Continued airworthiness amphibious floats at-802a fire boss conversion (116 pages)
Summary of Contents for Wipaire 7000
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WIPLINE 7000 FLOATS WIPLINE FLOATS • SKIS • MODIFICATIONS • AIRCRAFT SALES AVIONICS • INTERIOR • MAINTENANCE • PAINT REFINISHING SERVICE MANUAL & ICA FOR THE WIPLINE 7000 AMPHIBIAN FLOAT ON THE QUEST MODEL 100 KODIAK Revision P P/N 1004646...
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Reformatted manual in new software. Removed Comet Industries GP-730A. Added sections 9/16/2022 1.4 through 1.8. Added notes to Figure 9-1 and at the end of Section 9.3. View most current revision of this ICA at www.wipaire.com. P/N 1004646 Revision P...
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SERVICE MANUAL & ICA WIPLINE 7000 FLOATS CONTENTS CHAPTER 1 INTRODUCTION AND GENERAL INFORMATION ................7 CHAPTER 2 AIRWORTHINESS LIMITATIONS ....................25 CHAPTER 3 NOSE GEAR ............................27 CHAPTER 4 MAIN LANDING GEAR BRAKES & GEAR RETRACTION ............35 CHAPTER 5 HYDRAULICS ..........................53 CHAPTER 6 WATER RUDDER ..........................59 CHAPTER 7 ELECTRICAL ...........................63...
1.0 INTRODUCTION This manual is provided for the owners of Wipaire model 7000 Floats as installed on the Quest model 100 Kodiak. It has two main priorities: to inform owners of the level and amount of servicing required to properly maintain their floatplane, and to provide technical data and servicing as specified to maintenance professionals charged with servicing the floats.
WIPLINE 7000 FLOATS 1.1 GENERAL FLOAT INFORMATION The model 7000 amphibious float is a clean- sheet, all aluminum structure, designed to be installed on the Quest Kodiak 100. The alloy used throughout is mostly corrosion resistant 6061-T6. Interior parts are cleaned, acid- etched and then primed prior to being riveted for enhanced corrosion resistance.
SERVICE MANUAL & ICA WIPLINE 7000 FLOATS FIGURE 1-5 HYDRAULIC FLUID LEVEL PLACARD The nose wheels are fully castoring for maneuverability while the airplane is under engine power or being towed. The main landing gear has dual 6:00x6 8-ply tires and the nose gear has a single 5:00x5 10-ply tire. All tires must be approved to TSO C62, type III.
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SERVICE MANUAL & ICA WIPLINE 7000 FLOATS Grease zerks are provided in many locations that have pivoting joints. Greasing is recommended at 25 hour intervals, or more often depending on operating environment, with HCF Grease or equivalent. See Figure 3-2 for nose gear grease zerk locations.
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SERVICE MANUAL & ICA WIPLINE 7000 FLOATS Optional Left Exhaust Stack with optional Heat Shield Optional Right Exhaust Page 16 Revision P P/N 1004646...
SERVICE MANUAL & ICA WIPLINE 7000 FLOATS 1.2 CLEANING The outside of the float should be kept clean by washing with fresh water and soap. Special care should be taken to remove engine exhaust trails, water-line marks, and barnacle deposits. After salt water operations, washing...
WIPLINE 7000 FLOATS 1.3 CORROSION Reference the Wipaire Structural Repair Manual (SRM) for allowable corrosion/material loss limits. Corrosion is the process by which metals are turned into oxides. It is a natural and ultimately unavoidable chemical reaction that is accelerated by dissimilar metals in contact with each other, and enclosed spaces and contaminants like dirt and exhaust deposits that hold moisture against the metal.
Cladding, plating, anodizing, painting, greasing and waxing are all processes used to help protect metal from corrosion; Wipaire uses all these techniques during manufacture. But due to the rugged way our floats are used and the environment, these surface sealers become abraded or wear away, leaving the metal exposed.
(X = WIDTH OF CRADLE) FIGURE 1-7: JACK CRADLE RECOMMENDED MODIFICATION NOTE: This is not required and Wipaire does not have the parts for modification. It is recommended a similar modification be performed to the jack saddle to prevent the slippage of the cradle.
