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Wipaire AT-802 Service Manual And Instructions

Amphibious floats, fire boss conversion
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SERVICE MANUAL & ICA
10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802
WIPLINE FLOATS • SKIS • MODIFICATIONS • AIRCRAFT SALES
AVIONICS • INTERIOR • MAINTENANCE • PAINT REFINISHING
SERVICE MANUAL AND INSTRUCTIONS FOR
WIPLINE MODEL 10000 AMPHIBIOUS FLOATS
AT-802 FIRE BOSS CONVERSION
P/N 1003546
CONTINUED AIRWORTHINESS
Revision W
Revision W
Page 1

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Summary of Contents for Wipaire AT-802

  • Page 1 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 WIPLINE FLOATS • SKIS • MODIFICATIONS • AIRCRAFT SALES AVIONICS • INTERIOR • MAINTENANCE • PAINT REFINISHING SERVICE MANUAL AND INSTRUCTIONS FOR CONTINUED AIRWORTHINESS WIPLINE MODEL 10000 AMPHIBIOUS FLOATS...
  • Page 2 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 THIS PAGE INTENTIONALLY LEFT BLANK Page 2 Revision W P/N 1003546...
  • Page 3 Date For previous revision changes, reference Service Manual for 10000 18, 84, Amphibian Floats on Air Tractor AT-802 - Fire Boss Conversion Revision L 1/23/2020 part number 1003546. Updated Nose Box Track tolerance from .070" to .050". Added info about hardware replacement.
  • Page 4 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 THIS PAGE INTENTIONALLY LEFT BLANK Page 4 Revision W P/N 1003546...

  • Page 5: Table Of Contents

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 TABLE OF CONTENTS INTRODUCTION ...............................7 CHAPTER 1 GENERAL INFORMATION ......................9 CHAPTER 2 MAIN GEAR AND NOSE GEAR OPERATION, REMOVAL AND SERVICE ......21 CHAPTER 3 HYDRAULIC PUMP SYSTEM, DISASSEMBLY AND SERVICE ...........41 CHAPTER 4 SCOOP SYSTEM OPERATION, REMOVAL, AND SERVICE ..........47...
  • Page 6 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 LIST OF FIGURES FIGURE 1.1 JACK CRADLE RECOMMENDED MODIFICATION ............12 FIGURE 1.2 JACKING LOCATION ......................12 FIGURE 1.3 FLOAT SECURING LOCATIONS ..................13 FIGURE 1.4 FLOAT SECURING LOCATIONS OVERVIEW ..............14 FIGURE 2.1 SCHEMATIC - HYDRAULIC SYSTEM ................31 FIGURE 2.2 SCHEMATIC - ELECTRICAL SYSTEM ................32...

  • Page 7: Introduction

    10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 INTRODUCTION This manual describes the general servicing and maintenance for the Model 10000 float, on the Air Tractor AT-802 aircraft. Includes hull, landing gear, and scooping systems. For services and repairs not covered by this manual contact Wipaire Customer Service.
  • Page 8 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 THIS PAGE INTENTIONALLY LEFT BLANK Page 8 Revision W P/N 1003546...

  • Page 9: Chapter 1 General Information

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 CHAPTER 1 GENERAL INFORMATION CONTENTS 1.1 AIRPLANE ..............................10 1.2 FLOATS ..............................10 1.3 TOWING ..............................11 1.4 HOISTING ..............................11 1.5 LEVELING ..............................12 1.6 JACKING PROCEDURES ........................12 1.7 JACK REMOVAL ............................14 1.8 AMPHIBIAN LANDING GEAR SYSTEM ....................14 1.8.1 LANDING GEAR HANDLE ........................15...

  • Page 10: Airplane

    1.1 AIRPLANE The airframe of the Fire Boss is adapted from the Air Tractor AT-802 agricultural airplane. It is an all-metal, low cantilever wing design. It is powered by a Pratt and Whitney PT6A-67F turboprop engine of 1600 SHP. The airframe is detailed in Air Tractor publications.

  • Page 11: Towing

    If the lifting rings are not installed, reference applicable aircraft maintenance/ service manual for additional hoisting specifications. Lake & Air Training and Pilot Shop has this hoisting rig available for purchase. Contact Wipaire Customer Service for additional guidance in removal or installation of floats.

