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A-10038 ICA 6650-Kodiak rev 0 approved

1. CLOCKWISE TURN TO CLOSE Figure 9 2 Fwd Hinging Latch Operation EROCET Incorporated Bea 02 11 15 62 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION ayes SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 Investigation should be prompted if excessive water is pumped from any of the pump out cups during preflight Water can leak through the pump out plugs that need to be vented for expansion and contraction from flying to altitude and may also seep through the access panel seals Condensation will also generate water inside the float compartments More than four or five full pumps of water using an aircraft float pump should raise concern for maintenance In contrast if a pump out tube is cracked or broken a significant sucking sound will not be heard when the pump is removed from the pump out cup If there is question regarding the integrity of the pump out tube the operator must investigate and determine the cause Attention should be given to any bolts that pass through the stern or other external float structures These should be sealed into place using a single part urethane such as Sika Flex 292 It should also be noted that more water is typically pumped from the stern and bow compartments because they are often covered with water during operation and allow more seepage through the plugs and seals Pump out plugs m
2. FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION aan SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 0 9 RECOMMENDED PROCESSES PRODUCTS AND INSPECTION CHECKLISTS 9 1 1 Cleaning Seaplanes operating in salt water or brackish water should be thoroughly hosed down or flushed with fresh water each day including the landing gear bays The float s design which uses an all composite structure basically eliminates hull corrosion and leakage The floats should be kept clean with biodegradable soap and water The sides and the bottoms from the step aft can be waxed to help in the cleaning process The bottoms of the floats from the step forward should not be waxed as this gives unpredictable water performance Stains from the waterline down may be removed using marine fiberglass stain remover FSR Fiberglass Stain Remover manufactured by Davis is recommended Do not use abrasive cleaners or pads these will scratch the white gel coat surface The gel coat color surface should always be maintained on the floats for ultraviolet radiation protection When healing in to shore care should be taken to avoid the rock shield area ahead of the step This shield normally flushes the area on takeoff but any build up of debris needs to be addressed if the float plane is typically healed in especially with clay and rocks There cannot be any obstruction preventing the main landing gear f
3. AEROCET ISSUE r mT pate 02 11 15 Incorporated FILE NO TITLE Maintenance Manual and ICA REVISION PATE SUBTITLE Aerocet 6650 Floats on a 02 11 15 Quest KODIAK 100 REVISION MAINTENANCE MANUAL AND INSTRUCTIONS FOR CONTINUED AIRWORTHINESS FOR AEROCET MODEL 6650 TWIN SEAPLANE FLOATS INSTALLED ON A QUEST KODIAK 100 AIRPLANE Aerocet Inc P O Box 2119 265 Shannon Lane Priest River Idaho 83856 Phone 208 448 0400 Fax 208 448 1644 This ICA must be followed when Aerocet 6650 Floats are installed in accordance with Supplemental Type Certificate STC No ST12414SE A The information contained in this document supplements or supersedes the basic manuals only in those areas listed herein For limitations procedures and performance information not contained in this manual consult the basic aircraft ICA or maintenance manual EROCET Incorporated 02 11 15 TITLE Maintenance Manual and ICA REVISION ayes SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 This page intentionally left blank PAGE FILE NO REVISION EROCET 02 11 15 Incorporated PME FILE NO TITLE Maintenance Manual and ICA ee SUBTITLE Aerocet 6650 Floats ona o 02 11 15 Quest KODIAK 100 LOG OF REVISIONS Revision Pages Affected Description Date Approved
4. 02 11 15 55 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION as SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 7 ELECTRICAL 7 1 Aerocet GC700 Gear Advisory Unit Reference A 10039 Service Manual and Instructions for Continued Airworthiness for Aerocet GC700 Gear Advisory On the gear advisory display eight position indicator lights four gear up and four gear down indicate landing gear position The Hyd Pump indicator light illuminates during the electric hydraulic pump operation The landing gear system is also equipped with an emergency hand pump which accomplishes the same task manually should the electric pump fail to operate properly TEST BUTTON FOR INDICATOR LIGHTS AND AUDIO CANCEL GEAR UP AUDIO ee a WHEN LIT 3 06 GEAR IS UP FOR WATER LANDING WHEN LIT ELECTRIC HYDRAULIC PUMP IS RUNNING C WHEN LIT GEAR IS DOWN FOR J _ RUNWAY LANDING CANCEL GEAR DOWN AUDIO The WATER LAND and PUMP light circuits are protected by the Landing Gear Advisory circuit breaker and are therefore independent of the landing gear motor circuit and will function when using the emergency hand pump The Landing Gear Advisory Unit includes an audio output that is connected to the audio output source for verbal pilot information regarding gear position A static and pitot pressure source is connected to the Unit whic
5. 45 of 91 i FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION aan SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 the actuator rod in the extended position sets the default wheel height in the gear well when retracted for water operation 6 Adjust the gear down submersible sensor so that the drag link sensor tab is 018 031 away from the face of the sensor when the drag link is in the complete retracted position It is very important that the sensor does not trigger prematurely Assure that the drag link is over centered and against the stop bracket at the time that the sensor is triggered If the sensor and target are too far apart then the signal may be weak or intermittent causing frequent gear advisory enunciations If the sensor and target are adjusted too closely then a false gear safe condition could result the target being in range before the gear are fully deployed yet the drag link being just out of position This latter condition is hazardous 018 qm SENSOR IS ADJUSTED BY TURNING THESE NUTS DO NOT OVER TIGHTEN ASSURE DRAG LINK FULLY SEATED AGAINST STOP BRACKET WHEN ACTUATOR IS FULLY RETRACTED VIEW FROM RHS 7 The gear up position sensor may only be adjusted after the actuator has been fully adjusted to the down condition With the actuator adjusted and the gear up position sensor beyond range retract the gear compl
6. 4 1 Main Wheel Removal amp Assembly Reference 35A 51800 Sheets 1 amp 2 Consult Parker Cleveland Maintenance Manual and Parts Catalog for brake maintenance and Aerocet Component Maintenance Manual A 10036 for wheel and or brake maintenance and repair NOTE Make sure gear is in the down position and hydraulic gear motor circuit breaker is pulled 1 Block and jack the airplane according to Section 11 1 2 WARNING BE SURE TO DEFLATE TIRE BEFORE ANY DISASSEMBLY OF THE MAIN WHEEL 2 Drain oil bath wheel in a similar manner to the nose wheel Figure 3 5 3 Remove brake pads to allow the wheel and brake disc assembly to be pulled off the axle One need not disconnect the brake line unless further inspection and maintenance to the brake system is intended Secure the caliper in a manner that does not stress the brake hose Remove the wheel 4 Inspect all components for corrosion and wear according to procedures in Aerocet Component Maintenance Manual A 10036 EROCET ISSUE PAGE pate 02 11 15 Incorporated 38 of 91 5 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION ayes SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 0 5 Replace o rings in the tensioner bushing 6 Reassemble in reverse order of disassembly Consult the proper Component Maintenance Manual for further inspection and maintenance of wheel and brake assemblies
7. 66 T45201 rHajprovides an easier leveraged way to facilitate this and keep alignment 8 Using the two Bottom Sleeve Clamps 66 T45269 rHs and a vice remove the bottom cap from the oleo Locate the service wrench in a vise Position the oleo bottom facets into the wrench Place a 3 4 steel rod through the bottom cap bushings and unscrew the bottom cap from the oleo bottom in a counter clockwise motion Drain residual fluid into the bucket Check fluid for contamination 9 Remove the high pressure charging valve 10 Push the top cap and chrome sleeve down through the oleo bottom EROCET ISSUE PAGE pate 02 11 15 Incorporated 40 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION ayes SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 0 11 Inspect and replace all available seals as necessary 12 Further disassembly may be accomplished by removing the internal snap ring and metering insert 13 The top cap may be removed from the chrome upper by clamping the chrome using Chrome Sleeve Clamp 66 T45268 rHe pH7 in a vise Remove the top cap turning counter clockwise using the 3 4 rod CAUTION Make sure the clamp tools surfaces are perfectly clean before use 14 Top cap seals may be inspected and serviced at this time 15 Examine the metering rod for damage and if removed secure with safety wire 16 Examine bushings f
8. 7 Tighten the axle nut ensuring the proper amount of friction on the wheel bearings Use procedures outlined in the appropriate Component Maintenance Manual or a Fully tighten axle nut until the tire and wheel assembly begin to drag when spun This will assure that the tapered roller bearings are seated properly b Loosen the axle nut until the wheel assembly will spin freely again No torque c Tighten the axle nut until the nut begins to tighten but the wheel assembly spins freely and has no perceptible play Axle nut may be backed off to align the nearest slot to the nearest cotter hole no more than turn is necessary 6 Install cotter pin through the axle nut 7 Install brake mount and brake 8 Service the wheel with oil according to Aerocet Component Maintenance Manual A 10036 4 2 Brake Removal and Inspections Reference Parker Cleveland Maintenance Manual AWBCMM0001 7 Each main wheel has a dedicated brake caliper To remove the brake caliper 1 Remove the safety wire from the four bolts holding the back plate on Loosen those four bolts until the back plate is free Remove back plate 2 Slide the caliper away from the wheel until it is flush with other caliper and remove Brake pads should be replaced when the minimum section thickness is less than 0 100 Generally the brake discs should be checked for wear grooves deep scratches and excessive pitting Pitting deeper or coning more than 0 015 or
9. TITLE Maintenance Manual and ICA A 10038 REVISION REVISION BNR SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 If weighing the aircraft is not practical use the following data Item Weight Arm Moment W Arm Ibs in from datum in Ibs Certified Empty Weight as currently equipped verify the equipment list Exchange Weight 775 6 75 03 58 194 New Empty Weight Total Total Arm divide moment by weight M W 14 1 1 Weights for components left installed For temporary float removals such as for winter flight on skis it may be desirable to leave certain float equipment on board such as hydraulic lines amp fittings and electrical wiring per the Gear Advisory and hydraulics pedestal The following table shows weight and balance data for typical equipment Equipment not listed must be weighed separately It Weight Ibs Flight Station F S in m i ha on Kodiak 100 Electric Hydraulic Pump w hardware 10 0 Ibs 167 50 Hydraulics Pedestal 18 7 43 23 GC600 Gear Advisory wiring and 4 0 44 97 hydraulic lines EROCET ISSUE ERGE pate 02 11 15 Incorporated 91 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION aaa SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 15 Support Documentation including Installation
10. TITLE Maintenance Manual and ICA A 10038 REVISION REVISION ays SUBTITLE Aerocet 6650 Floats ona 02 11 Quest KODIAK 100 1 4 6 Fastener Use and Discretion aw21 1 4 7 Fastener Lengths Rivets Where replacement or repair of rivets is required use rivets of proper specifications only For instance MS20426AD4 xxx Lengths may be determined by measuring the thickness of the material s to be assembled and adding 1 5 X Diameter of the rivet to be used Over sized rivets may be substituted where holes have been drilled out Bolts and screws shall have a minimum of one thread visible through the nuts upon final torque Washers may be rearranged if necessary to accommodate proper fit up to two washers beneath the nut and one beneath the fastener head Typically Aerocet intends to put one thin washer beneath the fastener head and one thicker washer beneath the nut 1 4 8 Fastener Reuse Fasteners are to be inspected per Section 4 of this manual for condition Such fasteners that are acceptable may be cleaned re lubricated and re installed as determined Self locking nuts shall meet the minimum prevailing torque as listed in Figure 1 4 2 or shall be replaced All external retaining rings on the main gear pivot pins should be replaced with new ones each time to assure proper retention EROCET Incorporated PACE 02 11 15 19 of 91 FILE NO TITLE Maintenance Manual and ICA A
11. removing repairing and maintaining Aerocet Model 6650 Amphibious Twin Seaplane Floats on a KODIAK 100 Instructions in this supplemental manual replace specific noted sections of the Quest manual This manual is organized as follows 1 Airworthiness Limitations 2 Nose Gear 3 Main Landing Gear and Brakes 4 Hydraulics 5 Water Rudder 6 Electronics 7 Spot Mirror Assembly 8 Recommended Processes Products and Inspection Checklists 9 Troubleshooting 10 Installation and Removal Information 11 Strut and Composite Repair Manual 12 Illustrated Parts Catalog Drawings and parts necessary to use the Aerocet Model 6650 Twin Seaplane Floats on a Quest KODIAK 100 airplane 1 4 Fastener Torque 1 4 1 Torque Value Conversion To convert in lbs to ft lbs Value ft lbs x 12 Value in lbs To convert ft lbs to in lbs Value in lbs x 0 0833 Value ft lbs EROCET ISSUE ERGE pate 02 11 15 Incorporated 15 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION aaa SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 0 1 4 2 Tooling Requirements Calibrated torque wrench Adapters that affect the length of the torque wrench will affect the required torque indication and must be calculated according to Figure 1 4 3 1 4 3 Hardware Cleanliness All hardware is to be free of dirt and grit All dirty hardware shal