NOTE: A smaller jack may be needed to slightly lift the float into a high enough position for the main jack. 4. Secure floats with fore and aft supports as shown in Figure 1-9 and Figure 1-10. FIGURE 1-9: FLOAT SECURING LOCATIONS ALTERNATE JACKING METHOD IF WIPAIRE JACKING FIXTURE IS NOT AVAILABLE (8000A model shown for reference only)
SERVICE MANUAL & ICA WIPLINE 7000 FLOATS Fore Cradle Cradle Stand Aft Cradle Fore Stand Support Support (8000A MODEL SHOWN FOR REFERENCE ONLY) FIGURE 1-10: FLOAT SECURING LOCATIONS OVERVIEW 1.8 JACK REMOVAL Make sure nothing is under or above the airplane or floats when removing the jacks from the aircraft 1.
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SERVICE MANUAL & ICA WIPLINE 7000 FLOATS For water operations, the floats are equipped with two deck cleats on each float, one forward near the pilot/copilot doors, and one aft near the cargo door. Mooring Procedure on Water at Dock: 1.
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SERVICE MANUAL & ICA WIPLINE 7000 FLOATS 2.1 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 Amphibious Floats and the associated systems addressed by this STC.
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SERVICE MANUAL & ICA WIPLINE 7000 FLOATS CHAPTER 3 NOSE GEAR CONTENTS 3.0 NOSE GEAR ..............................28 3.1 ADJUSTMENT/TEST NOSE GEAR ......................30 3.2 NOSE GEAR BASIC SERVICING ......................30 3.3 NOSE GEAR DISASSEMBLY ........................32 3.4 NOSE GEAR ASSEMBLY .........................32 P/N 1004646 Revision P...
SERVICE MANUAL & ICA WIPLINE 7000 FLOATS 3.0 NOSE GEAR The nose gear consists of composite fiberglass beams that are attached at the bottom to blocks that caster. Inside the block is a castering pin that is set into the machined fork assembly. The castering pin allows the nose wheel to pivot in a complete circle.
SERVICE MANUAL & ICA WIPLINE 7000 FLOATS 3.1 ADJUSTMENT/TEST NOSE GEAR Refer to Figure 3-1 for visual reference. Adjustment of actuator stroke is provided at the ends of the piston rods. The length of the nose gear rod is adjusted such that the over-center knuckle (brass) rollers just bottom out on the down side and the piston just bottoms out on the mounting flange.
SERVICE MANUAL & ICA WIPLINE 7000 FLOATS 3.3 NOSE GEAR DISASSEMBLY (In float or removed from float) Items refer to areas on Figure 3-3 1. Disconnect hydraulic lines, Item 1. 2. Remove 4, NAS1103-2 bolts and washers attaching the Nose Ram, Item 2, to the Flange Assembly, Item 3, and slide the Nose Ram off of the Flange Assembly.
SERVICE MANUAL & ICA WIPLINE 7000 FLOATS FIGURE 3-3 NOSE GEAR ITEMS P/N 1004646 Revision P Page 33...
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SERVICE MANUAL & ICA WIPLINE 7000 FLOATS CHAPTER 4 MAIN LANDING GEAR BRAKES & GEAR RETRACTION CONTENTS 4.0 GENERAL ..............................36 4.1 MAIN GEAR RETRACTION DESCRIPTION ..................40 4.2 MAIN GEAR ASSEMBLY SETUP AND ADJUSTMENT .................46 4.3 ADJUSTING THE GEAR UP POSITION ....................48 4.4 ADJUST MAIN GEAR UP AND DOWN POSITION SWITCHES ............48...
SERVICE MANUAL & ICA WIPLINE 7000 FLOATS 4.0 GENERAL The main landing gear incorporated within the amphibious floats are retractable, quadricycle type with four main wheels in a dual tire formation. Air-oil shock struts on the two main landing gear assemblies provide shock absorption.
SERVICE MANUAL & ICA WIPLINE 7000 FLOATS FIGURE 4-1 MINIMUM BRAKE LINING THICKNESS P/N 1004646 Revision P Page 37...
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SERVICE MANUAL & ICA WIPLINE 7000 FLOATS MAIN GEAR/WHEEL ALIGNMENT There is no way to adjust the alignment within each main gear wheel set. If the tires are showing signs of abnormal/asymmetric wear, some component has likely been worn/bent. Starting with the axle, examine each main gear component and mounting point for signs of damage/deformation.
