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Model 7000 Service Manual

1. FIGURE 1 2 amp SIDE VIEWS Revision D Page 16 of 109 P N 1004646 Doc No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS ASO IONINAAL NOWWOOD ASSV H3HM ISON 3NIHO 1a N 133 1515 ASSV E TH3HM NIV S HAOO 3930 dO L 11515 OM IN3IWHOV L IV TIVMANND 54008 NOTAd INAWHOVLLV SS3OOV NY39 NOLLOJdSNI NOTAd 14V ines 1 ALL JSON FIGURE 1 3 FLOAT TERMINOLOGY Page 17 of 109 P N 1004646 Doc No W7001 24 01 Revision D SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS 9 soul 8 uo d Suea pn somunq pue s umu inns ssoooe seuip pue juourgoejj AIM 58010 j2edsur oq UMOYS Sq ues 101 8657001 29 9657001 e3e osn uo UOTPULIOJUI IIOU 10 enut A ooueuojure A 1son oos spoued
2. SIDE VIEW HYDRAULIC ROUTING FIGURE 5 2 HYDRAULIC PLUMBING P N 1004646 No W7001 24 01 Page 65 of 109 Revision G SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS 5 1 BLEEDING THE HYDRAULIC SYSTEM The system automatically bleeds provided sufficient oil is maintained in the reservoir To check the fluid level fill the reservoir through the servicing point on the power pack assembly with MIL H 5606 hydraulic oil and cycle the gear If the reservoir empties stop the cycle by pulling the pump motor circuit breakers Fill the reservoir again and complete the cycle Continue this procedure until the fluid level in the reservoir stabilizes it will vary in level between gear up and down positions If the fluid level continues to decline during gear cycles check for external leaks When the fluid level stabilizes fill the reservoir to the normal operating range as placarded on the pump reservoir Revision G Page 66 of 109 P N 1004646 Doc No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS THIS PAGE INTENTIONALLY LEFT BLANK Revision G Page 67 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS CHAPTER 6 WATERR RUDDER Revision G Page 68 of 109 P N 1004646 Doc No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS 6 0 BASIC D
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6. 10 1 u Buu Q eAnoejeg 72 lt sujui exejq exeig Q O 1IOA1 S 1 ouneapAu o B 15 lt se eoejdaJ 10 ue O pue perejnuinooe Jo pue osip eoejdeu e 2 lt pue 545 usnj 5 soul ojnejp u gt Hued 72 Bured Alu doiuduul 19 m 1 eoejdau 10 q uolsid exeiq uexoug q 9 sued eAnosjep gt sjulod ep d speped m ua P N 1004646 No W7001 24 01 Page 105 of 109 Revision G SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS CHAPTER 11 INSTALLATION PRINT INFORMATION Revision G Page 106 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS WIPAIRE DRAWINGS REQUIRED FOR 7000 FLOAT INSTALLATION 1004099 1004211 1004469
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10. aR 69 CHAPTER 7 BREC ERICA s s nananman Cau 72 7 0 ELECTRICAL SYSTEM BASIC DESCRIPTION J I a RA u n uq nee 73 CHAPTER 8 HARTZELE 3 BLADE PROPELLER renatin aiai 76 8 0 HARTZELL 3 BLADE PROPELLER DESCRIPTION AND OPERATION 77 MAINENANCE PRACTICES n e taii 78 CHAPTER 9 RECOMMENDED PROCESSES PRODUCTS AND INSP CHECKLISTS 80 9 0 SERVICING INSTRUCTIONS a umu use sa Toren odia gode 81 dtt quideni hen edo qu edet qun tisse Reed petitum dee 83 9 2 MAINTENANCE CHECKLIST 84 9 3 FLOAT REMOVAL AND RE INSTALLATION GUIDE eret 91 9 4 WIPAIRE FEGATS SPECIAL TOOLS u E E 100 CHARTER IU TROUBLESHOOTING S dh 102 CHAPTER 11 INSTALLATION PRINT 106 APPENDIX A OPTIONAL YAGI ANTENNAS IR TI en 108 END c eU 109 Revision D Page 8 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS THIS PAGE INTENTIONALLY LEFT BLANK Revision D Page 9 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS LIST OF FIGURES AND TABLES FIGURE I
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13. 2 Remove wing root fairings 3 Install finlets amp strakes and seal 4 Remove pilot and co pilot steps 5 Disconnect brake lines and cap 6 Cuttie wrap from pump circuit breakers 7 Tie ropes from tie down rings Connect lifting rig to hoist and inspect aircraft lifting points at wing root for proper assembly before connecting to aircraft Use ballast from tie down ropes to ensure level lifting 8 Raise aircraft until wheels are just touching the ground and assemble crew minimum 6 people for installation 9 Remove main gear per Kodiak Maintenance Manual section 32 10 Install cross tubes in belly Caution take care not to crush cut brake or gear hydraulic lines 11 Install main pylon attach fitting into gear