12. 10038 REVISION REVISION Anse SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 Availability One complete copy of this manual shall be provided with each new set of Aerocet Model 6650 floats Additional copies and minor revisions shall be available via email U S P S Mail UPS or FedEx by request Fees and delivery charges may apply Notification of any changes that require service for airworthiness shall be distributed to all applicable Aerocet float owners on record with Aerocet Inc In such a case copies of the applicable revised portions of this manual shall be provided Aerocet Inc maintains record of purchasers and or owners collected at the time of purchase in order to comply with the above as well as to maintain a high standard of service If you have moved since your original purchase have purchased a used product or otherwise have reason to believe that the contact information on file is incorrect please provide the following information to Aerocet Inc Aerocet contact information is on the front of this document Float Information Float Model Float S N R L Aircraft Information Aircraft Make Model Aircraft Registration Aircraft S N Owner Information as applicable Previous Owner Previous Address Present Owner Present Address Present Phone Number Present Email Address 02 11 15 REVISION DATE
13. 10038 REVISION REVISION aA SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 10 TROUBLESHOOTING 10 1 Basic Troubleshooting Possible Cause Corrective Action Missing plug Install plug Pump out float bays Improperly fastened access Install panel latch locker door panel or locker door Damaged or missing door seals Inspect seals replace as necessary Water in floats Missing Access Panel fasteners Replace as necessary Disassemble clean inspect and reinstall with Improperly sealed fasteners lant sealant Cracked cable sheathes Replace as necessary Damaged float hull Inspect float bays for signs of penetration Water Rudder rigging is mis Align the float rudders by re adjusting the aligned steering cables and or the balance cable Excessive drift left or right h _ Debris caught on floats during water taxi Damage to one float Inspect and repair damage operations Damage to water rudder blade s Locate and replace damaged pieces Howling noise from one or both floats after take Locker door left open Fly the airplane Land Latch the doors off Aircraft is unstable during Inspect Struts Tie Rods etc for breaks and for A Broken structural members water operations adjustment Correct the alignments of the exit holes through the floats to the aircraft mounted pulleys Over tightened turnbuckles Adjust tension Over tightened internal float ci g Loosen the fitting
14. 12 3 Repair Types and Procedures esseeeessesessesersrrseesrrsresrrsterresrenrrstessesreeresreesene 74 12 4 Higa rine IA of PTI yo dac sa nanan saan dagtaayannnaeaasasaasoneseanuedionasnoshaneaoosanesanseaeate 75 12 5 Resim MIXING sissie aieiaa e E EE E ENEE 76 12 6 Preparation of Carbon fiber Materials s cccsssssssaeunssossassneseeaosonsaanneqoocansennavasseays 76 12 7 Surface Coat Application Gel Coat assis sasansanssaenancsasossenasaasedonsannntaoosonsaanasassoane 11 12 8 Keel Wear Strip and Chine Bonding seesseseeseesessserrerrssesreeresrrssesrerseereesesee ay 3 Instructions for Continued Air wOriitess sssaessssssehsensotansssssaacaansesssensacniseapaseuantasosaunennavaasoane 19 13 1 General Pra EGGS nsii nn e e aie aE E aE ieai 79 13 2 PartI Preethi ohteni aaa A A E E E EEEE 79 13 3 Part2 Day IMSpECtIONS snose sisare iaa r a ra E a eriein 80 13 4 Part 3 Periodi Tis Per elon sisisi aissis iiiar 80 13 4 1 Continued Airworthiness Service Schedule eee eeeeeeeseeeseeseeeeees 81 Table 13 4 1 1 Service Sele cies nassonnsncciansserannransoanencpentaneceaspnnannsiiensnenagnemarees 84 13 3 Sp ci l Ti SSC ais asien esra E E E EEEE oE 85 EROCET 02 11 15 Incorporated Paiz FILE NO TITLE Maintenance Manual and ICA ee SUBTITLE Aerocet 6650 Floats ona o 02 11 15 Quest KODIAK 100 13 6 General PractiGe ssscicecscc6ecedaiesshbdcdbeccecetonudeaeyisbbedecescscecccutadub
15. 7 Surface Coat Application Gel Coat 1 All surface coats must be applied to a thickness of 10 to 15 mil Use a mil gauge and check often Waterline down is very critical to prevent blistering from water absorption 2 All surface coats must be catalyzed with 2 percent MEKP 3 Thinning of surface coats can only be done to manufacturer s recommendations 12 8 Keel Wear Strip and Chine Bonding 1 Prepare keel area by sanding float surface with 80 grit sandpaper It is desirable to mask out the area immediately surrounding the strips in order to avoid excess damage to the gel coat KEEL STRIP MASKING TAPE WEAR STRIPS FLEXIBLE WOOD STRIP OR SERIES OF BLOCKS BOTTOM OF FLOAT HULL SHOWING WEAR STRIP INSTALLATION EROCET Incorporated ERCE 02 11 15 78 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION ayes SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 2 Bond aluminum keel strips and chine aluminum angle extrusions using a marine grade urethane adhesive e g Sikaflex 292 Fiberglass wear strips should be bonded using a mixture of Hydrex resin and Aerosil 202 thickener A thick epoxy resin clear type not yellow may be used to bond the fiberglass wear strips as well 3 Wear Strips only Affix strips as shown in diagram Do not allow the resin to fully harden before trimming excess Time to harden varies wi
16. Aerocet 6650 Floats on a A 02 11 15 Quest KODIAK 100 correct materials for equal strength status Damage larger than 4 0 inches in size requires consulting Aerocet Inc for proper laminate orientation and assuring correct number of laminates in the damaged area 12 3 Repair Types and Procedures All repaired areas on the exterior must be surface coated gel coated with a minimum of 10 mil thickness to assure UV protection Types of repairs are described below 1 Resin starved Areas Exposed Fibers or Small Impact Damaged Soft Spots 0 5 Inches Diameter or less a Sand surface in defective area to remove gloss b Use a brush squeegee or syringe to work resin into defective area Use the same resin as the original laminate 2 Small Bruises Punctures Less than 0 25 Inches Diameter or Surface Voids a Sand surface surrounding defect to remove gloss b Cut patches to fit correction area using the same fabric as the original part Extending a minimum of 0 5 inch past the damaged area All patch corners must be rounded c Apply a light brush coat of resin so that it appears similar to the original coat d Place one or more plies on detail covering correction area using impregnation of fabric as described below 3 Cuts Fractures or Punctures 0 25 Inch Diameter or Larger a Cut back enough material to ascertain the extent of the damage Trim back plies to a smooth oval generally 0 5 inch per ply b If the area is
17. Cut Away View 8 Reassemble the bottom cap to the oleo bottom and torque should be 80 foot pounds using Oleo Sleeve Clamp 66 T45260 and Torque Spanner Tool 66 T45267 TH14 9 Align the top cap shear pin holes to those of the lower cap using the two 3 4 rods Always turn the chrome sleeve and top cap clockwise to align the lug holes in order to avoid loosening parts 10 With the assembly upright fill the oleo with the proper amount of fresh MIL H 5606 The use of the Oleo Bleeder Assembly tool 66 T45201 TH1s DHi6jhelps facilitate this process and assures final alignment of the pin holes when charging the oleo with nitrogen Hook a clear piece of tubing to the charge valve Place the other end into a clean bucket of EROCET ISSUE PAGE pee 02 11 15 Incorporated 43 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION SUBTITLE Aerocet 6650 Floats on a DATE 02 11 15 Quest KODIAK 100 0 MIL H 5606 aircraft hydraulic fluid Slowly cycle the oleo at its full travel Repeat until there is little or no air in the tubing 11 Check final alignment 12 Charge the oleo using nitrogen according to the placard on the oleo This can be done in the bleeder assembly tool to assure alignment 13 Replace oleo in float using shear pins washers and retaining rings 4 5 Complete Disassembly of Main Gear Reference 65 45000 Sheets 2 5 CAUTION USE CARE TO AV
18. Drawing listing and Illustrated Parts Catalog Contact Aerocet for copies of latest approved documents Installation Drawings 66 12000 wiscescetstiectoecesna en wierd bed ovinbe nena leis MASTER DRAWING LIST 6606 12010 segini ieena eeii AEROCET MODEL 6650 FLOAT INSTALLATION 66 12020 sicsisccaugerticetieheeecsees Anane iE des ae EEE aa noe EEE STRUT INSTALLATION 66212040 figs itiicniinhanedahindduieeacaee STEERING GEAR BUNGEE INSTALLATION OC 12050 cee aee E E EN PLACARDS INSTALLATION 66 12060 siiesriei eaei ari OTE A CE DRAIN GROMMET INSTALLATION 66212200 egri iueiio agosan a i n WATER RUDDER RIGGING INSTALLATION 66 123 00ers oreert ese N ENNE BOARDING STEP INSTALLATION 66 12400 ereenn ea ionian EEEE EE E E TAREE iE eea eh FAIRING ASSEMBLY 66212410 eea EE E EON NOSE GEAR COVER INSTALLATION OF 66212600 iiine ria s PLACARD INSTALLATION LOCKER LOADING DATA 660 127 00 eei ELECTRIC AND HYDRAULIC INSTALLATION 66 1270 miava teed at N A ees CENTER PANEL MODIFICATION 66 1270600 e BRAKE MASTER CYLINDER INSTALLATION 66 128 00 iiitr ete it anaeetioetieess MIRROR ASSEMBLY INSTALLATION 66212900 iinne E A neni tities VENTRAL FIN INSTALLATION 66212910 si eaieieinieiule nun idea andi enn VENTRAL FIN ASSEMBLY 65 460 10 nianon tei IN FLOAT INSTRUMENTATION WIRE HARNESS TSO 66246020 ess ciiivnatedeatitadsdestueditsiebanllucheseantidheeetinabaleaets SCHEMATIC HYDRAULIC SYSTEMS 66 47 100 neroni aon HYDRAULIC HAND PUMP DOUBLE ACTING 66 47 200 icc ceeaaay
19. Normal landing gear extension and retraction is accomplished by hydraulic actuators for each gear The hydraulic system is powered by an electrically driven hydraulic pump Hydraulic pump operation is initiated by moving the landing gear lever on the pedestal to either the up or down position This selector releases pressure which activates the electric hydraulic pump and moves the gear to the selected position The pump is shut off as the gear reaches its full extents increasing the pressure in the system causing the pressure switch to switch off the hydraulic motor The landing gear handle is on the hydraulic pedestal and has two positions UP for gear up and DOWN for gear down which give a mechanical indication of the gear position selected From either position the handle must be pulled out to clear a detent before it can be repositioned Moving the handle to UP or DOWN will start the electrically driven hydraulic pump in the selected direction of gear travel 5 1 Hydraulic Lines Reference Drawings 65 47000 66 47200 amp 66 12700 1 All hydraulic lines are serviceable according to the drawings The aluminum lines are made up of 5052 0 4 outside diameter 035 wall with conventional 37 degree flared ends These can be purchased by part number or made up by a certified mechanic The flexible lines are custom sized and may be purchased according to their part numbers 2 Ensure lines are all clean and flared properly upon replace
20. REVISION Da SUBTITLE Aerocet 6650 Floats on a 02 11 15 Quest KODIAK 100 0 Reassembly of the Nose Gear to the Nose Gear Box Reference 65 42000 Sheets 1 3 65 42100 Sheets 1 amp 2 65 42300 Sheets 1 amp 2 and 65 42400 1 Assemble in reverse order of section 3 3 Make sure the lock bracket part 65 42021 is clean Clean dry and Teflon spray the slide tracks for lubrication 2 Setting the proper adjustment of the rod end to the hydraulic piston is critical 3 Ensure the rod end part 65 42029 is screwed onto the nose gear hydraulic actuator at least as far as it was prior to disassembly If uncertain screw the rod end onto the actuator until it bottoms Danger if the rod end adjustment is incorrect the piston rod may be bent with full gear extension 4 Put the gear into the down position and adjust the rod end to the piston rod until the lock bushings part 65 42021 just touch the end of their travel in the slide brackets Lock into position by tightening the jam nuts to the rod end 5 The gear down position sensor should be adjusted as far forward as possible with full contact on the hydraulic cylinder part 65 42401 This will cause indication when the lock bracket comes into a roughly vertical position However the lock bushings and lock bracket travel beyond this point when positioned properly 6 The gear up position sensor should be located on the hydraulic cylinder to activate when the gear is in
21. SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 INSPECTION TIME Inspect for damage and corrosion Struts and Sink Remove strut fairings to check upper Fairines attachments and inspect heat shrink X Hulls and Struts ing of Weight on Wheels strain gage assembly Baggage Inspect seals latches internal xX Compartment damage from baggage Cabin Placards Inspect for placement and legibility SENEZ Nose ear Inspect clean and re lube Note 3 Tracks Nose Gear Lubricate Do not lubricate without Bottom Block reading warning Note 4 Nose Wheels Inspect according to Aerocet Dwg Axles and A 10036 Inspect O rings on bearings tensioner bushings Nose Wheel Spray corrosion inhibitor on metal Seals component of seal TH20 Nose Wheel Fiberglass Spring Inspect for cracks delamination paint Nose Landing Gear Internal Protection of Nose Gear Box Apply corrosion spray to box inside front float compartment note 3 Bolts Inspect for corrosion apply Hardware corrosion protection note 4 Nose Gear Lock Inspect for wear apply light amount amp Slide of grease to slide pins through holes Bushings in lock Seal Around the Inspect for gaps and reseal between x x Nose Gear Box box and float front 02 11 15 TITLE REVISION DATE SUBTITLE 02 11 15 EROCET Incorporated Maintenance Manual and ICA Aerocet 6650 Floats on a Quest KOD