  • Page 12: Figure 1.1 Jack Cradle Recommended Modification

    (X = WIDTH OF CRADLE) FIGURE 1.1 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.

  • Page 13: Figure 1.3 Float Securing Locations

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 1. Jack one side at a time, taking care to check the balance of the aircraft and adding more weight to the front if needed. 2. Two people, both outboard, lift the fore and aft cradle stands up to the cradle as a 3rd person release the pressure slowly, allowing the cradle and stands to gently contact the ground.

  • Page 14: Figure 1.4 Float Securing Locations Overview

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 Fore Cradle Cradle Stand Aft Cradle Fore Stand Support Support (8000A MODEL SHOWN FOR REFERENCE ONLY) FIGURE 1.4 FLOAT SECURING LOCATIONS OVERVIEW 1.7 JACK REMOVAL Make sure nothing is under or above the airplane or floats when removing the jacks from the aircraft 1.

  • Page 15: Landing Gear Handle

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 Per Service Letter 103, a Spin-on Type filter assembly with a Baldwin Filter has been incorporated to facilitate additional filtering of the hydraulic system. Replace Baldwin filter if pop out gage (if equipped) has been released indicating bypass has been activated due to clogged filter or at time of annual inspection.

  • Page 16: Emergency Pump Handle

    1.9 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 17: Vent And Overflow Protection

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 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.

  • Page 18: Cleaning

    1.14 CORROSION Reference the Wipaire Structural Repair Manual (SRM) for allowable corrosion/material loss limits. Corrosion is a reaction that destroys metal by an electrochemical action that converts metal to oxide. Corrosion is accelerated when in contact with dissimilar metals such as aluminum and steel, or any material that absorbs moisture like wood, rubber, or dirt.

  • Page 19: Means For Leveling

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 1.15 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.
  • Page 20 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 THIS PAGE INTENTIONALLY LEFT BLANK Page 20 Revision W P/N 1003546...

  • Page 21: Chapter 2 Main Gear And Nose Gear Operation, Removal And Service

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 CHAPTER 2 MAIN GEAR AND NOSE GEAR OPERATION, REMOVAL AND SERVICE CONTENTS 2.1 DESCRIPTION AND OPERATION ......................22 2.2 SERVICE – NOSE GEAR .........................23 2.3 NOSE BOX TRACK WEAR ........................23 2.4 SERVICE –...

  • Page 22: Description And Operation

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 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 23: Service - Nose Gear

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 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 24 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 inflated to approximately 3-4 inches on an unloaded aircraft while sitting static on level ground. Seals – Seals should be replaced whenever the oleo is disassembled or leaking. CAUTION: Release air pressure and remove air valve before attempting to disassemble oleo.
  • Page 25 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 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. Install inner cylinder into top end cap with PR-1422.
  • Page 26 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 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 27 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 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.

  • Page 28: Service Nose And Main Gear Rams

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 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 29: Bleeding Hydraulic System After Service

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 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 30: Removal Of Main Gear Drag Link

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 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 31: Figure 2.1 Schematic - Hydraulic System

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 2.1 SCHEMATIC - HYDRAULIC SYSTEM P/N 1003546 Revision W Page 31...

  • Page 32: Figure 2.2 Schematic - Electrical System

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 2.2 SCHEMATIC - ELECTRICAL SYSTEM Page 32 Revision W P/N 1003546...

  • Page 33: Figure 2.3 Layout - Main Gear

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 2.3 LAYOUT – MAIN GEAR P/N 1003546 Revision W Page 33...

  • Page 34: Figure 2.4 Carriage Assembly - Main Gear

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 2.4 CARRIAGE ASSEMBLY – MAIN GEAR Page 34 Revision W P/N 1003546...

  • Page 35: Figure 2.5 Assembly - Main Gear Shock Strut

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 2.5 ASSEMBLY – MAIN GEAR SHOCK STRUT P/N 1003546 Revision W Page 35...

  • Page 36: Figure 2.6 Assembly - Main Gear Assembly

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 2.6 ASSEMBLY – MAIN GEAR ASSEMBLY Page 36 Revision W P/N 1003546...

  • Page 37: Figure 2.7 Assembly - Main Gear Drag Link

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 2.7 ASSEMBLY – MAIN GEAR DRAG LINK P/N 1003546 Revision W Page 37...