saddles and pin to cross tubes 12 Torque saddle bolts to 40 ft Ibs 13 Lower aircraft to floats install front struts first then lower aircraft onto pylon attach fitting and install bolts 14 Remove the nose gear 15 Install rear flying wires rig with regard to airflow 16 Install boxing wires 17 Secure the steering bungee amp connect the hydraulic lines Re rig Steering Bungee per Quest Kodiak Maintenance Manual 18 Locate jack stands under floats 19 Perform gear check amp ensure all lights agree with gear and gear advisory 20 Cycle time up 45 seconds check for leaks 21 Cycle time down 45 seconds check for leaks 22 Hand pump the gear down and up and check for leaks again 23 Route and rig
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16. Aq pessoooe oq sour ounoo o or ne1pAH urqeo ye A quiessy FIGURE 1 4 MAINTENANCE ACCESS POINTS Page 18 of 109 P N 1004646 Doc No W7001 24 01 Revision D SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS 1 1 GENERAL FLOAT INFORMATION The model 7000 amphibious float is a clean sheet all aluminum structure designed to be installed on the Quest Kodiak 100 The alloy used throughout is mostly corrosion resistant 6061 T6 Interior parts are cleaned acid etched and then primed prior to being riveted for enhanced corrosion resistance Exterior surfaces are cleaned alodine is applied as a corrosion resistant barrier and then primed and custom painted with enamel Model 7000 floats contain fifteen 15 water tight compartments per hull Access to the inside of the floats for cleaning inspection and repairs is through the covers on the float deck and the covers inside the wheel well Figures 1 1 and 1 2 show three view drawings of the Kodiak 100 as installed on Wipline model 7000 amphibious floats Revision D As a part of the float installation the following additional changes are made to the landplane 1 The hydraulic landing gear retraction system components and cockpit controls are added 2 The landing gear emergency gear operation hand pump and system are added A water rudder steering sy
17. SNOILONULSNI g gt x SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS 9 3 FLOAT REMOVAL AND RE INSTALLATION GUIDE Revision G Page 91 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS optionally removed when the aircraft is taken off of floats ITEM Remove Leave Opilonally Remove 1 Horizontal Strakes x 2 Floats and Struts x 3 Auxiliary Fins Finlets x 4 Waterline Cut Exhaust System x 5 Mounting Hardpoints installed in horizontal stabilizer for finlets x 6 Doublers on empennage and horizontal stabilizer for strake mounting x 7 Hardpoints installed in tailcone for hydraulic pump mounting x 8 Elevator Trim Tab Extension x 9 Vertical Stabilizer VG Array x 10 Forward strut attachment fittings on firewall x 11 Hand operated emergency hydraulic pump and water rudder retract handle x 12 Landing Gear Selector x 13 Hydraulic Power Pack located in tailcone x 14 Emergency Trim Timer Override System ETTOS x FIGURE 9 2 FLOAT KIT INSTALLATION ITEMS Revision G Page 92 of 109 P N 1004646 Doc No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS uoene SINN Ajj Sjuiod uo d om sinuis deis 1001 syog 5115 deis
18. bea iha qala ashaka 60 BIGUREO EHYDRAUDICSCHENUSTIU u Q aussi oie te ui OPI a oes 64 FIGURE 5 2 HYDRAULIC PLUMBING o stein En Erb e sect 65 FIGURE 6 1 WATER RUDDER RETRACTION amp EMERGENCY GEAR PUMP 69 FIGURE 6 2 WATER RUDDER CABLEROUTING nennen nennen rennen nnne 70 TABLE 1 MAINTENANCE INFORMATION IN KODIAK AND HATZELL MANUALS 78 FIGURE 9 1 CORROSION LIMIT 83 FIGURE 9 2 FLOAT KIT INSTALLATION TITEMS 92 FIGURE 1 YAGI ANTENNAS INSTALLED 00000 108 FIGURE A 2 CUFF REMOVAL eia eee Tre dido eei 108 Revision G Page 10 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS THIS PAGE INTENTIONALLY LEFT BLANK Revision D Page 11 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS SSIPAIRE INC CUSTOMER INFORMATION Customer Name Billing Address Shipping Address Phone Number Fax Number Purchasing Contact Phone Number E Mail Fax Number Accounts Payable Contact Phone Number E Mail Fax Number Type s of Aircraft Owned or Maintained Model s of Floats and Skis Owned or Maintained