22. and connectors J5 pin 13 Aircraft ground Check wire harness and connectors Resistance between J5 pin 14 and Check wire harness and connectors Check J5 pin 6 350 5 ohms left mid strut for damage to strain gage Resistance between J5 pin 13 and Check wire harness and connectors Check J5 pin 6 350 5 ohms left mid strut for damage to strain gage Flight HOBBS meter Resistance between J5 pin 13 and Check wire harness and connectors Check J5 pin 14 700 5 ohms left mid strut for damage to strain gage does not log flight time and aural stall warning inhibited when in flight With aircraft on ground WOW circuit powered and cover removed from WOW assembly perform the following calibration checks through the test header J1 on the WOW circuit board Voltage on pin 10 relative to pin 16 gnd 2 700 0 010 VDC Adjust R24 if required Voltage on Pin 12 relative to pin 16 2 500 0 005 VDC Adjust R6 if required If either voltage cannot be set properly contact Aerocet Customer Service With aircraft hangin rom wings or in ight WOW circuit powered and cover removed from WOW assembly perform the following calibration checks through the test header J1 on the WOW circuit board Voltage on pin 10 relative to pin 16 gnd lt 2 400 40 100 VDC If voltage out of range contact Aerocet Customer Service Voltage on Pin 12 relative to pin 16 2 500 40 005 VDC If voltage out o
23. hardware and bolts that pass through the bulkhead should be sealed with a one part urethane adhesive to assure water tightness and all main pivot pins are to be lubricated with Loctite Marine Grade Anti Seize 8023 or equivalent 3 When installing the main gear hydraulic actuator back into the bulkhead note that there is a washer seal on the each side of the bolt Aerocet also recommends use of a one part urethane marine grade sealant here as well such as Sika Flex 292 Do not use silicone 4 Install the drag link Assure the proper orientation of the spring bushing to prevent the extension spring from contacting the drag link during gear operation BULKHEAD ATTACH BRACKET _ DRAG LINK GEAR LINK SPRING BUSHING NOTE ORIENTATION EXTENSION SPRING z LOWER SPRING BRACKET NOTE ORIENTATION WARNING FLOATS MUST BE LIFTED AND SECURED PER SECTION 11 1 2 BEFORE ACTUATING GEAR 5 After installing the drag link and affixing it to the hydraulic actuator adjust the actuator rod end so that the drag link rests firmly against the stop bracket with the hydraulic actuator fully retracted The system must be powered up to assure that the actuator is fully retracted main gear in down position Add 3 4 turn of thread clockwise motion into the rod end allowing for assurance of force against the stop Do not allow more than this as the travel of EROCET ISSUE ERGE pate 02 11 15 Incorporated
24. negligible damage Holes in the struts may be classified as negligible damage provided they do not exceed 0 25 inch diameter for example a miss drilled hole for a step Multiple holes in one strut may be classified as negligible damage provided there are no more than two holes for every 4 inches of length 12 1 2 Repairable Damage No other repairs are authorized without FAA approval 12 1 3 Damage Repairable by Replacing Parts Any damage to the struts that exceeds the negligible limits or causes any bending twisting or cracking of the struts will necessitate complete replacement 12 2 Composite Float Hulls Composite float repair done correctly will obtain the strength required to put the float back into service and cosmetically show little or no evidence of damage ever having taken place The materials used for original construction and repair are conventional to the industry Any damage on the bottom of the float should be repaired immediately because of the tremendous water pressures encountered Contact Aerocet Inc prior to beginning a repair to obtain correct materials including resin resins have shelf lives catalyst cloth gel coat and resin thickeners Epoxy underwater patch kits may be used in an emergency if the damage is relatively small but the repair must be replaced with EROCET PAGE 02 11 15 Incorporated 74 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 oo SUBTITLE
25. or metal distortion elongation of holes rivet damage 3 Critical Bolts check for corrosion rust wear torque 4 Composite Parts check for stress cracks gel coat presence UV protection punctures 5 Nose Wheel Slide Tracks clean and lubricate with a dry Teflon coating spray 13 7 Product Listings 1 Hydraulic Fluid Mil H 5606 updated Mil PRF 5606 EROCET ISSUE ERGE pate 02 11 15 Incorporated 87 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION aaa SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 0 2 Teflon Spray Accupro Dry Lube 0024636 Comet Industries 6P 730A 3 Nose Gear Lock Bracket Grease Texas Refinery Corp TRC 880 C amp C BG Products HCF 605 Parker P N 219 06300 4 Rudder pulleys after installed LPS Industries LPS 2 5 Main gear pivot pins Loctite Marine Grade Anti Seize 8023 LPS 2 HCF Grease 6 Float Sealant for Bolts and Chine Strip attachment Sika Manufacturing Sikaflex 292 7 Rust corrosion Protection ACF 50 Corrosion X Boeing Co Boeshield T9 8 Bolt Protection PUR AL KETONE LPS Industries LPS 3 Zip Chemical Co Zip D 5029NS EZ Turn Lubricant United Erie 9 Composite Materials for Hull Repair Contact Aerocet Inc for resin cloth gel coat and resin thickeners 02 11 15 REVISION DATE 02 11 15 EROCET Incorpo
26. shaft threads and contact faces with small amount of lithium grease 5 Install axle through fork bushings and wheel bearings CAUTION Note positions of flats in the axle forks and bushings Misalignment may cause damage to components if tightened EROCET ISSUE PAGE ieee 02 11 15 Incorporated 32 of 91 gt FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION ar SUBTITLE Aerocet 6650 Floats on a 02 11 15 Quest KODIAK 100 0 ALIGN FLATS OF TENSIONER 3 BUSHINGS AND AXLE 4 WASHER TENSIONER BUSHING NOTE FLATS TENSIONER BUSHING j NOTE FLAT AXLE Figure 3 6 Exploded View of Nose Wheel Installation 6 Fully tighten axle nut until the tire and wheel assembly begin to drag when spun This will assure that the tapered roller bearings are seated properly 7 Loosen the axle nut until the wheel assembly will spin freely again No torque 8 Tighten the axle nut until the nut begins to tighten but the wheel assembly spins freely and has no perceptible play The axle nut may be backed off to align the nearest slot to the nearest cotter hole no more than 1 4 turn is necessary 9 Install cotter pin through the axle nut 10 Service the wheel with oil according to Aerocet Component Maintenance Manual A 10036 11 Check the pressure in the 5 00 5 tire Pressure should be 50 psi 5 psi EROCET ISSUE ERGE
27. the reference drawings 3 Note that the nose gear actuator incorporates a ceramic magnet to trigger the nose gear sensors This is located on the piston behind the retaining washer 4 Inspect and replace all seals and any damaged parts for service 5 Pre lube all seals and mating surfaces with a lithium grease or MIL H 5606 6 Upon reassembly assure that the ports on the main gear actuator in the piston cap lines up with the holes in the cylinder VEND CAP amp MOUNTING FLANGE J CYLINDER v STATIC O RING STATIC O RING PISTON ACTUATOR ROD END CAP On yg NE LALO RRL RA i ROD WIPER DYNAMIC O RING STATIC O RING STATIC O RING STATIC O RING PISTON SEAL RING MAGNET 65 42400 NOSE GEAR ACTUATOR CUT AWAY VIEW Figure 5 3 Nose Gear Actuator Cut Away EROCET Incorporated aea 02 11 15 50 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 oe SUBTITLE Aerocet 6650 Floats ona Re 02 11 15 Quest KODIAK 100 PISTON CYLINDER y STATIC O RING STATIC O RING J PISTON SEAL f STATIC O RING if ff 7 i BOTTOM CAP y STATIC O RING J T TOP CAP ap SSSA SAN SAY ACI OY NO Cee eee ere IREI BIROSO OOOO Tan A ERE A B ENA lt x ap MEF KSEE RNA RRNA RRNARARARAO ROD WIPER DYNAMIC O RING 65 45300 MAIN GEAR ACTUATOR CUT AWAY VIEW Figure 5 4 Mai
28. three announcements listed above will repeat as long as the button is depressed This announcement will continue to repeat and complete the phrase until the button is released Adjustments to the Gear Advisory unit are identified in A 10039 The Gear Advisory unit is a sealed unit and it should be returned to Aerocet Inc for any servicing NOTE Information included here is for reference only The service manual should be consulted for the most up to date information EROCET Incorporated PACE 02 11 15 57 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION Anish SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 8 SPOT MIRROR ASSEMBLY Spot Mirror and Bracket Assembly provides a visual verification of landing gear position It installs on an inspection panel under the aircraft wings both port and starboard Aircraft equipped with weather radars will have the starboard mirror attached to the aft fairing of the weather radar Install according to Drawing No 66 12800 02 11 15 REVISION DATE 02 11 15 EROCET Incorporated TITLE Maintenance Manual and ICA SUBTITLE Aerocet 6650 Floats ona Quest KODIAK 100 This page intentionally left blank PAGE 58 of 91 FILE NO A 10038 REVISION EROCET ISSUE ERGE pate 02 11 15 Incorporated 59 of 91
29. to the following l Landing completed on grass or other runway surfaces Inspect bottom of float including wear strips and keel plate EROCET Incorporated ERGE 02 11 15 86 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION DATE REVISION SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 2 Harsh landings on either runway or water Remove and inspect float strut attachment hardware for bent hardware and elongated holes including all fitting bolts and AN4 bolts through struts 3 Impact with a submerged object during taxi take off or landing on water Remove and inspect float strut attachment hardware for bent hardware and elongated holes Inspect entire bottom of float 4 Suspected damage incurred during tie down or mooring e g damage from wind or wave action Remove and inspect attachment hardware and deck plates Inspect both exterior and interior of float sides where contact with object may have occurred 5 Excessive water encountered during pump out on pre flight inspection Inspect to determine cause of excess water Note Exceptional inspections are not limited to this list other scenarios may occur that warrant exceptional inspections 13 6 General Practices 1 Wiring attachment to terminals damaged or corroded terminals melting of insulation chafing of insulation 2 Metal Parts check for corrosion stress cracks
30. 0 All Initial Release 02 11 2015 EROCET ISSUE DATE Incorporated ERCE 02 11 15 7 FILE NO TITLE Maintenance Manual and ICA REVISION DATE REVISION SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 Table of Contents Log of REVISIONS saci saucy tvasistintarecsasscoanaseaeuits ckaceesecoase ananieayecaccecianantiamsesuemmeen mates 3 I TIME VCTA CU i cen EE E 9 1 1 Warnings Cautions Notes essesseessesesssesssesssreseeesersssrssteeseesseessrsssresreesesssessres 9 1 2 General TASC iri Pett serere tepatna sta eaei esera eee SEERA Era EEN S E 10 Figure 1 1 Showing Overview of Basic Components sessseeeserereeererersrerrrrerreese 11 Figure 1 2 View of Model 6650 Floats on a Quest KODIAK 100 12 Figure 1 3 General Float Terms sseeeseseeesesrerresresresrsseesrrsresresrertesrerresrerrerseseese 12 Figure 1 4 Front View of Floats and Rigging sseesessereeeesresresrerresrerresrrrresrresese 13 Figure 1 5 Model 6650 Float Side View 5 scccicccssssscececcasdossssrecsanscpuocsensadavssseraevassness 13 1 3 How to Use This Supplemental Manual eseesseeeeeeeeseesreeresreeresrerresrrererrereese 14 1 4 Fastener LOrgU S ecrire a e EEN EE 14 1 4 1 Torque Value Conversion eesseeesesesessrrseesersrserrsrreresrrsrertessesreesesrrssesees 14 1 4 2 Tooling RSCQUMSINCIESS si icrscceecaanie Grass iisaiicetancbiaceaqsumanben reski i
31. 02 11 15 EROCET Incorporated TITLE Maintenance Manual and ICA SUBTITLE Aerocet 6650 Floats ona Quest KODIAK 100 This page intentionally left blank PAGE 20 of 91 FILE NO A 10038 REVISION EROCET ISSUE ERGE pate 02 11 15 Incorporated 21 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION Anat SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 0 2 AIRWORTHINESS LIMITATIONS 2 1 GENERAL The Airworthiness Limitations Section is required per 14 CFR 23 1529 This includes mandatory replacement times for type certification mandatory inspection times for type certification and inspection procedures for those approved mandatory times The Airworthiness Limitations section is FAA approved and specifies inspections and other maintenance required under 43 16 and 91 403 of the Federal Aviation Regulations unless an alternative program has been FAA approved 2 2 DESCRIPTION A TIME LIMITED ITEMS None B REQUIRED INSPECTIONS INTERVAL None C SCHEDULED MAINTENANCE Aerocet Model 6650 Amphibious Twin Seaplane Floats recommended Inspection or Replacement Schedule is located in Section 13 4 1 02 11 15 REVISION DATE 02 11 15 EROCET Incorporated TITLE Maintenance Manual and ICA SUBTITLE Aerocet 6650 Floats ona Quest KODIAK 100 This pag
32. ACTICE WHICH MAY RESULT IN PERSONAL INJURY OR DEATH IF NOT CAREFULLY FOLLOWED CAUTION An operating procedure technique or maintenance practice which may result in damage to equipment if not carefully followed NOTE An operating procedure technique or maintenance condition which is considered essential or beneficial to emphasize EROCET Incorporated ERCE 02 11 15 10 of 91 gt FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION ays SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 1 2 General Description Provision is made on the airplane for fitting a twin float installation complete with retractable cable operated water rudders The complete float unit comprising floats main landing gear nose landing gear landing gear retraction system water rudders spreader bars struts and fittings streamline wires and rudder control systems may be fitted to the airplane in place of the main wheel and nose wheel units The Aerocet Model 6650 Amphibious Twin Seaplane Floats are all composite float hulls The float hulls are separated by spreader bars that slide into the float assemblies The float design uses a double fluted bottom contour from the step forward and has a flat top deck design with built in lantiskid aw1 Each float offers six water tight compartments for safety three of which serve as large storage lockers Access to these compartm
