Page 67...
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Page 69: Chapter 12 Electrical
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A CHAPTER 12 ELECTRICAL CONTENTS 12.1 GENERAL ..............................70 P/N 1002545 Revision U Page 69...
Page 70 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A CHAPTER 12 - ELECTRICAL 12.1 GENERAL Figures 12.0 through figure 12.10 show the electrical schematic for the auxiliary instrument panel along with electrical schematics for each noted system. Page 70 Revision U P/N 1002545...
Page 71: Figure 12.0 Schematic - Auxiliary Instrument Panel
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 12.0 SCHEMATIC – AUXILIARY INSTRUMENT PANEL P/N 1002545 Revision U Page 71...
Page 72: Figure 12.1 Schematic - Circuit Breaker Panel
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 12.1 SCHEMATIC – CIRCUIT BREAKER PANEL Page 72 Revision U P/N 1002545...
Page 73: Figure 12.2 Schematic - Installation - Angle Of Attack
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 12.2 SCHEMATIC – INSTALLATION – ANGLE OF ATTACK P/N 1002545 Revision U Page 73...
Page 74: Figure 12.3 Aoa Flap Calibration Readings
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 12.3 AOA FLAP CALIBRATION READINGS Page 74 Revision U P/N 1002545...
Page 75: Figure 12.4 Schematic - Installation - Foam Tanks/Pumps
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 12.4 SCHEMATIC – INSTALLATION – FOAM TANKS/PUMPS P/N 1002545 Revision U Page 75...
Page 76: Figure 12.5 Schematic - Installation - Bilge Pumps
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 12.5 SCHEMATIC – INSTALLATION – BILGE PUMPS Page 76 Revision U P/N 1002545...
Page 77: Figure 12.6 Schematic - Installation - Scoop/Fill System
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 12.6 SCHEMATIC – INSTALLATION – SCOOP/FILL SYSTEM P/N 1002545 Revision U Page 77...
Page 78: Figure 12.7 Schematic - Installation - Probe Position
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 12.7 SCHEMATIC – INSTALLATION – PROBE POSITION Page 78 Revision U P/N 1002545...
Page 79: Figure 12.8 Schematic - Installation - Pdr 60 Audio
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 12.8 SCHEMATIC – INSTALLATION – PDR 60 AUDIO P/N 1002545 Revision U Page 79...
Page 80: Figure 12.9 Schematic - Installation - Itt / Excess Power Light
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 12.9 SCHEMATIC – INSTALLATION – ITT / EXCESS POWER LIGHT Page 80 Revision U P/N 1002545...
Page 81: Figure 12.10 Schematic - Installation - Water In Float Sensors
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 12.10 SCHEMATIC – INSTALLATION – WATER IN FLOAT SENSORS P/N 1002545 Revision U Page 81...
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Page 83: Chapter 13 Repairing Float Hull Sheet Metal, Bulkheads And Other Areas
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A 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 P/N 1002545 Revision U Page 83...
Page 84: Description
10.1 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.
Page 85 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A NOTES: 1. When installing any structural 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).
Page 86: Figure 13.1 Typical Skin Repairs
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A 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.
Page 87: Figure 13.2 Typical Skin Repairs
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A 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.
Page 88: Figure 13.3 Typical Skin Repairs
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A 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.
Page 89: Figure 13.4 Bulkhead Access Holes
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A 13.3 BULKHEAD ACCESS HOLES 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.
Page 90: Repairing Float Hull Extrusions (Keel, Chine, Etc.)
All extrusions in the float hull are formed 6061-T6 aluminum alloy. All extrusions may be repaired by splicing as shown in figures 11.1 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.
Page 91: Figure 13.5 Gunwall Extrusion Repair
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 13.5 GUNWALL EXTRUSION REPAIR P/N 1002545 Revision U Page 91...
Page 92: Figure 13.6 Forward Chine Extrusion Repair
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 13.6 FORWARD CHINE EXTRUSION REPAIR Page 92 Revision U P/N 1002545...
Page 93: Figure 13.7 Main Keel Extrusion Repair
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 13.7 MAIN KEEL EXTRUSION REPAIR P/N 1002545 Revision U Page 93...
Page 94: Figure 13.8 Aft Keel Extrusion Repair