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23. FedEx and or UPS account number if applicable Please return to Wipaire Customer Service Fax 651 306 0666 Phone 651 306 0459 CustomerService 2 wipaire com Revision D Page 12 of 109 P N 1004646 Doc No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS THIS PAGE INTENTIONALLY LEFT BLANK Revision D Page 13 of 109 P N 1004646 Doc No W7001 24 01 Revision D SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS CHAPTER 1 INTRODUCTION AND GENERAL INFORMATION 1 0 INTRODUCITON This manual is provided for the owners of Wipaire model 7000 Floats as installed on the Quest model 100 Kodiak It has two main priorities to inform owners of the level and amount of servicing required to properly maintain their floatplane and to provide technical data and servicing as specified to maintenance professionals charged with servicing the floats The service products referred to throughout this manual are described by their trade names and may be purchased from the Wipaire Parts Department We at Wipaire welcome your purchase and look forward to years of satisfying exchanges with you Your floats are built with pride and attention to detail but we want that care to extend beyond your purchase Our customer service department is available for your questions 24 hours a day 7 days a week where ever you are in the world Parts Sales and Technical Support Dept Wipaire Inc 1700 Henry Aven
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25. 1004472 1004500 1004527 1004651 1004652 1004653 1004690 1004693 1004973 1004976 1005260 1006721 Revision J INSTALL FINLETS INSTALL STEERING amp RETRACT SYSTEM INSTALLHYDRAULIC SYSTEM WIRE ROUTING WIRING SCHEMATIC INSTALL STRAKES INSTALL VORTEX GENERATORS TRIM TAB EXTENSIONS INSTALL FWD STRUTS amp PYLONS STANDARD CONFIGURATION STRUT INSTALLATION HS KODIAK 100 OPTIONAL INSTALL PILOT COPILOT STEPS INSTALL EXHAUST STACK MODIFICATION amp ELEVATOR DOWNSPRING INSTALL MISC FUSELAGE ITEMS FAIRINGS amp COVERS INSTALLATION FUEL HANDLES OPTIONAL INSTALLATION ANTENNA OPTIONAL INSTALLATION 3 BLADE 102 PROPELLER OPTIONAL INSTALLATION HINGED WINDOW KODIAK OPTIONAL Page 107 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS APPENDIX A OPTIONAL YAGI ANTENNAS INTRODUCTION Select serial numbers of the Kodiak 7000 amphibian may be optionally equipped with wing strut mounted Yagi antennas for the purpose of wildlife tracking The antennas are approved only when the aircraft is equipped with floats and does not apply to the wheel equipped aircraft The installation includes a padded cuff that bolts around the wing lift strut with a mount for a boom that the antenna is attached to Specific data related to the limitations and performance of the aircraft with the antennas installed can be found in AFMS Doc No W 7001 25 01 latest revision Note
26. 5 Remove the rod linkages from the arms Note There are qty 2 NAS1149F0463P washers between the rod end and the actuator arm Remove the spring attached to the actuator arm NOTE Steps 5 through 16 are for re rigging the actuator If no changes are done to actuator skip to step 17 Loosen the bolt and nut holding the actuator arms Item 5 to the actuator shaft Remove the two arms from the shaft being careful not to lose the parallel keys It is not necessary to remove the visual gear position indicator assembly from the outboard actuator arm Remove the qty 4 5 16 18 bolts that hold the actuator into the channel that runs across the top of the wheel well Allow the actuator to drop down from channel and remove the up and down hydraulic lines Revision G Page 51 of 109 P N 1004646 Doc No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS 8 NOTE The actuator should not need 10 1 E adjustment while in service The only time adjustment should be necessary is when the actuator is disassembled in order to replace internal seals Assuming this has been done the remaining steps are for re rigging the actuator to be installed back in the float With the actuator assembled and removed from float attach Wipaire Tool 1004800 to the actuator taking note that the FORWARD arrow is pointing forward on the actuator Use the 5 16 18 bolts to attach the tool to the act