33. AEE 65 10 1 Basic Troubleshooting ocaeais ivan saaasatanngrancttsobakeginceneqianientedaesunndoateauasnenauanrengnnsanbinsnannsanes 65 10 2 Troubleshooting Pump Failure to Stat tj cssivssnsccideasavnrsancntionnnss seeanssedaiuebaonsnsnangaaceanyenyns 66 10 3 Troubleshooting Weight on Water WOW system esesseeesesssseeseesesrrsseereesesreesesee 67 11 Installation and Removal Information sssesseeeeeseeseeseeseeseesessessresessrestrsresessresresresrerresreesesee 69 11 1 Fl ts TTA AAO eco stcasnadanctadonyetaeausirin sansiedasiongheatoesantebacaentaaueusnenancnspsaebanasadagauy 69 TLI PSST ssoptsscchsseatea ch onsranatodenateeescuraiaanensbontteauhnis stanceqaheiuatpenspeadaneceuad giants 69 11 1 2 Float Handling Jacking and TOW oxic scsisccssnnavsenscasonennssnessrononbaccansstanns 69 11 1 3 Boxing the Floats Reference 65 10001 ee eeseeeeceseeeseeeseeeeeee 70 11 1 4 Aerocet Drawings Required for Conversion from Wheels to Floats 71 12 Strut and Composite Repair Mamie isin sssnvcuiairiannicsdadaynvenssansanbndossaqnisaennpanadanensmaanacaedenton 13 A Ana LA T E E E neat 13 IZ411 Negligible Damage siaisscasectanensonanneqaca yannsieaacanransnonsaaehionsiastantsnanineadaaaniante 713 124 2 Rep irable D ma eee ois cossnasiceassbossosaacdaonautenarsooensansionsoaseaanantecbansnentsonnne 73 12 1 3 Damage Repairable by Replacing Parts cece ceeeeeeeeeeeeeeeeeeeneeeeeee 73 12 2 Composite Float HUllS esiisa naiai aiies 73
34. ALLATION OF BRACE ASSEMBLY LOWER ENGINE MOUNT PLACARD INSTALLATION LOCKER LOADING DATA KODIAK 100 AIRCRAFT ELECTRIC AND HYDRAULIC INSTALLATION AEROCET MODEL 6650 FLOATS KODIAK AIRCRAFT CENTER PANEL MODIFICATION GEAR ADVISORY amp CIRCUIT BREAKERS BRAKE MASTER CYLINDER INSTALLATION MIRROR ASSEMBLY INSTALLATION AEROCET MODEL 6650 FLOAT INSTALLATION KODIAK AIRCRAFT VENTRAL FIN INSTALLATION VENTRAL FIN ASSEMBLY IN FLOAT INSTRUMENTATION WIRE HARNESS PART OF FLOAT TSO SCHEMATIC HYDRAULIC SYSTEMS HYDRAULIC HAND PUMP DOUBLE ACTING PEDESTAL HYDRAULIC KODIAK AIRCRAFT WATER RUDDER RETRACT HANDLE ASSY IN AIRCRAFT INSTRUMENTATION WIRE AIRCRAFT PEDESTAL WIRING SCHEMATIC QUEST KODIAK AIRCRAFT IN AIRCRAFT FLOAT ATTACH TRANSITION WIRE HARNESS AEROCET 6650 AMPHIB FLOATS ENCLOSURE ASSEMBLY WEIGHT ON WHEELS EROCET ISSUE PAGE pate 02 11 15 Incorporated 73 of 91 i FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION aA SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 0 12 STRUT AND COMPOSITE REPAIR MANUAL 12 1 Struts 12 1 1 Negligible Damage Smooth dents in the skin surface of the float struts that are free from cracks and sharp corners may be classified as negligible damage provided they do not exceed 1 0 inch diameter and 0 10 inch in depth Multiple dents in one strut provided they are at least 1 0 feet apart may be classified as
35. B Table 7 2 02 11 15 TITLE REVISION DATE SUBTITLE 02 11 15 Short Open End Adapter AEROCET Incorporated PAGE 17 of 91 Maintenance Manual and ICA FILE NO A 10038 Aerocet 6650 Floats on a Quest KODIAK 100 WHEN USING A TORQUE WRENCH ADAPTER WHICH CHANGES THE DISTANCE FROM THE TORQUE WRENCH DRIVE TO THE ADAPTER DRIVE APPLY THE FOLLOWING FORMULAS TO OBTAIN THE CORRECTED TORQUE READING TORQUE ADAPTER WRENCH REVISION DRIVE CENTERLINE HANDGRIP CENTERLINE PREDETERMINED WRENCH DRIVE lt CENTERLINE Set Screw Adapter TxL L E EXAMPLE WITH E AS PLUS DIMENSION FORMULA Y T 135 LB IN Y UNKNOWN Hose Clamp Adapter L 10 0 IN E 41 51N Y 117 LB IN LEGEND T ACTUAL DESIRED TORQUE Y APPARENT INDICATED TORQUE L EFFECTIVE LENGTH LEVER E EFFECTIVE LENGTH OF EXTENSION Open End Wrench Adapter Flare Nut Wrench Adapter TORQUE WRENCH WRENCH DRIVE CENTERLINE ADAPTER HANDGRIP CENTERLINE PREDETERMINED mm DRIVE CENTERLINE TxL FOR A sY ORMUL L E EXAMPLE WITH E AS MINUS DIMENSION 135 x 10 1350 T 135 LB IN Y UNKNOWN Spanner Wrench Adapter L 10 0 IN E 1 5 1N Y 159 LB IN Figure 1 4 3 Torque Wrench with Various Adapters from AC43 13 1B Figure 7 2 EROCET Incorporated ERCE 02 11 18 of 91 FILE NO
36. DIAK 100A 66 12010 AIRCRAFT 66 12020 STRUT INSTALLATION AEROCET MODEL 6650 FLOATS KODIAK AIRCRAFT 66 12050 PLACARDS AEROCET MODEL 6650 FLOAT INSTALLATION KODIAK 100 SERIES AIRCRAFT 66 12060 DRAIN GROMMET INSTALLATION AEROCET MODEL 6650 FLOAT INSTALLATION KODIAK AIRCRAFT 66 12120 STRUT ASSEMBLY FWD AEROCET MODEL 6650 FLOAT INSTALLATION KODIAK AIRCRAFT STRUT ASSEMBLY MID MODEL 6650 FLOAT INSTALLATION KODIAK 66 12130 AIRCRAFT 66 12160 STRUT ASSEMBLY AFT AEROCET MODEL 6650 FLOAT INSTALLATION KODIAK AIRCRAFT 66 12170 STEERING GEAR BUNGEE MOUNT AEROCET 6650 FLOAT INSTALLATION KODIAK AIRCRAFT 66 12200 WATER RUDDER RIGGING INSTALLATION AEROCET MODEL 6650 FLOATS KODIAK AIRCRAFT AAEROCET 02 11 15 Incorporated PECE T2 of 91 3 FILE NO TITLE Maintenance Manual and ICA REVISION DATE 02 11 15 DRAWING NUMBER 66 12300 66 12350 66 12400 66 12410 66 12500 66 12600 66 12700 66 12701 66 12760 66 12800 66 12900 66 12910 65 46010 66 46020 66 47100 66 47200 66 47400 66 60015 66 60016 66 60017 66 60025 A 10038 SUBTITLE Aerocet 6650 Floats on a SE STON Quest KODIAK 100 DESCRIPTION CABIN BOARDING STEP INSTALLATION AEROCET MODEL 6650 FLOATS KODIAK AIRCRAFT BOARDING STEP STRUT ASSEMBLY AEROCET MODEL 6650 FLOAT INSTALLATION KODIAK AIRCRAFT FAIRING ASSEMBLY AEROCET MODEL 6650 FLOAT INSTALLATION KODIAK AIRCRAFT NOSE GEAR COVER INST
37. IAK 100 PAGE 83 of 91 FILE NO A 10038 REVISION INSPECTION TIME Zaa re ais an ED Centering Device Check Nose Landing Gear Perform Retraction Test Main Wheel and Bearings Main Gear Truck Drain Brake Assemblies Main Landing Gear Assure side to side travel at the axle is within limits and vertical travel is also within limits Any shimmy indication should cause investigation of side play limits Inspect travel amp extra side play in deployed position also perform emergency gear extension amp retraction test Inspect according to Aerocet Dwg A 10036 Remove lower plug on gear truck block between the axles to check for water Note It is filled with Styrofoam balls to protect from freezing damage Don t spray or add any oil to this cavity attacks foam Inspect for wear leakage corrosion Keep debris from building up P especially on the drag brace stop to Cleanliness assure overcenter operation amp rock deflector Main Gear and Axle Seals TH21 Bolts Hardware Spray corrosion inhibitor on metal component of seal Inspect O rings on tensioner bushings Inspect for corrosion apply corrosion protection Notes 1 2 5 EROCET Incorporated ERCE 02 11 15 84 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION ayaa SUBTITLE Aerocet 6650 Floats ona 02 11 15 Ques
38. Las LSS 2S gt SY S7 ey KS Pox Cp Ds TO DRAIN WHEEL ROTATE WHEEL ALIGNING BLEEDER ASSEMBLIES AS SHOWN VERTICALLY TO ONE ANOTHER ATTACH TUBING TO LOWER TO CATCH HYDRAULIC FLUID OR PLACE A CATCH BASIN BENEATH ASSEMBLY OPEN UPPER BLEEDER ASSEMBLY VENT OPEN LOWER BLEEDER DRAIN CUT AWAY VIEW OF 65 42170 NOSE WHEEL ASSEMBLY SOME PIECES OF 65 42100 LOWER NOSE GEAR ASSEMBLY SHOWN TIRE NOT SHOWN Figure 3 5 Oil Bath Wheel Drain Instructions 4 Remove cotter pin castellated nut and the nose gear axle 65 42178 WARNING DEFLATE TIRE BEFORE DISASSEMBLY 5 Note position of tensioner bushings and washer for later reassembly 6 Disassemble wheel as necessary according to A 10036 Component Maintenance Manual EROCET Incorporated PACE 02 11 15 31 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION Da SUBTITLE Aerocet 6650 Floats on a 02 11 15 Quest KODIAK 100 7 Inspect wheel bearings bearing seals tensioner bushings o rings and washer Replace as necessary 3 7 Nose Wheel Installation Reference 65 42100 Sheets 1 amp 2 and Figure 3 6 1 Reverse procedures in Section 3 6 2 Lubricate o rings and contact faces of bushings with small amount of grease or MIL H_5606 3 Lubricate bearing rollers and bores with small amount of oil Wipe a small amount of grease on wheel seal lips 4 Lubricate axle
39. OID DAMAGING GEAR POSITION SENSORS WHEN SERVICING MAIN GEAR 1 Make sure gear is in the down position and hydraulic gear motor circuit breaker is pulled 2 Jack the airplane according to Section 11 1 2 3 Remove oleo and main wheel according to Sections 4 1 and 4 2 4 Remove lower main gear assembly by removing attachment pins 5 Remove extension springs by removing upper attachment bolts Remove drag link by removing upper attachment pins 6 Disconnect hydraulics and cap lines then remove the main gear hydraulic actuator NOTE Note placement of washer seals on the bolt that attaches the lower actuator to the main bulkhead actuator housing 7 Any remaining brackets and the submersible sensor may be removed 8 Check all parts for corrosion and bushings for wear Replace as necessary 4 6 Complete Assembly of Main Gear including adjustment of submersible sensor and main gear hydraulic actuator Reference 65 45000 Sheets 1 5 1 Reverse procedure in Section 4 5 with the following particulars It should be noted that it is easier to install the drag brace and work the adjustment of the hydraulic actuator prior to attaching the gear truck and oleo EROCET ISSUE PAGE pate 02 11 15 Incorporated 44 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION ays SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 0 2 Any attachment
40. TITLE Maintenance Manual and ICA SUBTITLE Aerocet 6650 Floats ona Quest KODIAK 100 This page intentionally left blank PAGE 52 of 91 FILE NO A 10038 REVISION AEROCET Incorporated PACE 02 11 15 53 0f 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION a s SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 6 WATER RUDDER SEE SHEET 3 FOR VARIATIONS DETAIL G SCALE 1 4 DETAIL B p 19 SCALE 1 2 DETAIL E SCALE 1 4 CODEN Figure 6 1 From page 4 of Drawing 66 12200 Each of the float water rudder assemblies consists of a rudder post which is hinged to upper and lower hinge brackets on the float and carries a steering lever at its upper end and a rudder at its lower end on a swing type pivot bracket The swing type pivot bracket permits the rudder to be retracted Nyliner type bushings are installed on the assembly as bearings for the rudder post pivot points and the rudder retraction pivot points No lubrication is required The water rudders are controlled together through a series of EROCET Incorporated ERCE 02 11 15 54 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION ayes SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 pulleys turnbuckles extension springs and clamps to th
41. UE VALUES ARE DERIVED FROM OIL FREE CADMIUM PLATED THREADS TORQUE LIMITS RECOMMENDED FOR INSTAL MAXIMUM ALLOWABLE TIGHTENING LATION BOLTS LOADED PRIMARILY IN SHEAR TORQUE LIMITS Thread Size Tension type nuts Shear type nuts MS20364 Nuts MS20365 and Nuts MS20364 and MS20365 and AN310 and AN320 24 000 psi in AN310 90 000 psi in AN320 54 000 psi in 40 000 psi in bolts bolts FINE THREAD SERIES 8 36 12 15 7 9 20 12 10 32 20 25 12 15 1 4 28 50 70 30 40 5 16 24 100 140 60 85 3 8 24 160 190 95 110 7 16 20 450 500 270 300 1 2 20 480 690 290 410 9 16 18 800 1000 480 600 5 8 18 1100 1300 600 780 3 4 16 2300 2500 1300 1500 718 14 2500 3000 1500 1800 1 14 3700 5500 2200 3300 1 1 8 12 5000 7000 3000 4200 1 1 4 12 9000 11 000 5400 6600 Figure 1 4 1 Recommended Torque Values inch pounds from AC43 13 1B Table 7 1 FINE THREAD SERIES MINIMUM PREVAILING Self Locking Nuts Self locking nuts when re used must 1 2 20 10 inch pounds 9 16 18 13 inch pounds have at least the minimum prevailing torque listed in figure to the left Nuts that are smaller than those listed in the table 1 1 8 12 73 inch pounds 1 1 4 12 94 inch pounds aR TS GE shall not be used if they can be run up by THREAD SIZE MINIMUM PREVAILING TORQUE hand 1 8 51 inch pounds 1 1 8 8 68 inch pounds 1 1 4 8 88 inch pounds Figure 1 4 2 Minimum Prevailing Torque Values for Re used Self Locking Nuts from AC43 13 1
42. aasanatonsennaneaanienes 53 Figure 6 1 From page 4 of Drawing 66 12200 sssssessesssesesrrssesresresrrssesrersenressesss 53 gA ES i a E EAEE sates EE EE I E AAA EEO AE E E EA 55 EROCET ISSUE PAGE pate 02 11 15 Incorporated TITLE Maintenance Manual and ICA Sans nae SUBTITLE Aerocet 6650 Floats ona aout 02 11 15 Quest KODIAK 100 dake Aerocet GC700 Gear Advisory Unit Reference A 10039 Service Manual and Instructions for Continued Airworthiness for Aerocet GC700 Gear PRCEVISONY oona a r EAA r ER EA anaes 55 Sad POU Mirror ASSOCIA Viscassssssaccctecestiaqansssuaionnecdendeanteapanaasbuasanacvesectosdasassgniemiucdomsestidadupaxebvenss 57 9 Recommended Processes Products And Inspection Checklists eseeesceessreeeneeeeeeeeeeee 59 9 1 1 CTE ATA cate hip tats woherana aces aaen eeann aein e E esa aE aie E RARES 59 9 1 2 Float Hull Description and Maintenance sseeeeeeeeeeeeeseereeserrreserrresrees 59 Figure 9 1 Showing typical pump out cup plug and access panel eee 60 Figure 9 2 Showing Fwd Hinging Latch Operation 0 eee eeeeesseeeeeceseeeeeeees 61 9 1 3 Met l Hafdware sasicsancpunnivaishes stata casyialntantedaoubssnealastanaiqyeynnnneagsnaasbicsiqasiune 62 9 1 4 Winter Storage of the Floats seeeesseeeessesesseeseesresessresersesersresrenreereeseses 63 9 1 5 Dilora erinto o An E E 63 10 Troubleshooting isss sepesi nger aeaaee nae EEE Aa Es
43. aes i eiten ieinter ues ee tens ATEEN FLOAT PEDESTAL HYDRAULIC 6624 1400 recen AARE WATER RUDDER RETRACT HANDLE ASSEMBLY 66 6005 ieissa IN AIRCRAFT INSTRUMENTATION WIRE HARNESS 66 600 16 0 0 eee eee eeeee AIRCRAFT FLOAT PEDESTAL WIRING WIRING SCHEMATIC Illustrated Parts Catalog IPC A 10038 Appendix A sisssevecccsevncatncadsvnylt docs toapstdecessedusoievacaccssuutenesverstenynateveny Bound seperately