SERVICE MANUAL & ICA WIPLINE 7000 FLOATS 4.1 MAIN GEAR RETRACTION DESCRIPTION Refer to Figures 4-1, 4-2, 4-3, 4-4A, 4-4B, 4-5 and 4-6 for visual reference. Retraction and extension of the main gear is accomplished with a hydraulic rack and pinion type actuator. The actuator consists of two opposing pistons connected by a geared rack, with a rotating pinion gear in the middle.
SERVICE MANUAL & ICA WIPLINE 7000 FLOATS In addition to the over center locking provided by the rod linkages and actuator arm for the gear extended position, a second down locking method is provided as well. The geometry of the main gear drag link, oleo- pneumatic shock strut and the top arm assembly, provide an additional over center locking method.
11. To adjust the “DOWN” position, loosen the “DOWN” adjustment screw jamb nut (Item 9) and back off the adjustment screw. 12. Align the keyway on the actuator shaft (Item 4) with the keyway on Wipaire Tool 1004800. Insert the parallel key removed in step 5 into the aligned keyways.
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SERVICE MANUAL & ICA WIPLINE 7000 FLOATS 19. Shorten the Rod Linkage until the Top Arm Contact Face (Item 15) touches the contact face of the Top Mount (Item 7). Make equal adjustments to each rod. Actuator needs to be rotated fully against the Down Adjustment Screw.
Top Dead Center (TDC) by pushing and pulling on the Top Arm Assembly. The “UP” adjustment screw (Item 10) should not need to be adjusted if properly set using Wipaire Tool 1004800 during the actuator maintenance. (If it is found that one can reverse drive the rotary actuator and pull the gear down by hand, the rod linkage and the actuator arms have not moved past TDC.
SERVICE MANUAL & ICA WIPLINE 7000 FLOATS into the proximity switch initially illuminates with the gear arm in the full down over center locked position, then thread the set screw in an additional half turn. 5. Reposition the gear to the “UP” position.
SERVICE MANUAL & ICA WIPLINE 7000 FLOATS 4.5 EMERGENCY GEAR OPERATION An emergency hand pump is provided in case of total electric pump failure or loss of fluid. The emergency hand pump draws hydraulic fluid from the bottom of the hydraulic power pack reservoir. The hydraulic power pack electric pumps have fluid pickup tubes that do not reach the bottom of the hydraulic fluid reservoir.
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SERVICE MANUAL & ICA WIPLINE 7000 FLOATS CHAPTER 5 HYDRAULICS CONTENTS 5.0 HYDRAULIC SYSTEM BASIC DESCRIPTION ..................54 5.1 BLEEDING THE HYDRAULIC SYSTEM ....................57 P/N 1004646 Revision P Page 53...
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SERVICE MANUAL & ICA WIPLINE 7000 FLOATS 5.0 HYDRAULIC SYSTEM BASIC DESCRIPTION A pressure of between 500 psi and 700 psi in the DOWN position and 500 psi and 1200 psi in the UP position is maintained in the supply line. When the pressure falls below 500 psi in the UP and DOWN position, the pressure switch activates the pump solenoid, providing power to the pump.
SERVICE MANUAL & ICA WIPLINE 7000 FLOATS FIGURE 5-2 HYDRAULIC PLUMBING Page 56 Revision P P/N 1004646...
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SERVICE MANUAL & ICA WIPLINE 7000 FLOATS 5.1 BLEEDING THE HYDRAULIC SYSTEM The system automatically bleeds, provided sufficient oil is maintained in the reservoir. To check the fluid level, fill the reservoir through the servicing point on the power pack assembly with MIL-H-5606 hydraulic oil and cycle the gear.
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SERVICE MANUAL & ICA WIPLINE 7000 FLOATS CHAPTER 6 WATER RUDDER CONTENTS 6.0 BASIC DESCRIPTION ..........................60 P/N 1004646 Revision P Page 59...
SERVICE MANUAL & ICA WIPLINE 7000 FLOATS 6.0 BASIC DESCRIPTION The water rudder retract system is manually operated by a lever through a system of cables and pulleys. FIGURE 6-1 WATER RUDDER RETRACTION & EMERGENCY GEAR PUMP HANDLES Steering is directed from the aircraft rudder steering system. The controls are interconnected and seamless to the operator aside from retraction and extension of the water rudder.