27. Antennas are certified for specific serial number aircraft and are equipped on a mission specific basis REMOVAL AND INSTALLATION Loosen bolts and remove antenna boom See Figure 2 Remove three bolts at the trailing edge of the cuff to unclamp cuff from wing strut Installation is reverse of removal refer to Wipaire drawing 1004976 MAINTENANCE Every 100 hours and at Annual Inspection of Wing Strut Mounted Antennas Inspect wing strut cuff and antennas for secure attachment Inspect all hardware for cracks and damage Ensure pad is in place and cuff is securely attached to the wing strut and all fasteners are tight WIPAIRE DRAWINGS REQUIRED FOR INSTALLATION 1004976 INSTALLATION STRUT ANTENNA CUFF KODIAK FIGURE A 1 YAGI ANTENNAS INSTALLED FIGURE A 2 CUFF REMOVAL Revision G Page 108 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS END Revision G Page 109 of 109 P N 1004646 No W7001 24 01
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29. 1004646 No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS FIGURE 4 6 MAIN GEAR DOWN STOP P N 1004646 Doc No W7001 24 01 Page 50 of 109 Revision G SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS 4 2 MAIN GEAR ASSEMBLY SETUP AND ADJUSTMENT Put aircraft on jacks to allow free extension and retraction of the landing gear Use safe operating practices when working around moving hydraulic components The actuators operate at high pressures and generate high forces when repositioning the landing gear Adjusting the Gear Down position See figure 4 4A and 4 48 1 Bleed pressure off the hydraulic lines by moving emergency gear position selector both directions to Up and Down This will relieve pressure in the lines allowing hydraulic lines to be unhooked without spilling fluid that is under pressure Item 1 Leave emergency gear position selector in Up position to allow actuator movement 2 Remove the ANI2 bolt at the top of the oleo shock strut attaching it to the top arm assembly Item 1 This will allow the retraction mechanism to be repositioned by hand without having to move the weight of the tires oleo and drag link assembly Place a rag between the drag link and the bulkhead as the gear will rotate and make contact with bulkhead possibly scratching the finish 3 4 Remove the 4 nuts connecting the rod linkages Item 3 to the actuator arms Item
30. At this point check to insure that the built in LED on the proximity sensor is illuminated when the sensor plate is rotated in front of the sensor 9 With the gear in the full up position loosen the AN6 bolt holding the proximity sensor plate to the Main Gear Top Arm and the socket head cap screw that prevents rotation of the sensor plate 10 Rotate the sensor plate so that the sensor is near the edge of the plate with the gear in the up position Reference Figure 4 5 inset 11 Tighten the AN6 bolt socket head cap screw and re safety AN6 bolt Revision G Page 57 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS 12 Check for proper light illumination on the gear selector in the cockpit in both the up and down position 13 If necessary reattach the oleo shock strut to the Top Arm Assembly 14 Remove aircraft from jack stand Revision G Page 58 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS BACKUP RING SEAL O RING SEAL O RING SEAL O RING BACKUP RING ROTARY ACTUATOR FIGURE4 7 ROTARY ACTUATOR Revision G Page 59 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS 17915 MOOHS Od lO SNId O 9 22825 11 A 1V3S 1 92081 0089 LE m ONI SLITIVH H3dlM L H3dlM 0161888 H3MHVd 9NIH O 60
31. Hand Operated Emergency Hydraulic Pump and Water Rudder Retract Handle Unbolt Pedestal from floor Disconnect cap and secure hydraulic lines under the floor 3 lines Disconnect water rudder retract cable coil and secure under floor Pw pm Install appropriately sized bolts in pedestal attachment locations Gear Selector 1 Unscrew selector face and remove from panel 2 Disconnect gear position connector and secure behind panel 3 Install Filler plate in panel Emergency Trim Timer Override System ETTOS 1 Remove Guarded Switch from panel 4 Follow wires from override switch to trim timer connection 5 Unplug override switch connectors and reconnect trim timer using existing connectors 6 Plug Hole in panel left from override switch 7 Remove Emergency Aileron Trim Timer Bypass Placard Revision G Page 97 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS FLOAT RE INSTALL INSTRUCTIONS PROCEEDURES MECHANIC THIS IS INTENDED AS A GENERAL GUIDE EACH INSTALLATION MAY HAVE SUBTLE DIFFERENCES ALWAYS USE THE INSTALLATION DRAWINGS AS THE FINAL REFERENCE ALL WORK SHOULD BE DONE BY CERTIFIED AIRCRAFT TECHNICIANS Right Left INSP 1 Remove the nose and main gear fairings