44. as a bulkhead or the float deck must be sealed with marine grade urethane adhesive such as Sikaflex 292 13 2 Part 1 Preflight Conduct Preflight inspections according to existing KODIAK 100 Airplane Maintenance Manual Float Specific items 1 Check for water in all compartments with the float hand pump 2 Check float lockers secured 3 Water rudders are free and cables in place 4 Ifon land check for debris in the wheel well area and in the front nose gear tracks 5 Ifon land visually check the bottoms of the floats for any damage 6 Assure that no lines have damaged wires or hydraulic lines protruding from the floats into the struts 7 Check the flying wires for tautness EROCET Incorporated ERCE 02 11 15 80 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION ayes SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 8 Assure the ventral fins and strakes have no damage from docks or other obstacles 13 3 Part 2 Daily Inspections Conduct daily inspections according to existing KODIAK 100 Airplane Maintenance Manual and refer to Table 13 5 1 1 Continued Airworthiness Service Schedule below 13 4 Part 3 Periodic Inspections Conduct periodic inspections according to existing Quest KODIAK 100 Airplane Maintenance Manual and refer to Table 13 4 1 1 Continued Airworthiness Service Schedule below EROCET Incorporate
45. ctive locators to keep them in the low spots and that they have no blockages If a pump out tube is cracked it will not pull the water out of its respective compartment resulting in extra weight and CG problems Replace as necessary PUMP OUT PLUG ACCESS PANEL CABLE TIE PUMP OUT TUBE Figure 9 1 Typical pump out cup plug and access panel Any damage penetrating to the float structure de lamination of the layers of cloth or wearing through of gel coat must be repaired according to Hull Repair Section in the Repair Manual section of this supplemental manual Significant damage warrants consultation from Aerocet Inc Float locker latches and seals are to be maintained as needed Adjust the locker latches by spacing the black catch ramp using thin washers the correct distance to maintain a detent when the locker catches Orient the arrow shaped handle pointing forward toward the hash mark in the CLOSE position shown on the placard and in the detent To close the latch push downward on 02 11 15 TITLE REVISION DATE 02 11 15 SUBTITLE AEROCET Incorporated Maintenance Manual and ICA Aerocet 6650 Floats on a Quest KODIAK 100 PAGE 61 of 91 FILE NO A 10038 REVISION the knob and the door panel as necessary and turn clockwise to engage the catch and reach the detent FORWARD
46. d PACE FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION aaa SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 81 of 91 02 11 15 13 4 1 Recommended Service Schedule INSPECTION TIME Inspect for damage and freedom of Water Rudders movement Check immediately after and Tiller Posts a take off or landing with the rudders down Inspect for fraying especially around Water Rudder System Cables pulleys and inspect cable guards cotter pins Inspect for freedom of rotation and condition of pulleys Lube with LPS 2 Pulleys and Bushings Inspect for damage surface coat gel Float exterior ji coat UV protection Rinse with fresh water daily if in Float exterior i salt or brackish water Note 5 Float exterior Inspect for damage wear keel wear bottoms strips and chine wear strips Hulls and Struts Inspect for evidence of damage from Float interior the interior vantage point Access Panels Inspect seals cracks in pump out and Pump Out tubes attachment of pump out tubes System tube routing Spray coat protection according to Note 1 and hardware according to Note 2 If working in saltwater protect more frequently Deck Blocks Deck Plates and Hardware EROCET Incorporated ERGE 02 11 15 82 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION ays
47. d steel bolts yearly No action is required for stainless hardware 9 1 4 Winter Storage of the Floats If possible store floats indoors and or under cover where temperatures do not drop below freezing In locations where temperatures drop below freezing add one quart of RV antifreeze through each of the pump out cups and tape over the pump out holes to minimize the amount of moisture that enters each of the six compartments Masking tape is not a suitable option duct tape or similar is recommended 9 1 5 Lubrication Nose tracks and blocks are to be kept clean and should lubricated by cleaning and spraying with a dry Teflon spray Nose block lubrication is addressed in Section 3 8 HCF Grease or equivalent should be used and use caution when applying the grease The main gear pivot pins and attach points for the drag brace gear truck and oleo attach must be kept lubricated with Loctite Marine Grade Anti Seize 8023 HCF Grease or equivalent If using 8023 clean mating surfaces remove any existing grease prior to application 02 11 15 REVISION DATE 02 11 15 EROCET Incorporated TITLE Maintenance Manual and ICA SUBTITLE Aerocet 6650 Floats ona Quest KODIAK 100 This page intentionally left blank PAGE 64 of 91 FILE NO A 10038 REVISION EROCET Incorporated PACE 02 11 15 65 of 91 FILE NO TITLE Maintenance Manual and ICA A
48. e intentionally left blank PAGE 22 of 91 FILE NO A 10038 REVISION 3 1 3 2 3 3 EROCET ISSUE PAGE pate 02 11 15 Incorporated 22 0f J1 FILE NO REVISION TITLE Maintenance Manual and ICA A 10038 REVISION ays SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 0 3 NOSE GEAR General Description The nose gear utilizes a composite fiberglass strut to absorb energy on landing along with the deflection of the nose tire The nose gear uses a 5 00 5 tire on an Aerocet oil bath wheel assembly that is full swiveling utilizing braking for steering and incorporates a centering device to keep the nose gear aligned for landing The nose gear is retracted by a hydraulic ram which pulls the gear along a slide track stowing the landing gear strut into a box in the nose of the float leaving only the tire exposed on the front of the float A towing lug is located on the lower clamp block Reference should be made to Nose Gear Assembly 65 42000 Sheets 1 3 and Lower Nose Gear Dwg No 65 42100 Sheets 1 3 Nose Gear Partial Removal Reference 65 42000 Sheets 1 3 1 Position gear in the down position and remove circuit breaker for the hydraulic gear motor 2 Jack up the airplane according to Section 11 1 2 3 Unbolt the bottom block from the composite nose spring Nose Gear Full Removal of the Nose Gear apart from the g
49. e rudder control cables The steering system consists of two control cables one attached through an extension spring to the outboard end of each water rudder steering lever and a single balance cable attached to the inboard ends of the steering levers The cables run through a series of pulleys through the fuselage skin and terminate at clamps which are attached to the rudder control cables under the floorboards in the aircraft To enable the water rudders to be retracted for take off and mooring a retraction cable control is provided Reference 66 12200 Sheets 1 7 The retraction handle located on the center pedestal is connected to the retraction cables which are routed over pulleys and through guides to the water rudders which are located within a pivot bracket and held in the down position by springs The rudder may be retracted by putting the Water Rudder Retract Handle in the aft position see Sheet 3 of Drawing 66 47200 The rudder steering rigging should align the rudders straight ahead when the airplane rudder is centered Cables should be just taut There should be no pre stretching of the springs which connect to the airplane rudder system This keeps the friction low not hampering yaw stability The water rudder retract cables should be rigged so that the rudders are tucked neatly behind the float transoms when retracted and the cables just become slack in the down position AEROCET Incorporated PACE
50. ear box and riveted on slide brackets Reference 65 42000 Sheets 1 3 65 42100 Sheets 1 amp 2 and 65 42300 Sheet 1 amp 2 1 Remove bumper by removing the eleven screws attaching it to the float 2 Remove the composite nose spring as shown below in Figure 3 1 EROCET Incorporated ERCE 02 11 15 24 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION ayes SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 yl REMOVE BUMPER Ss 2 DISCONNECT NOSE SPRING 65 42000 NOSE GEAR MODEL 6650 FLOATS TOP SHELL OF FLOAT HULL HIDDEN Figure 3 1 Removal of Composite Nose Spring 3 Retract the nose gear cylinder 4 Disconnect and plug the hydraulic lines from the hydraulic piston 5 Pull the box cap of the gear box by removing the nine AN3 fasteners as shown in Figure 3 2 The box cap is sealed into place using single part urethane adhesive Care must be taken to break the seal yet not damage the mating parts EROCET ISSUE ERGE pate 02 11 15 Incorporated 29 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION aaa SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 REVISION 5 REMOVE BOX CAP ACTUATOR LOCK BUSHING SLIDE BUSHING 65 42000 NOSE GEAR MODEL 6650 FLOATS TOP SHELL OF FLOAT HULL HIDDEN Figure 3 2 Remo
51. ents is facilitated through fastened access panels on the deck or the storage locker hatch covers The floats incorporate pump locations into each compartment These pump locations are used to remove any excess water present resulting from condensation leakage from the access panel gaskets bolts pump out plugs or a damaged float hull Replacement plugs are readily available and are common to many brands of floats PAGE 11 of 91 Incorporated FILE NO A 10038 REVISION Maintenance Manual and ICA Aerocet 6650 Floats on a Quest KODIAK 100 PANELS 3X FLOAT 02 11 15 TITLE SUBTITLE ACCESS WATER RUDDERS 2X f REVISION DATE 02 11 15 AFT SPREADER MID AND AFT STRUTS FWD DECK CLEAT 2X f MAIN LANDING GEAR N BOARDING STEPS FWD STRUT ASSEMBLY NOSE LANDING GEAR Figure 1 1 Showing Overview of Basic Components Water rudders are mounted on the stern of each float for water taxi operations and are connected to the rudder control pedals The retraction system is controlled by a lever located on the pedestal EROCET ISSUE PAGE pate 02 11 15 Incorporated 12 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION TT SUBTITLE Aerocet 6650 Floats on a 02 11 15 Quest KODIAK 100 17 3 APPROX Figure 1 2 View of Model 6650 Float
52. ersresessresrrseeseereesreeseseerseneesseses 25 Figure 3 3 Slide tracks to be inspected ssessesessseesessesessrrsrrsresresresrrrsesrersesresseses 26 3 4 3 5 3 6 Reassembly of the Nose Gear to the Nose Gear Box Reference 65 42000 Sheets 1 3 65 42100 Sheets 1 amp 2 65 42300 Sheets 1 amp 2 and 65 42400 27 Figure 3 4 Bolts for Adjustment of Nose Spring Movement cece 28 Removal of the Complete Nose Box and Gear from the front of the float Reference 65 42000 Sheets 1 3 65 42100 Sheets 1 amp 2 and 65 42300 SNESE K cress ee a E et eases EE ceeeaccaiccmnernetos 28 Nose Wheel Removal and disassembly Reference 65 42100 Sheets 1 amp 2 and Nose Wheel Drawing 65 42170 Sheets 1 3 eesessessesesseseerrssesrerserresesee 29 EROCET ISSUE tae pate 02 11 15 Incorporated TITLE Maintenance Manual and ICA ae EEA KEN SUBTITLE Aerocet 6650 Floats on a D 02 11 15 Quest KODIAK 100 Figure 3 5 Oil Bath Wheel Drain Instructions eseseeesseeeesessesseeseerreresrerserressesee 30 3 7 Nose Wheel Installation Reference 65 42100 Sheets 1 amp 2 and Figure 3 6 31 Figure 3 6 Exploded View of Nose Wheel Installation eee eeeeeeeeeeeeee 32 3 8 Detent Piston and Nose Pivot Pin Service Reference Drawing No 65 42100 Sheets 1 3 Drawing No 65 42120 Drawing No 65 42150 Sheet 1 and Fig res 3 7 and th 25 sash atiachysienvataiiedarbsaiaatdias
53. etely and then adjust the sensor to trigger range With proper hook up this sensor will activate red lights in the upper barrel when the target main gear drag link is in range within 1 8 It should be adjusted closer an additional 1 2 to 3 4 of a turn to avoid intermittent signals If the gear up sensor is adjusted with too much gap EROCET PAGE 02 11 15 Incorporated 46 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION TE SUBTITLE Aerocet 6650 Floats on a 02 11 15 Quest KODIAK 100 then intermittent signal may cause frequent gear advisory enunciations If the gear up sensor is adjusted too closely then there is increased risk of damaging the sensor face GEAR UP SENSOR ADJUSTMENT 1 COMPLETE ROD END ACTUATOR ADJUSTMENTS WITH THE ACTUATOR FULLY RETRACTED GEAR FULLY DEPLOYED DEPLOYED GEAR SHALL BE OVER CENTER AND AGAINST STOP BRACKET 65 45021 2 WITH THE SENSOR OUT OF RANGE OR NOT INSTALLED RETRACT THE GEAR ACTUATOR FULLY EXTENDED AS SHOWN 3 ADJUST SENSOR UNTIL IT ACTIVATES THEN ADJUST ADDITIONAL 1 2 TO 3 4 TURN MIN RANGE 018 030 CLEARANCE EROCET ISSUE ERGE pate 02 11 15 Incorporated 47 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION aA SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 0 5 HYDRAULICS
54. f range contact Aerocet Customer Service Note When aircraft is in flight or is hanging from wings the green LED on the WOW circuit board should be ON When aircraft is on the ground or on the water the green LED on the WOW circuit board should be OFF If both of these are correct and the flight HOBBS meter still does not log flight time and aural stall warning is still inhibited when in flight contact Aerocet Customer Service 02 11 15 REVISION DATE 02 11 15 EROCET Incorporated TITLE Maintenance Manual and ICA SUBTITLE Aerocet 6650 Floats ona Quest KODIAK 100 This page intentionally left blank PAGE 68 of 91 FILE NO A 10038 REVISION EROCET ISSUE ERGE pate 02 11 15 Incorporated 69 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION aaa SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 0 11 INSTALLATION AND REMOVAL INFORMATION 11 1 Floats Installation This section should be used in conjunction with Chapter 32 of the KODIAK 100 Airplane Maintenance Manual 11 1 1 Description Each float is attached to the airplane by forward mid and aft struts The front strut is bolted at the top to the forward fuselage fitting part 66 12102 The boarding step strut is attached to the cabin boarding step mount The mid and aft struts are bolted to the t