  • Page 38: Figure 2.8 Assembly - Main Gear Wheel And Brake

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 2.8 ASSEMBLY – MAIN GEAR WHEEL AND BRAKE Page 38 Revision W P/N 1003546...

  • Page 39: Figure 2.9 Assembly - Nose Gear Box And Retraction

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 2.9 ASSEMBLY – NOSE GEAR BOX AND RETRACTION P/N 1003546 Revision W Page 39...

  • Page 40: Figure 2.10 Assembly - Nose Gear Lower End

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 2.10 ASSEMBLY – NOSE GEAR LOWER END Page 40 Revision W P/N 1003546...

  • Page 41: Chapter 3 Hydraulic Pump System, Disassembly And Service

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 CHAPTER 3 HYDRAULIC PUMP SYSTEM, DISASSEMBLY AND SERVICE CONTENTS GENERAL ................................42 3.1 OPERATION TROUBLESHOOTING .......................43 P/N 1003546 Revision W Page 41...
  • Page 42 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 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.
  • Page 43 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 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.
  • Page 44 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 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 45 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 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.
  • Page 46 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 THIS PAGE INTENTIONALLY LEFT BLANK Page 46 Revision W P/N 1003546...

  • Page 47: Chapter 4 Scoop System Operation, Removal, And Service

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 CHAPTER 4 SCOOP SYSTEM OPERATION, REMOVAL, AND SERVICE CONTENTS 4.1 DESCRIPTION AND OPERATION ......................48 4.2 ADJUSTMENT AND TEST........................48 4.3 REMOVAL OF SCOOP AND FILL SYSTEM ...................48 4.4 SERVICE – SCOOP SYSTEM .........................49 4.5 SERVICE OF SELONOID VALVE –...
  • Page 48 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 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 49 4.7 ASYMMETRIC SCOOP REPORTING In order to better gather fleet operational data, Wipaire needs the following information reported when a suspected asymmetrical scoop event, leads maintenance to ground the aircraft to investigate the possible event: -Date and local time...
  • Page 50 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 -Results of the investigation Provide the preceding information to Wipaire Customer Support as soon as practical after the maintenance action is completed. Page 50 Revision W P/N 1003546...

  • Page 51: Figure 4.1A Assembly - Scooping System - Complete

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 4.1A ASSEMBLY – SCOOPING SYSTEM - COMPLETE P/N 1003546 Revision W Page 51...

  • Page 52: Figure 4.1B Assembly - Scooping System

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 4.1B ASSEMBLY – SCOOPING SYSTEM Page 52 Revision W P/N 1003546...

  • Page 53: Figure 4.2A Assembly - Cylinder Probe Jack

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 4.2A ASSEMBLY – CYLINDER PROBE JACK P/N 1003546 Revision W Page 53...

  • Page 54: Figure 4.2B - Probe Up Position Adjustment

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 4.2B – PROBE UP POSITION ADJUSTMENT FIGURE 4.2C – PROBE DOWN POSITION ADJUSTMENT Page 54 Revision W P/N 1003546...

  • Page 55: Chapter 5 Foam Delivery System Operation, Removal And Service

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 CHAPTER 5 FOAM DELIVERY SYSTEM OPERATION, REMOVAL AND SERVICE CONTENTS 5.1 DESCRIPTION AND OPERATION ......................56 5.2 ADJUSTMENT AND TEST........................56 5.3 REMOVAL OF FOAM SYSTEM .......................56 5.4 SERVICE – FOAM SYSTEM ........................56...
  • Page 56 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 57: Figure 5.1 Schematic - Plumbing - Foam System

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 5.1 SCHEMATIC – PLUMBING – FOAM SYSTEM P/N 1003546 Revision W Page 57...
  • Page 58 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 THIS PAGE INTENTIONALLY LEFT BLANK Page 58 Revision W P/N 1003546...