32. THE 7000 AMPHIBIOUS FLOATS 17 18 19 20 2 22 Reattach linkages to arms Loosen the rod linkage Jamb nuts and lengthen the rods slightly Item 3 Make equal adjustments to each rod Rotate actuator arms until the internal piston is against the Down Adjustment Screw Shorten the Rod Linkage until the Top Arm Contact Face Item 15 touches the contact face of the Top Mount Item 7 Make equal adjustments to each rod Actuator needs to be rotated fully against the Down Adjustment Screw Visually inspect the Rod Linkage position Item 3 versus the actuator shaft Item 4 When rigged correctly the bottom edge of the rod linkage should pass through the shaft as shown in Figure 4 4A Ensure gear is in down and locked position Using a small digital protractor the over center angle will be verified Lay the protractor across the bottom of the lower two screw holes in the actuator arm Note Older float models may not have flat spot shown use the same location as shown Revision G 23 24 25 26 Page 53 of 109 Zero the protractor See Figure 4 4B Then place the protractor on the top or bottom of the rod linkage The measured angle should be 4 1 Repeat for the other actuator arm and rod linkage by zeroing the protractor on the other actuator arm and measuring the rod linkage angle If angle is lower than required the down Adjustment Scre
33. W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS 3 3 NOSE GEAR DISASSEMBLY in float or removed from float Items refer to areas on Figure 3 3 1 Disconnect hydraulic lines Item 1 2 Remove the 4 NAS1103 2 bolts and washers attaching the Nose Ram Item 2 to the Flange Assembly Item 3 and slide the Nose Ram off of the Flange Assembly 3 Inspect interior bore of the Nose Ram for corrosion and pitting 4 Loosen AN316 10R Jam Nut Item 4 on Nose Ram Rod End Item 5 5 Using a strap wrench or other suitable non marring tool unthread the Ram Item 6 from the Nose Ram Rod End Do not attempt to remove the ram piston top brass from the ram shaft stainless steel They are assembled as a unit and permanently secured 6 Remove Ram Assembly Item 3 if desired to replace the T seals Item 10 felt wiper Item 7 and plastic wiper Item 8 Revision D Page 36 of 109 7 Replace T seals on the Nose Ram Item 9 and Ram Assembly Item 3 if necessary The T Seal in the Cylinder End Cap Item 11 can be replaced by removing the NAS1103 2 bolts and removing the cap from the Cylinder 8 Slide the Trolley Item 12 out bottom of nose gear track 9 If worn or damaged replace the 4 Slide Blocks Item 13 and the 2 Track Rollers Item 14 10 Grease the 2 axles Items 15 amp 16 when reassembling P N 1004646 No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 70
34. and 500 psi and 1200 psi in the UP position is maintained in the supply line When the pressure falls below 500 psi in the UP and DOWN position the pressure switch activates the pump solenoid providing power to the pump When the pressure reaches 700 psi in the DOWN position and 1200 in the UP position the pressure switch deactivates the solenoid and the pump motor stops A check valve on the output side of the pump retains pressure in the system while the pump is off The pump has an interval relief valve that directs fluid back to the un pressurized pump reservoirs when the line pressure exceeds 1400 psi The system also has an internal relief valve to protect against thermal expansion when line pressure exceeds 1900 psi The pilot line attached to each of the piloted check valves prevents thermal expansion of hydraulic fluid from activating the Up and Down pressure switches If the Up and or Down switch were to be activated from thermal expansion the pump would not run when commanded by the gear selector switch Revision H Page 63 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS UP AND DOWN PREASURE SWITCHES FOR EACH PUMP UP 500 1000 PSI DOWN 500 700 PSI DUAL DIRECTION PUMP INTERNAL SHUTTLE VALVE WITH 1150 RELIEF 150 PSI 1400 PSI THERMAL RELIEF CHECK VALVE 150 PSI MIN BREAKING UP UP N RET