55. h determines airspeed The Landing Gear Advisory Unit has a trigger point set at approximately 85 knots This adjustment is factory set and user accepts liability for altering EROCET Incorporated ERCE 02 11 15 56 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION ais SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 these settings As the airplane passes through approximately 100 knots speed the system is armed When the airplane slows through the trigger speed an audio voice will announce the position of the gear and what kind of landing it is suited for With the gear up the message will say Water landing gear is up for water landing With the gear down the message will say Runway landing gear is down for runway landing This message will continue and repeat itself until acknowledged by the pilot by canceling out the message by the appropriate button on the Landing Gear Advisory Unit itself If the gear goes to a landing position and remains there without all four gears in place for a period of time beyond normal cycle time the gear will advise the pilot that the gear is unsafe with the following message Gear is unsafe check gear The message will repeat until canceled The TEST button in the center left position of the face when depressed will sound an audible announcement indicating the current position of the gear One of
56. his procedure Fill any seam voids with a resin glass bubble mixture Apply the final laminates according to the ply schedule to finish the repair 12 4 Impregnation of Fabric To impregnate fabric with resin cut the fabric in a suitable shape lay it on a flat surface and apply the resin mixture evenly with a squeegee Alternatively you may impregnate the fabric with resin with the fabric on the defective area providing voids and starved areas are not produced Impregnate the fabric in place by applying a thin coat of resin to the area to be laminated applying the resin directly to the fabric using a squeegee or brush and then laying the fabric down rolling it into the resin Any air in the laminate should be removed using a squeegee or brush See section 12 5 below regarding resin mixing EROCET Incorporated ERCE 02 11 15 76 of 91 gt FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION ar SUBTITLE Aerocet 6650 Floats on a 02 11 15 Quest KODIAK 100 12 5 Resin Mixing Gel times or pot life is the time it takes the resin to set up in the container after proper and thorough mixing with accelerators and catalysts Gel times can be adjusted significantly by varying the amounts of these materials Gel times will also vary significantly with the batch size if left in a bucket or with a very thick laminate TYPICAL GEL TIMES USING HYDREX 33253 33350 15 is simi
57. is heat shrunk into the nose block The nose block and pivot pin are supplied from Aerocet Inc assembled If the pivot pin is pressed out the anodized surface is opened up causing dissimilar metal contact between the two components when reassembled 4 Lightly grease all parts prior to reassembly using marine grade waterproof grease CAUTION Do not over grease these components Severe filling of the cavity may cause hydraulic lock Components must move freely 5 Lightly introduce grease through the fitting on the top of the bottom block Initial amounts should be two very slow pumps with a conventional hand grease gun Each stroke should take one minute Never use a pneumatic or electric grease gun Continually check pivoting action of the nose assembly to assure proper function watching for hydraulic lock and proper vertical movement If too much grease has been introduced push down on the grease check ball and rotate the nose gear 360 degrees a couple of times to expel excess amounts EROCET ISSUE ERGE pate 02 11 15 Incorporated 35 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION aan SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 0 6 Introduction of grease through the grease fitting during normal operation should be minimal 1 2 pump max of a hand grease gun per week always watching for hydraulic lock and any damage from g
58. ith dry Teflon coating spray Salt buildup should be cleaned and recoated with a dry Teflon spray Note 4 Nose block grease warning Introduction of grease through the grease fitting during normal operation should be minimal 1 2 pump max of a hand grease gun per week always watching for hydraulic lock and any damage from grease gun pressure Introduce grease very slowly Note 5 Coating with anti corrosion spray is recommended in situations where there is extensive exposure to non fresh water i e salt water An aerosol container or a pump sprayer is recommended for ease of application Note 6 Check all connections between stainless flex lines and aluminum fittings in bulkheads for corrosion and that they are not loose Note 7 Use Loctite Marine Grade Anti Sieze 8023 or equivelant for pin bushing lubrication 13 5 Special Inspections Conduct special inspections per existing KODIAK 100 Airplane Maintenance Manual In a variety of circumstances it is necessary to perform prompt inspections for damage Details relating to these investigations are addressed in Sections 9 1 2 and 11 of this supplemental manual and in the Service Schedule Table 13 4 1 above The pilot is responsible for determining the severity of damage to the aircraft and its flightworthiness while in the field Inspections and repairs are to be performed as necessary and per practices outlined in this manual A list of possible scenarios includes but is not limited
59. l be thoroughly cleaned lubricated or protected by the various products suggested in this document It is recommended that all stainless hardware be thoroughly lubricated with anti seize lubricant of good quality to prevent galling upon assembly 1 4 4 Torque Procedure Assure that hardware is clean and properly prepared for installation Assemble nuts to bolts measuring the tension required to turn the nut and add this to the required final torque Where possible apply torque to the nut and not to the fastener head Apply a smooth even pressure stopping and re torqueing if chattering or premature loading occurs This may warrant disassembly and subsequent inspection for burrs or galling Replace any damaged hardware Access panels should be torqued only to hand tight The fiberglass should exhibit only mild deformation A portable hand drill could be used provided that the clutch is set at a very low torque setting not risking damage to the plastic nutplates All other nuts shall be torqued per Section 1 4 unless otherwise noted i e AN8 through bolts to hold the spreaders in are torqued only to 25 ft Ibs EROCET Incorporated ERCE 02 11 15 Le of 91 i FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION ARSC SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 1 4 5 Fastener Torque Values Except where otherwise noted CAUTION THE FOLLOWING TORQ
60. lar 100gm castings only laminate times are typically double that of the gel times 33 MEKP Resin Catalyst Qty 50 F 60 F 70 F 80 F 1 00 100gm 60 min 32 min 23 min 15 min 1 50 100gm 43 min 23 min 17 min 11 min 2 00 100gm 35 min 20 min 15 min 8 min Note Under no circumstances should more than 2 0 percent catalyst mixture be used Conversely if you use less than the recommended minimum amount of catalyst 1 00 percent the resin may never completely cure resulting in a reduction of strength WARNING Be extremely careful with the MEKP catalyst Contact with eyes must be prevented Blindness may result Flush eyes immediately if MEKP catalyst makes contact with eyes and contact a physician immediately Never mix MEKP catalyst into the resin without eye protection 12 6 Preparation of Carbon fiber Materials 1 Carbon fiber cloth shall be trimmed on a clean table to prevent contamination EROCET Incorporated PACE 02 11 15 77 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION aan SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 2 When laps are necessary lap widths of at least 0 5 inch shall be maintained for carbon fiber pieces in any given ply and no more than one of the component plies shall be lapped at any one place The number of laps shall be kept to a minimum 12
61. large enough supply backing to hold the shape of the original contour Put a parting agent on this backing to assure its release c Replace the fabric on a ply for ply basis overlapping 0 5 inch minimum on each succeeding ply using impregnation of fabric as described in EROCET Incorporated PACE 02 11 15 15 of 91 i FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION aaa SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 section 13 4 Any smooth areas need to be sanded with 80 grit sandpaper to assure proper bonding d If damage has occurred where there is sandwich construction involving the core work each layer separately Fix either the outside or inside skins Then cut to fit like core material to replace the damaged core Bond the core onto the repaired skin using the proper resin and thickener A mixture of Hydrex resin and Aerosil 202 thickener should be applied to the bonding surface of the core using a squeegee using Torin Corebond alternative is acceptable A film of approximately 0 015 inches should be used Apply pressure to the bond to assure proper adhesion to the skin and to eliminate air voids Apply this pressure to small areas of core bonding using weights such as lead shot bags with a release film that eliminates sticking to any excess bonding material Larger areas require the use of a vacuum bag for core bonding Consult Aerocet Inc for t
62. ment 3 Hydraulic lines that run up the struts need to be placed in position prior to installation of the aircraft onto the floats Ensure the lines are centered in the struts as they enter from either end so as to not allow wear from vibration Also ensure the step attachment bolts clear the lines upon installation Shrink tubing may be installed where these lines enter and exit the struts AAEROCET Incorporated BACE 02 11 15 48 of 91 5 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION ARIS SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 4 All hydraulic lines need to be clear of all electrical and control cables and must be secured and isolated from surrounding structures to avoid damage during service Ref AC 43 13 ELECTRIC HYDRAULIC amp PUMP _ RESERVOIR 66 47510 J FILTER SCREEN He m an CHECK VALVE _ PRESSURE RELIEF VALVE Figure 5 2 Hydraulic Pedestal Components continued EROCET Incorporated PACE 02 11 15 49 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION aaa SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 5 2 Hydraulic Actuators Reference 65 42400 Sheet 1 amp 2 and 65 45300 Sheet 1 amp 2 1 Both the nose and main gear actuators can be rebuilt 2 Disassemble according to
63. n Gear Actuator Cut Away 5 3 Electric Hydraulic Pump The electric hydraulic pump is the primary hydraulic drive for landing gear operation The pump head is a positive displacement gear pump specifically designed for this application It is driven by a DC motor The pump and motor are intended to pump fluid in only one direction The motor is thermally protected in two ways The resettable thermal disc will trip first when the temperature of the motor housing rises above normal operating temperatures Once it cools off it can be reset by pressing the white button on the thermal disc housing If the thermal disc fails to function properly the thermal fuse will trip at a higher temperature The thermal fuse is not resettable and is not repairable in the field Contact Aerocet Inc for replacement EROCET Incorporated PACE 02 11 15 51 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION aaa SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 THERMAL FUSE s THERMOSTAT DISC RESETTABLE ELECTRICAL PUMP Figure 5 3 Electric Hydraulic Pump 5 4 Backup Hand Pump 1 Normal operation the Hand Pump handle should be vertical 2 Hand Pump operation should be according to the AFMS 3 If pump should leak contact Aerocet Inc for replacement 02 11 15 REVISION DATE 02 11 15 EROCET Incorporated
64. nding gear will shut motor Thermal cutoff switch tripped due to position Pump cuts off because of a premature overheating of motor off pressure build up aw17 Pressure switch relay or motor failure Check pump breaker cB18 Hydraulic teak Inspect all connections and check for fluid Pump running Eu continuously or Hydraulic leak with no leak Me a n ap eat Messe i position and locked Isolate the pump and intermittently apparent pump failure or each actuator for pressure tests Replace actuator piston seal failure P the pump or repair the actuator CB19 Check gear for damage and debris Check adjustments especially for the nose gear assembly Check hydraulic lines for damage such as kinks or blockages Check screens electrical connections pump gears Replace as necessary Slow gear operation Mechanical interference ISSUE DATE 02 11 15 TITLE REVISION DATE 02 11 15 SUBTITLE EROCET Incorporated Maintenance Manual and ICA Aerocet 6650 Floats on a Quest KODIAK 100 0 PAGE 67 of 91 FILE NO A 10038 REVISION 10 3 Troubleshooting Weight on Water WOW system Problem Possible Cause Corrective Action Disconnect J5 from WOW box and perform the following electrical checks WOW box located in MID BAY forward of the cross tube bay 20 VDC lt J5 pin 8 lt 32 VDC Check breaker Check wire harness
65. nnunsstnnesreasaaandaniase ASE EE ea EENS 33 Figure 3 7 Maximum Side to Side Free travel of Nose Wheel 33 Figure 3 8 Maximum Vertical Movement Nose Block cece ceceeseeeeeeseeeeeees 34 4 Main Landing Gear and DUAR jsssascsacsaradainteoanseavsnmnadiaastaunscanpurysbsossnvuiialstadanenesnpiaada bays 37 4 1 Main Wheel Removal amp Assembly Reference 35A 51800 Sheets 1 amp 2 Consult Parker Cleveland Maintenance Manual and Parts Catalog for brake maintenance and Aerocet Component Maintenance Manual A 10036 for wheel and or brake maintenance and TEP AU sccccanrnsnnrsersnerrnrnraacaratnnpsasnnnennsnansaaanengunsion 37 4 2 Brake Removal and Inspections Reference Parker Cleveland Maintenance Manual AWBCMM 0001 7 x stevsisaeasiessecaaedcutantnstennessspaancadaginentntanstsmasiagusayanes 38 4 3 Oleo Removal and Disassembly Reference 65 45000 Sheets 2 amp 5 and 65 45200 Sheets 1 amp 2 Oleo Bleeder Assembly 66 T45201 may be available from Aerocet upon request itaveruscesinbssansiaysnenncnii tnsabisanesaipnnaasduneasansantauaasasnanen 39 4 4 Oleo Assembly Reference 65 45000 Sheets 2 amp 5 and 65 45200 Sheets 1 amp 2 Oleo Bleeder Assembly 66 T45201 may be available from Aerocet upon raa LOTES S E A E ER 40 Figure 4 1 Oleo Seals and O rings sseeeesseeeeeseseesrrseesrrsresrrsresresrenresrenresrerresressese 41 Figure 4 2 Oleo Cut Away VieW e esseeseeseeseeseeseesrrsersrrseesrrstesresrestesrerrsre