  • Page 59: Chapter 6 Float Bilge System Operation, Removal, And Service

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 CHAPTER 6 FLOAT BILGE SYSTEM OPERATION, REMOVAL, AND SERVICE CONTENTS 6.1 DESCRIPTION AND OPERATION ......................60 6.2 ADJUSTMENT AND TEST........................60 6.3 REMOVAL OF THE SYSTEM ........................60 6.4 SERVICE – BILGE SYSTEM ........................60...
  • Page 60 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 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 61: Chapter 7 Vent And Overfill Protection System

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 CHAPTER 7 VENT AND OVERFILL PROTECTION SYSTEM CONTENTS 7.1 DESCRIPTION AND OPERATION ......................62 7.2 ADJUSTMENT AND TEST........................62 7.3 SERVICE OVERFILL VENT SYSTEM .....................62 P/N 1003546 Revision W Page 61...
  • Page 62 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 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 63: Chapter 8 Float Steering And Retract System

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 CHAPTER 8 FLOAT STEERING AND RETRACT SYSTEM CONTENTS 8.1 DESCRIPTION AND OPERATION ......................64 8.2 ADJUSTMENT ............................64 8.3 REMOVAL AND ACCESS .........................64 8.4 SERVICE OF STEERING AND RETRACT SYSTEM ................64...
  • Page 64 Steering is directed from the aircraft steering system. See Figure 8 for retract and steering schematic. The 2-pilot AT-802 uses an electric water rudder actuator. The water rudder retracts are operated by means of a cockpit-mounted toggle switch with position indicators. AT-802 uses an electric rudder actuator.

  • Page 65: Figure 8.1 Water Rudder Steering And Retraction System

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 8.1 WATER RUDDER STEERING AND RETRACTION SYSTEM P/N 1003546 Revision W Page 65...
  • Page 66 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 THIS PAGE INTENTIONALLY LEFT BLANK Page 66 Revision W P/N 1003546...

  • Page 67: Chapter 9 Aircraft Wing And Control Surface Modifications

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 CHAPTER 9 AIRCRAFT WING AND CONTROL SURFACE MODIFICATIONS CONTENTS 9.1 DESCRIPTION AND OPERATION ......................68 9.2 MAINTENANCE ............................68 P/N 1003546 Revision W Page 67...
  • Page 68 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. If one falls off, replace it according to the drawing instructions. Additionally, the AT-802 has 19 vortex generators installed on the aft canopy.

  • Page 69: Chapter 10 Auxiliary Instrument Panel

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 CHAPTER 10 AUXILIARY INSTRUMENT PANEL CONTENTS 10.1 DESCRIPTION AND OPERATION ......................70 P/N 1003546 Revision W Page 69...

  • Page 70: Figure 10.1 Instrument Panel

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 CHAPTER 10 - AUXILIARY INSTRUMENT PANEL 10.1 DESCRIPTION AND OPERATION Figure 10.1 is an auxiliary instrument 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. There is an optional rear-seat auxiliary panel installation.

  • Page 71: Figure 10.2 Instrument Panel (Circuit Breaker)

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 10.2 INSTRUMENT PANEL (CIRCUIT BREAKER) P/N 1003546 Revision W Page 71...
  • Page 72 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 THIS PAGE INTENTIONALLY LEFT BLANK Page 72 Revision W P/N 1003546...

  • Page 73: Chapter 11 Electrical

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 CHAPTER 11 ELECTRICAL CONTENTS 11.1 GENERAL ..............................74 P/N 1003546 Revision W Page 73...
  • Page 74 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 CHAPTER 11 - ELECTRICAL 11.1 GENERAL Figures 11.1 through figure 11.10 show the electrical schematic for the auxiliary instrument panel along with electrical schematics for each noted system. Page 74...

  • Page 75: Figure 11.1 Schematic - Auxiliary Instrument Panel

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 11.1 SCHEMATIC – AUXILIARY INSTRUMENT PANEL P/N 1003546 Revision W Page 75...

  • Page 76: Figure 11.2 Schematic - Circuit Breaker Panel

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 11.2 SCHEMATIC – CIRCUIT BREAKER PANEL Page 76 Revision W P/N 1003546...

  • Page 77: Figure 11.3 Schematic - Electrical Retract

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 11.3 SCHEMATIC – ELECTRICAL RETRACT P/N 1003546 Revision W Page 77...

  • Page 78: Figure 11.4 Installation - Foam Tanks / Pumps

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 11.4 INSTALLATION – FOAM TANKS / PUMPS Page 78 Revision W P/N 1003546...

  • Page 79: Figure 11.5 Schematic - Installation - Bilge Pumps

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 11.5 SCHEMATIC – INSTALLATION – BILGE PUMPS P/N 1003546 Revision W Page 79...