SERVICE MANUAL & ICA WIPLINE 7000 FLOATS FIGURE 6-2 WATER RUDDER CABLE ROUTING P/N 1004646 Revision P Page 61...
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SERVICE MANUAL & ICA WIPLINE 7000 FLOATS CHAPTER 7 ELECTRICAL CONTENTS 7.0 ELECTRICAL SYSTEM BASIC DESCRIPTION ..................64 P/N 1004646 Revision P Page 63...
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For detailed information regarding the electrical system, refer to Installation Drawing 1004472. The following electrical systems are added with the installation of Wipline 7000 floats on the Quest Kodiak 100: 1. 24V DC Hydraulic pumps (2), each pump with its own dedicated circuit breaker.
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SERVICE MANUAL & ICA WIPLINE 7000 FLOATS 8.0 HARTZELL 3 BLADE PROPELLER Refer to document number 1009486 for information and procedures if the Hartzell 3 blade propeller is installed. Page 66 Revision P P/N 1004646...
Below is a list of recommended lubricants and “protection” products when servicing float hull, amphibious components. 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.
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SERVICE MANUAL & ICA WIPLINE 7000 FLOATS Tef-Gel Ultra Safety Systems, Inc. Float Sealant 890 B2 or B4 Pro Seal Company PR 1440 C PPG Aerospace RTV Silicones General Electric SIKAFLEX 201 or 252 Sika Manufacturing Hydraulic Fluid Mil-H-5606 Electrical Insulating Compound...
Reference the Wipaire Structural Repair Manual (SRM) for allowable corrosion/material loss limits. Corrosion is usually detected visually, which is why Wipaire strongly recommends the previous cleaning and inspection procedures. It can appear as a white or pale green powder, discoloration of the metal surface, or bubbles and blisters under the surface of the paint.
13. Hydraulic Power Pack (located in tailcone) 14. Emergency Trim Timer Override System (ETTOS) Note: G1000 Software - Reference Wipaire drawing 1002632 note 6. This is appropriate for landplane or floatplane. Note: If floats are installed or removed for the first time, reweigh aircraft.
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SERVICE MANUAL & ICA WIPLINE 7000 FLOATS 9.4 WEIGHING PROCEDURES FOR QUEST KODIAK ON WIPAIRE 7000 AMPHIBIAN FLOATS Level aircraft per the manufacturer’s instructions. Place scales under the right and left main and nose gears. Place blocking under the right and left main gears to level aircraft.
2. The tow bar mentioned in Chapter 1 is available in several models. Contact Wipaire Customer Service for details. 3. The lifting rig also mentioned in Chapter 1 is also available for purchase. Contact Wipaire Customer Service for details. P/N 1004646...
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SERVICE MANUAL & ICA WIPLINE 7000 FLOATS 10.0 TROUBLESHOOTING GUIDE Page 92 Revision P P/N 1004646...
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SERVICE MANUAL & ICA WIPLINE 7000 FLOATS CHAPTER 11 INSTALLATION PRINT INFORMATION CONTENTS 11.0 WIPAIRE DRAWINGS REQUIRED FOR 7000 FLOAT INSTALLATION ..........98 P/N 1004646 Revision P Page 97...
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SERVICE MANUAL & ICA WIPLINE 7000 FLOATS 11.0 WIPAIRE DRAWINGS REQUIRED FOR 7000 FLOAT INSTALLATION 1004099 INSTALL FINLETS 1004211 INSTALL STEERING & RETRACT SYSTEM 1004469 INSTALL HYDRAULIC SYSTEM / WIRE ROUTING 1004472 WIRING SCHEMATIC 1004500 INSTALL STRAKES 1004527 INSTALL VORTEX GENERATORS, TRIM TAB EXTENSIONS 1004651 INSTALL FWD.
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SERVICE MANUAL & ICA WIPLINE 7000 FLOATS APPENDIX CONTENTS APPENDIX A OPTIONAL YAGI ANTENNAS ....................100 P/N 1004646 Revision P Page 99...
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APPENDIX A OPTIONAL YAGI ANTENNAS INTRODUCTION Select serial numbers of the Kodiak 7000 amphibian may be optionally equipped with wing-strut mounted Yagi antennas for the purpose of wildlife tracking. The antennas are approved only when the aircraft is equipped with floats, and does not apply to the wheel equipped aircraft.
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