66. or wear corrosion or other damage and replace as necessary 4 4 Oleo Assembly Reference 65 45000 Sheets 2 amp 5 and 65 45200 Sheets 1 amp 2 Oleo Bleeder Assembly 66 T45201 TH8 DH9 May be available from Aerocet upon request 1 In general reverse disassembly procedures 2 Lube all seals with assembly lube white lithium grease or MIL H 5606 before installing Assure that all Polypak seals face correctly for keeping the pressure in the oleo The lip side of the seals should face to the inside of the oleo EROCET Incorporated PACE 02 11 15 41 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION aaa SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 VALVE NUT TURN CW TO OPEN TURN CCW TO CLOSE m SECURE VALVE BASE WHEN OPENING VALVE NUT O RING STATIC ROD WIPER DYNAMIC SEAL POLYPAK _ _ PRESSURE SIDE STATIC SEAL POLYPAK Figure 4 1 Oleo Seals and O rings 3 Reassemble the top cap to the chrome sleeve if these were disassembled Lube the threads lightly with grease Holding the chrome sleeve using the Chrome Sleeve Clamp 66 T45268 THIO DHLYIN a vise screw the top cap back into place Torque the top cap to the chrome sleeve using Torque Spanner Tool 66 T45267 TH12 DHI3 and a 3 4 rod inserted through the I Glide bushings Use a torque wrench to torque to 80 foot pounds 4 In
67. pate 02 11 15 Incorporated 33 0f 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION aaa SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 0 3 8 Detent Piston and Nose Pivot Pin Service Reference Drawing No 65 42100 Sheets 1 3 Drawing No 65 42120 Drawing No 65 42150 Sheet 1 and Figures 3 7 and 3 8 1 Remove detent piston assembly according to exploded view 2 Check wear on detent piston There should be no more than 3 16 free travel side to side at the axle as shown in Figure 3 7 R15 65 s SWING RADIUS FULL CASTERING NEN N MEASURE FREE PLAY HERE S VIEW SHOWING TOP VIEW OF LOWER NOSE GEAR Z N Figure 3 7 Maximum Side to Side Free travel of Nose Wheel There should be no more than 1 16 063 vertical movement of the nose block as shown in Figure 3 8 If the components fall outside of the acceptable range adjust or replace as necessary EROCET ISSUE PAGE pate 02 11 15 Incorporated 34 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION ayes SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 0 REVISION y 063_ MAX MOVEMENT 65 42100 LOWER NOSE GEAR MODEL 6650 FLOATS Figure 3 8 Maximum Vertical Movement Nose Block 3 The heat treated pivot pin part 65 42152
68. rated TITLE Maintenance Manual and ICA SUBTITLE Aerocet 6650 Floats ona Quest KODIAK 100 This page intentionally left blank Except for that line and this line PAGE 88 of 91 FILE NO A 10038 REVISION AEROCET PAGE 02 11 15 Incorporated 89 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION DAR SUBTITLE Aerocet 6650 Floats on a 02 11 15 Quest KODIAK 100 14 WEIGHT AND BALANCE 14 1 Weight and Balance The most accurate means to determine the weight and balance of a modified aircraft is by physical measurement CAUTION Aerocet highly recommends that the aircraft be weighed to determine the actual weight and balance of the Kodiak 100 modified aircraft An inaccurate CG may lead to exceeding the CG range resulting in inadequate control Modify the equipment list to include the 6650 float installation and verify the remaining items On level scales with each wheel on the scales aircraft empty no fuel Scale Measured Weight Arm Moment W Arm Front Left scale 44 25 Front Right Scale 44 25 Rear Left Scale 99 25 Rear Right Scale 99 25 Tare weights chocks Tare weights chocks Total Weight amp Moment Total Arm divide moment by weight M W AAEROCET Incorporated ERCE 02 11 15 90 of 91 FILE NO
69. rease gun pressure CAUTION DO NOT USE ELECTRIC OR PNEUMATIC GREASE GUNS FOR THIS OPERATION Introduce grease very slowly avoid applying too much pressure on the internal components Grease guns can develop forces in excess of 10 000Ib 02 11 15 REVISION DATE 02 11 15 EROCET Incorporated TITLE Maintenance Manual and ICA SUBTITLE Aerocet 6650 Floats ona Quest KODIAK 100 This page intentionally left blank PAGE 36 of 91 FILE NO A 10038 REVISION EROCET ISSUE PAGE pee 02 11 15 Incorporated 37 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 ae SUBTITLE Aerocet 6650 Floats ona oe Vac 02 11 15 Quest KODIAK 100 0 4 MAIN LANDING GEAR AND BRAKES The main landing gear utilizes 6 00 X 6 tires and an oleo shock strut The main gear is retracted and held in the up position by a hydraulic actuator There are no up locks to fail and the geometric design allows the actuator to hold the gear in the up position under high G forces with low hydraulic pressures In the down position the oleo and drag link travel into an over center position against the stop bracket When the gear is in the down position this position is maintained even without hydraulic pressure with two springs assisting the over center position Proximity sensors are used to give gear position information to the landing gear advisory
70. rom fully deploying for a land landing Leaving the float locker doors open when hangered minimizes condensation in these bays 9 1 2 Float Hull Description and Maintenance The metal chine strips are abrasive wear surfaces used to protect the floats from docks and pilings See Figure 1 3 These extrusions are bonded on using a one part urethane adhesive These strips should be kept intact Aluminum strips are bonded and screwed onto the keel for protection Optional fiberglass wear strips may be added upward and outward from the keel near the step area where the float would nest in the rocks on a beach See Figure 1 3 These wear strips should be inspected during pre flight and upon suspicion of damage The strips should never be EROCET Incorporated Bea 02 11 15 60 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION ayes SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 allowed to wear through to the gel coat surface on the float Replace the wear strips as necessary See section 12 8 for instructions on repairing or replacing these strips All float access panels are to be removed upon annual inspection to detect any hidden damage and to comply with the maintenance of this supplemental manual During this time ensure that all the pump out tubes are not cracked especially around the fitting to the pump out cup that they pass through their respe
71. rs and tie them back to protect them from damage EROCET ISSUE PAGE pate 02 11 15 Incorporated 29 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 Rae e SUBTITLE Aerocet 6650 Floats on a O 02 11 15 Quest KODIAK 100 4 Remove the 12 fasteners which hold the slide brackets onto the front of the float Remove the 4 fasteners which hold the rear of the nose box to the attach brackets 5 Pull the complete nose box and gear forward including the hydraulic actuator 6 Note that single part urethane sealant is used where the box attaches to the front of the float and seals the bolts that hold it on 7 Reverse these procedures for installation Reseal according to Note 1 on 65 42300 3 6 Nose Wheel Removal and disassembly Reference 65 42100 Sheets 1 amp 2 and Nose Wheel Drawing 65 42170 Sheets 1 3 1 Make sure gear is in the down position and hydraulic gear motor circuit breaker is pulled 2 Jack the airplane according to Section 11 1 2 Alternately the front of the plane can be jacked up 3 Drain wheel as shown in Figure 3 5 below EROCET Incorporated ERCE 02 11 15 30 of 91 gt FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION ar SUBTITLE Aerocet 6650 Floats on a 02 11 15 Quest KODIAK 100 EK ki st S gt Y F Sere x gt AN A p ax Kees
72. runnion on the upper end At the lower end the struts are bolted independently to lugs on the float The floats are braced by a system of crossed streamline wires tie rods These are connected from the trunnion to the opposite rear deck fitting and similarly from the top of each front strut to the opposite front deck fitting Each bracing wire tie rod is provided with a threaded end bushing and lock nut for tightening and rigging adjustment Two steps are attached between the forward and step strut on each side of the airplane for entrance to the cockpit 11 1 2 Float Handling Jacking and Towing In order to service the float bottoms or aircraft installation rigging the floats may be lifted with hydraulic jacks or by taking the top fairing off the wing fuselage intersection looping a strap through the front spar attach point and lifting with a spreader bar and winch The best lift point for hydraulic jacks on the keel is 7 inches ahead of the step this locates the jack directly under the main bulkhead in the float and nearest the strong step area Use a 2x6 board in between the jack and the keel to distribute the load and reduce point pressure on the float structure After raising the float block the float in two places one ahead of the step and the other aft of the step It s best to position sawhorse s beneath bulkheads which are located 80 00 inches or 122 64 inches aft of the step EROCET ISSUE PAGE pa
73. s and re snug them by hand fittings Broken cable Replace as necessary Debris caught in the tiller Reduced water rudder Check all pulley assemblies for missing keepers Jammed Cable steering and fouled cables Broken rudder retract spring s Rudders do not deploy fully Water Rudders do not Check for fouled cables and debris especially at Cable jammed retract tiller Mis aligned steering cables Rudder Pedal feels stiff Replace as necessary EROCET Incorporated ERCE 02 11 15 66 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION ays SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 10 2 Troubleshooting Pump Failure to start Problem Possible Cause Corrective Action Circuit breaker Tripped Reset circuit breaker Motor wiring connections Check motor wiring Faulty pressure switch or relay Replace Switch or Relay Faulty or dirty pressure relief Hiscitis Pam Will ae Clean and check Replace as necessary Not Start Cycle gear selector into up and down positions to relieve the pressure and return to Down position In this circumstance the pump will then operate normally If Pressure build up in system from both sides of up and Commins not replace the unit Caution floats must be jacked up on land prior to cycling gear Clean nose tracks and main gear pins Gear stops mid Bi
74. s on a Quest KODIAK 100 Each float is attached to the airplane by front mid and aft struts The upper end of the fore strut is attached to a fuselage fitting 66 12102 The upper ends of the mid and aft struts are bolted to the landing gear trunnion on the side of the fuselage The upper end of the step strut is attached to the step attachment on the fuselage At the lower end all the struts are bolted to lugs on the float STEP TRANSOM MAIN LANDING GEAR KEELSON OR SISTER KEEL Figure 1 3 General Float Terms ZIAEROCET ISSUE ERGE pate 02 11 15 Incorporated 13 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION aaa SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 0 Figure 1 4 Front View of Floats and Rigging 26 3 0 26 6 5 _ Figure 1 5 Model 6650 Float Side View EROCET ISSUE PAGE pate 02 11 15 Incorporated 14 of 91 gt FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION E SUBTITLE Aerocet 6650 Floats on a 02 11 15 Quest KODIAK 100 0 1 3 How to Use This Supplemental Manual Used in conjunction with the KODIAK 100 Airplane Maintenance Manual Repair Manual and Illustrated Parts Catalogue for a KODIAK 100 airplane this supplemental manual provides the operator with a source of information for installing
75. ser arrese 15 1 4 3 Hardware Cleanliness ssivisadstitcadarscunaanvustietecectassunctaaventensaneatseaaiscamcaumsianss 15 1 4 4 POGUE Proc dure pp cucsasievexsctecsndasasuansesviwiete cextasssausanvaninnsumelaneqaessoacsanstaues 15 1 4 5 Fastener Torque Values Except where otherwise noted cece 16 1 4 6 Fastener Use and Discretion cssescsaveasn vistibcececeaiacausaenen tte hua eceenionctactaaasiens 18 1 4 7 Fastener Sti TING ossis teeosa sere tectatssa re e eE EEESC Ee anae t 18 1 4 8 Fastener REUSE nisce cee oea E E O t 18 2 AirWworthiness Limitaigns ssiri eperen ee inita e siia raaa e eE EE ESRAS Eata E net 21 2 1 EIIN aa E E yoisenueeteneuaceenniulectemebasuss 21 22 DESCRIPTION sicceccassisocusanthesuselacstsecanscue siisinceatedectunesacteansauentecuetepietaiesasmasssas 21 DINOS AGM srebra n retann vsuaheaccecaa scan a eaa a e aa esl E ERE E E O EEE ENEE 23 3 1 General D scripti ni i225 sscaisnnredwedatctsnasesanasanslguuhcenseeiegonsaneavsuatbaenesebinniuesaatevienes 23 3 2 Nose Gear Partial Removal Reference 65 42000 Sheets 1 30 00 23 3 3 Nose Gear Full Removal of the Nose Gear apart from the gear box and riveted on slide brackets Reference 65 42000 Sheets 1 3 65 42100 Sheets il amp 2 and 5 42 500 Sheet 1 amp 2s 23 Figure 3 1 Removal of Composite Nose Spring e seessseseesessesrrereerrssesrerrenreeseses 24 Figure 3 2 Removal of Box Cap eeesssssessseeseseesessrrs