  • Page 80: Figure 11.6 Schematic - Installation - Scoop / Fill Systems

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 11.6 SCHEMATIC – INSTALLATION – SCOOP / FILL SYSTEMS Page 80 Revision W P/N 1003546...

  • Page 81: Figure 11.7 Schematic - Installation - Probe Position

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 11.7 SCHEMATIC – INSTALLATION – PROBE POSITION P/N 1003546 Revision W Page 81...

  • Page 82: Figure 11.8 Schematic - Installation - Pdr 60 Audio

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 11.8 SCHEMATIC – INSTALLATION – PDR 60 AUDIO Page 82 Revision W P/N 1003546...

  • Page 83: Figure 11.9 Schematic - Installation - Itt / Excess Power Light

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 11.9 SCHEMATIC – INSTALLATION – ITT / EXCESS POWER LIGHT P/N 1003546 Revision W Page 83...

  • Page 84: Figure 11.10 Schematic - Installation - Water In Float Sensors

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 FIGURE 11.10 SCHEMATIC – INSTALLATION – WATER IN FLOAT SENSORS Page 84 Revision W P/N 1003546...

  • Page 85: Chapter 12 Repairing Float Hull Sheet Metal, Bulkheads, & Other Sheet Metal

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 CHAPTER 12 REPAIRING FLOAT HULL SHEET METAL, BULKHEADS, & OTHER SHEET METAL CONTENTS 12.1 GENERAL ..............................86 P/N 1003546 Revision W Page 85...
  • Page 86 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 CHAPTER 12 - REPAIRING FLOAT HULL SKINS, BULKHEADS, & OTHER SHEET METAL 12.1 GENERAL For all float skin structural repairs, refer to Wipaire's Structural Repair Manual (SRM) part number 1008274. Page 86 Revision W P/N 1003546...

  • Page 87: Chapter 13 Repairing Float Hull Extrusions (Keel, Chine, Etc.)

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 CHAPTER 13 REPAIRING FLOAT HULL EXTRUSIONS (KEEL, CHINE, ETC.) CONTENTS 13.1 GENERAL ..............................88 P/N 1003546 Revision W Page 87...
  • Page 88 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 CHAPTER 13 - REPAIRING FLOAT HULL EXTRUSIONS (KEEL, CHINE, ETC.) 13.1 GENERAL For all float extrusion structural repairs, refer to Wipaire's Structural Repair Manual (SRM) part number 1008274. Page 88 Revision W P/N 1003546...

  • Page 89: Chapter 14 Continued Airworthiness

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 CHAPTER 14 CONTINUED AIRWORTHINESS CONTENTS 14.1 SERVICE SCHEDULE ...........................90 14.2 INSPECTION TIME INTERVALS CHECKLIST ..................93 14.3 OVERGROSS LANDING INSPECTION CHECKLIST .................97 14.4 FLOAT HARDWARE RECOMMENDED RETORQUE AND REPLACEMENT CHECKLIST ...101...

  • Page 90: Service Schedule

    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 91 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 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...
  • Page 92 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 joint in this manual or installation drawings. Reference checklist in Section 14.4 for specific hardware recommended torque and replacement. **TENSION APPLICATION **SHEAR APPLICATION Torque Limits Torque Limits Torque Limits...

  • Page 93: Inspection Time Intervals Checklist

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 14.2 INSPECTION TIME INTERVALS 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...
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  • Page 97: Overgross Landing Inspection Checklist

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 14.3 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...
  • Page 98 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 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,...

  • Page 99: Figure 14.1 Example Nose Spring Crack Measurements (Not To Scale)

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 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...
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  • Page 101: Float Hardware Recommended Retorque And Replacement Checklist

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 14.4 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 105: Chapter 15 Weight And Balance

    SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 CHAPTER 15 WEIGHT AND BALANCE CONTENTS 15.1 WEIGHING PROCEDURES FOR THE AT-802 FIREBOSS AMPHIBIAN .........106 P/N 1003546 Revision W Page 105...
  • Page 106 SERVICE MANUAL & ICA 10000 AMPHIBIAN FLOATS ON AIR TRACTOR AT-802 CHAPTER 15 - WEIGHT AND BALANCE 15.1 WEIGHING PROCEDURES FOR THE AT-802 FIREBOSS AMPHIBIAN Level aircraft per manufacturer’s instructions. Place scales under the right and left nose and main gear wheels.

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