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 13.8 AFT KEEL EXTRUSION REPAIR Page 94 Revision U P/N 1002545...
Page 95: Figure 13.9 Aft Chine Extrusion Repair
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A FIGURE 13.9 AFT CHINE EXTRUSION REPAIR P/N 1002545 Revision U Page 95...
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Page 97: Chapter 14 Continued Airworthiness
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A CHAPTER 14 CONTINUED AIRWORTHINESS CONTENTS 14.1 SERVICE SCHEDULE ...........................98 14.2 FLOAT HARDWARE RECOMMENDED RETORQUE AND REPLACEMENT CHECKLIST ...103 P/N 1002545 Revision U Page 97...
Page 98 Below is a list of recommended lubricants and “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.
Page 99 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A Float Sealant 890 B2 or B4 - Pro Seal Company PR 1440 C - PPG Aerospace 1422 B2, B4 or B6 - Pro Seal Company RTV Silicones - General Electric SIKAFLEX 201 or 252 - Sika Manufacturing Teflon 6P-730A - Comet Industries...
Page 100 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A Bolts in Critical Area For corrosion, correct torque when installed, or when visual inspection indicates a need for a torque check. Nut torque should be applied depending on the hardware application, unless the torque is specified for a certain joint in this manual or installation drawings.
Page 101 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A 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. P/N 1002545 Revision U Page 101...
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Page 103 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A 14.2 FLOAT HARDWARE RECOMMENDED RETORQUE AND REPLACEMENT CHECKLIST FOR 10000A FLOATS See next page for checklist. Notes: 1. Recommended RETORQUE of all items below: 100 hrs +/- 25 hrs 2.
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Page 107: Chapter 15 Inspection Checklists
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A CHAPTER 15 INSPECTION CHECKLISTS CONTENTS 15.1 INSPECTION TIME CHECKLIST ......................108 15.2 OVERGROSS LANDING INSPECTION CHECKLIST ............... 112 P/N 1002545 Revision U Page 107...
Page 108 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A 15.1 INSPECTION TIME CHECKLIST *Items denoted with (*) are considered preventative maintenance checks and can be completed and signed off by authorized personnel I.A.W. CFR 14 Part 43.3 and 43.7 and Appendix A subpart C, or equivalent CAA regulation Page 108 Revision U P/N 1002545...
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Page 112 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A 15.2 OVERGROSS LANDING INSPECTION CHECKLIST MECHANIC REQUIRED IN INSPECTION Landing Gear Systems Nose Wheels – Inspect for wear, Loose attaching hardware will damage, and loose attaching require further inspection for hardware to include axle deformation and hole elongation See Servicing Section in...
Page 113 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A MECHANIC REQUIRED IN INSPECTION Main Gear Trunnion attach – Inspect for damage, loose hardware, and surrounding bulkhead attach point for damage Main Main Landing Gear Shock Strut Landing – Inspect attach points for wear, Gear cracking, hardware failure Continued...
Page 114: Figure 15.1 Example Nose Spring Crack Measurements (Not To Scale)
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A MECHANIC REQUIRED IN INSPECTION Strut/Spreader Bar fittings – inspect fittings for material stress and cracks on attaching locations Fuselage float fitting attach points – Inspect area for Struts/ bending, cracking, or distortion Spreader Detailed Inspection of all strut Bars...
Page 115: Chapter 16 Weight And Balance
SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A CHAPTER 16 WEIGHT AND BALANCE CONTENTS 16.1 WEIGHING PROCEDURES FOR THE AT-802A FIREBOSS AMPHIBIAN ........116 P/N 1002545 Revision U Page 115...
Page 116 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802A CHAPTER 16 - WEIGHT AND BALANCE 16.1 WEIGHING PROCEDURES FOR THE AT-802A FIREBOSS AMPHIBIAN Level aircraft per manufacturer’s instructions. Place scales under the right and left nose and main gear wheels. Place blocking under right and left main gear wheels to level aircraft.

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Wipaire WIPLINE 10000 Service Manual

Table of Contents

Chapter 1 General Information

Chapter 2 Main Gear and Nose Gear Operation, Removal and Service

Chapter 13 Repairing Float Hull Sheet Metal, Bulkheads and Other Areas

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