76. sresreseese 42 13 Replace oleo in float using shear pins washers and retaining rings eee 43 4 5 Complete Disassembly of Main Gear Reference 65 45000 Sheets 2 5 43 4 6 Complete Assembly of Main Gear including adjustment of submersible sensor and main gear hydraulic actuator Reference 65 45000 Sheets 1 5 43 EBD y IT ABN esie raen er e ana ieee pa canna ona Ee E seai 47 5 1 Hydraulic Lines Reference Drawings 65 47000 66 47200 amp 66 12700 47 Figure 5 1 Hydraulic Pedestal Components 10 5 sccacssssssnceestassoaseunscssoessannenessasis 48 Figure 5 2 Hydraulic Pedestal Components continued ssseeeeeeeeeeeseeeeereerreseee 48 5 2 Hydraulic Actuators Reference 65 42400 Sheet 1 amp 2 and 65 45300 Sheet S a eter E npr ced at eca ae geeee eee vee E teen eee 49 Figure 5 3 Nose Gear Actuator CUtA Way sescaicsinssssecersossocscanatanssarnnenceoodesannetessasi 49 Figure 5 4 Main Gear Actuator Cut AWay ces cescessesscsseeeseceseesseeeaeeeseeseaeeeeenaes 50 5 3 Electric Hydraulic Pump seeseeseseeeseseeesseseereesrersesreseesreseereesrereesrereesreeresreeeeee 50 Figure 5 3 Electric Hydraulic Pump eeeesseeeessesesssrsresresessresrrsresresrenresrenrerseeresseses 51 3 4 Back p Hand PUMP seiscaasensnnanodsassigemansivencnlsenaiabgasadnanena nciectnanonsasmuanasensgnrmanasonseananenteebaes 51 6 Water Rudd OE isc ss asec oataienaitacesonoen iet e a E e Ea EE ponsaandean
77. stall the metering insert but do not install the snap ring It is much easier to fill the oleo with fluid while the metering insert is removed as described in step 7 5 Push the top cap and chrome sleeve through the seals on the oleo bottom Use a large socket and dead blow hammer to assist in getting the chrome sleeve started through the seal and wiper pushing on the metering insert Continue pushing until at least 4 of the chrome sleeve is showing through the rod wiper 6 Install the high pressure charging valve 7 Remove the metering insert turn the oleo upside down and fill the chrome sleeve to within 1 25 inches of the snap ring inset with MIL H 5606 aircraft hydraulic fluid Put the EROCET ISSUE PAGE pate 02 11 15 Incorporated 42 of 91 gt FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION e SUBTITLE Aerocet 6650 Floats on a 02 11 15 Quest KODIAK 100 metering insert back into place assuring the dome is properly positioned as shown in the figure Install snap ring 65 45231 TOP CAP 65 45202 CHROME SLEEVE 65 45201 CYLINDER 65 45241 METERING PIN SN aOR OA CATON 65 45242 METERING INSERT NOTE ORIENTATION MS 16625 3312 RETAINING RING e R oy exe H A aN m a a MS35275 240 MACHINE SCREW SECURED WITH SAFETY WIRE TO METERING PIN 65 45221 BOTTOM CAP 65 45200 SHOCK STRUT OLEO CUT AWAY VIEW Figure 4 2 Oleo
78. t KODIAK 100 INSPECTION TIME ED el aia epi Romove pins and relube Note 7 P fx ment Pins Extension Assure they are in place without X X Springs breaks Composite Gear Main Landing Gear Box Inspect for cracks damage ie Inspect for leakage damage pressure Inspect travel also perform Perform aa enc eat pe er amp X RetractionTest gency ge retraction test Hydraulic Fluid Check sight glass fill according to Level placard on reservoir RIR Ba eoi Clean and inspect screen Check for x Retraction Systam Cont cama moisture amp debris Fluid ERDEN Hydraulic Lines Inspect for leaks dents corrosion amp Fittings contact with airframe cables struts Hydraulic Inspect for leakage fittings seals Actuators rod straightness corrosion Pump Retraction System Solenoids Inspect wiring mounting loose x x Electric Pressure terminals general condition Switches Table 13 4 1 1 Service Schedule EROCET ISSUE ERGE pate 02 11 15 Incorporated 85 of 91 i FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION ee SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 Note 1 Spray coat of a migrating corrosion material ACF 50 Boeshield T9 or Corrosion X Note 2 Coat hardware with EZ Turn Lubricant PUR AL KETONE or LPS 3 Note 3 If working sand wash out tracks daily to remove abrasive potential and lubricate w
79. t is advisable to put some EZ Turn Grease or equivalent on the bolts for final assembly Wipe off excess under the bolt head before it seats 1 2 up and apply Sika Flex 292 or equivalent urethane adhesive sealant for a waterproof seal under the bolt head Insert opposite ends of the spreader bars into the opposite float It may be helpful to affix aa strap to the deck cleats of each float cinching them together in tandem with incremental movements until the pre drilled holes line up Note again in the process that the spreader bar is not inserted beyond the mounting holes and damaging to the float Finalize by introducing the clamps blocks 56 10202 necessary washers and self locking nuts Torque the bolts to 25 ft lbs and coat the bolt and nut with EZ Turn Grease or equivalent Seal the gap at the interface between the spreader bar and the inside of the float with a fillet of black Sika Flex 291 3M 5200 or equivalent Do not use silicone for this application AEROCET Incorporated PACE 02 11 15 Tl of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION ne SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 REVISION 11 1 4 Aerocet Drawings Required for Conversion from Wheels to Floats DRAWING NUMBER DESCRIPTION MASTER DRAWING LIST AEROCET MODEL 6650 FLOAT INSTALLATION Ceas KODIAK 100 AIRCRAFT AEROCET MODEL 6650 FLOAT INSTALLATION TO QUEST KO
80. te 02 11 15 Incorporated 70 of 91 gt FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION aise SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 0 The airplane may be otherwise lifted with a launching dolly or large forklift under the spreader bars Lift as closely as possible to the float hulls without touching the hulls Towing the amphibious aircraft can be done by a rigid V frame attached to the tow lugs on the front of the lower nose gear springs or by a rope yoke around the forward strut deck fittings Care should be taken to not run over curbs or other obstacles that could overstress the nose landing gear 11 1 3 Boxing the Floats Reference 65 10001 Place the floats a suitable distance apart and in a parallel position Identify by markings on the spreader bars which spreader bar goes to the front and which to the rear F for front or B for back The markings will always end up on the bottom of the spreader bar when installed Make a mark on each spreader bar by measuring the depth of the slip tubes socket to assure the spreader bar is not installed too deep fracturing the outside skin on the float Treat the insides of the slip tubes and outsides of the spreader bar ends with white lithium grease Insert the forward and aft spreaders into one float until the pre drilled holes align with the deck plate holes Insert AN8 bolts into position at this time I
81. th temperature and ratios mixed Another more advanced method of attaching these strips is with a vacuum bag setup 4 Keel and Chine Strips only Hold the keel or chine strip in place using an abundance of masking tape Remove tape after the urethane cures and clean up excess material Aerocet recommends carefully scoring the squeeze out along the edges of the keel strips then peeling it away in strips EROCET ISSUE ERGE pate 02 11 15 Incorporated 79 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION aan SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 0 13 RECOMMENDED SERVICE SCHEDULE GENERAL PRACTICES AND PRODUCT LISTINGS FOR SERVICE 13 1 General Practices 1 Metal Parts check for corrosion rust stress cracks or metal distortion elongation of holes and rivet damage 2 Critical Bolts check for corrosion rust wear and torque It is recommended that some form of corrosion inhibiting compound be applied to all threaded fasteners and other similar parts Possible products used include those listed in the Product Listings that follow but are not limited to these products Apply per manufacturer recommendations only 3 Composite Parts check for stress cracks gel coat presence UV protection and punctures Section 5 covers repair and re work of composite parts 4 All parts fasteners that penetrate float structures such
82. the fully retracted position If the position sensor is too far forward it may not indicate when the gear is fully up because the magnetic ring passes by the sensor 7 The tension of the upper AN5 63A and lower AN6 64A bolts sets the width of the slide brackets parts 65 42423 L amp R These should be tightened to allow 1 8 movement of the nose spring part 65 42103 where the bottom block part 65 42105 attaches shown below in Figure 3 4 If adjusted too tightly then the slide bushings may bind during gear operation If adjusted too loosely then nose wheel may shimmy and cause damage or excessive wear EROCET ISSUE PAGE pate 02 11 15 Incorporated 28 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION ayes SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 0 7 ADJUSTMENTS ANS 63A UPPER BOLT AN6 64A LOWER BOLT 65 42103 COMPOSITE WS SPRING 1 8 SIDE TO SIDE __ AS MEASURED AT A THIS LOCATION 65 42000 NOSE GEAR MODEL 6650 FLOATS Figure 3 4 Bolts for Adjustment of Nose Spring Movement 3 5 Removal of the Complete Nose Box and Gear from the front of the float Reference 65 42000 Sheets 1 3 65 42100 Sheets 1 amp 2 and 65 42300 Sheets 1 amp 2 1 Remove bumper by removing the eleven screws 2 Disconnect and plug the hydraulic lines from the hydraulic piston 3 Remove the position senso
83. thickness below 0 327 is cause for replacement EROCET ISSUE ERGE pate 02 11 15 Incorporated 39 of 91 i FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION aie SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 0 NOTE Minimum thickness is mentioned here as a reference only Refer to AWBCMMO0001 7 for most current wear limits 4 3 Oleo Removal and Disassembly Reference 65 45000 Sheets 2 amp 5 and 65 45200 Sheets 1 amp 2 Oleo Bleeder Assembly 66 T45201 px3may be available from Aerocet upon request 1 Make sure gear is in the down position and hydraulic gear motor circuit breaker is pulled 2 Block and jack the airplane according to Section 11 1 2 3 Remove the oleo by pulling shear pins 4 Keep oleo upright on the bench 5 Hook a length of 4 clear plastic tubing to the charge valve and locate the other end in a clean bucket 6 Release the oleo pressure while securing the base of the charge valve from by using a 34 wrench and slowly release the oleo pressure by opening the valve lock nut counter clockwise 7 Compress the strut to discharge all the fluid from the cylinder This is done by using a 3 4 steel rod positioned through the top cap bushings and pressing down on the cylinder Protect the bottom cap from damage by placing it on a piece of wood or rubber Bench service tool Oleo Bleeder Assembly
84. ust have some venting capability to allow for expansion and contraction of the air in each compartment during flight Two drilled holes are typical for venting or some pump out plugs have a pull string tied through a vent hole If the pilot strikes rocks or debris when on the water he must assess the damage as soon as possible Continuing into a high speed situation with the floats will typically exaccerbate the damage due to high water pressure 9 1 3 Metal Hardware Hardware such as cross wire terminals wire pulls bolt heads nuts and other hardware items should be protected with a coating of EZ Turn Paralketone rust preventative or heavy grease Operations in saltwater or brackish water demand extra attention to the metal components After operations in these environments washing should be done daily with fresh water if possible with attention paid to metal fittings Usage of an anti corrosion spray like Corrosion X or its equivalent should be used as often as possible This displaces moisture and contaminants and can be applied to wet or dry metal components It EROCET Incorporated PACE 02 11 15 63 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION REVISION SATs SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 is the cheapest defense for corrosion versus replacement of expensive parts It is advisable to remove and grease the shafts of all cad plate
85. ustedasgeseace ceannsnusueess 86 13 7 Product Listings ssiri sna ER E R 86 14 Ulistrated Parts Catalo g e sser ea A aE E EE EEAO EEEa 91 EROCET Incorporated 02 11 15 TITLE Maintenance Manual and ICA REVISION ayes SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 This page intentionally left blank PAGE FILE NO REVISION EROCET ISSUE PAGE pate 02 11 15 Incorporated FILE NO TITLE Maintenance Manual and ICA REVISION REVISION aan SUBTITLE Aerocet 6650 Floats ona 02 11 15 Quest KODIAK 100 1 INTRODUCTION Thank you for choosing Aerocet Floats This manual covers the installation and maintenance of the 6650 floats as installed on the Quest KODIAK 100 airplane This manual includes a list of the drawings for installation trouble shooting inspection time intervals hoisting jacking recommended lubricants and cleaners and best practices for maintenance especially in saltwater An Illustrated Parts Catalog is also provided 1 1 Warnings Cautions Notes It is vitally important to follow all safety standards listed by Aerocet Inc and its suppliers while maintaining Model 6650 Amphibious Twin Seaplane Floats Specific safety standards will be illustrated through the use of WARNINGS CAUTIONS and NOTES which are defined as follows WARNING AN OPERATING PROCEDURE TECHNIQUE OR MAINTENANCE PR
86. val of Box Cap 6 Taking care to avoid the wiring for the position sensors mark the position of the up position sensor for reassembly Wires do not need to be disconnected if the actuator assembly is only moved a short distance 7 Slide the box cap aft along with the hydraulic piston revealing the lock and slide bushings 8 Clean and inspect the gear box tracks for wear as shown below in Figure 3 3 0 EROCET ISSUE PAGE pate 02 11 15 Incorporated 26 of 91 7 FILE NO TITLE Maintenance Manual and ICA REVISION DATE SUBTITLE Aerocet 6650 Floats ona aa 02 11 15 Quest KODIAK 100 A 10038 8 CLEAN amp INSPECT SLIDE TRACKS AF a FOR CORROSION 65 42300 SLIDE BOX ASSEMBLY TOP HIDDEN TO SHOW TRACKS Figure 3 3 Slide tracks to be inspected 9 Inspect and replace slide pins as necessary 10 Inspect and replace lock bushings and slide bushings as necessary 11 Inspect slide truck and lock bracket for wear and replace as necessary 12 If removal of the rod end part 65 42029 from the nose gear hydraulic actuator is necessary readjustment upon reassembly will be required Prior to disassembling mark with a permanent marker or masking tape the original location of the rod end on the actuator rod EROCET ISSUE ERGE pate 02 11 15 Incorporated 27 of 91 FILE NO TITLE Maintenance Manual and ICA A 10038 REVISION

A-10038 ICA 6650-Kodiak rev 0 approved

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