35. consists of colored bands that rotate with the drive shaft allowing the pilot to visually determine the position of the main landing gear by looking at a placard on the deck of the float Since the actuator rotates through approximately 193 degrees the rod linkages and the actuating arm pass an over center point preventing reverse driving of the rack and pinion actuator in both the fully extended and fully retracted positions The actuator rotation is adjusted by setscrews that determine the length of travel of the actuator pistons Providing an over center up lock prevents inadvertent main gear extension in the case of a hydraulic failure As a secondary safety to ensure the geometry remains over center with a hydraulic failure a spring is installed on the actuating arm preventing motion of the rack and pinion actuator Since the retraction mechanism is over center the weight of the landing gear and oleo when retracted also prevent the retraction mechanism from rotating past the over center point P N 1004646 Doc No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS MAIN GEAR GREASE POINT LOCATIONS TOP ARM ZERK LOWER OLEO ZERK MAIN AXLE ZERKS FIGURE 4 3 MAIN GEAR GREASING Revision G Page 45 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS 4 1 MAINGEAR RETRACTION DESCRIPTION CONTINUED There are several s
36. door Mooring Procedure on Water at Dock 1 Position the aircraft near the dock and point into the wind as much as possible 2 Install the control column lock 3 Install the flight control gust lock 4 Tie down using both deck cleats to secure aircraft to dock and keep it from moving if wind direction shifts Mooring Procedure on Water at Buoy 1 Position the aircraft near buoy 2 Install the control column lock 3 Install the flight control gust lock 4 Tie to buoy using one deck cleat and leave sufficient slack in the rope so that the aircraft can move as the wind direction shifts without causing damage to aircraft P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS CHAPTER 2 AIRWORTHINESS LIMITATIONS Revision D Page 28 of 109 P N 1004646 Doc No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS THIS PAGE INTENTIONALLY LEFT BLANK Revision D Page 29 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS AIRWORTHINESS LIMITATIONS This Airworthiness Limitations section is FAA approved and specifies maintenance required under paragraphs 43 16 and 91 403 c of the Federal Aviation Regulations unless an alternative program has been FAA approved The aircraft Airworthiness Limitations are unchanged as a result of installation of the Amphibious Floats and the associated systems addressed by th
37. oleo pneumatic shock strut and the Top Arm Assembly The vector of the oleo force is over center about the rotation point on the Top Arm Assembly Thus one could effectively remove the entire gear actuator and the geometry of the Oleo and Top Arm alone would force the contact faces of the top arm and top mount together and lock it over center There are also two over center locks when the gear is in the retracted up position The first is a spring installed on the actuating arm that prevents motion of the rack and pinion actuator in the event of a hydraulic failure The second over center lock comes from the geometry of the gear in the up position Revision G Page 55 of 109 Since the retraction mechanism is driven over center the weight of the landing gear and oleo when retracted prevent the retraction mechanism from rotating past the over center point The weight of the gear wants to rotate the Top Arm Assembly however when rotating the Top Arm the rod linkages must also move geometry is such that the rod linkages are over center on the actuator shaft centerline and thus the rod linkages are trying to rotate the actuator more toward the UP position and hence force the actuator piston face into the up adjustment setscrew P N 1004646 No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS 4 33 ADJUSTING THE GEAR UP POSITION DO NOT adjust the rod linkag
38. position lights Set the proximity switch mounting clip along outer cylinder body to a position such that the light goes out when the over center track is about 1 4 inch from bottomed position while traveling in the up direction Lights should come on about 1 8 inch from the bottomed position while traveling in the down direction The cylinder piston has a magnet that will activate the proximity switches Revision D Page 34 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS 3 2 NOSE GEAR BASIC SERVICING Refer to Figure 3 2 for visual reference The nose wheels contain grease nipples for the wheel bearings They should be greased The nose gear pivot assembly should be cleaned every 25 hours and inspected every 25 hours or more frequently whenever in water for extended period of time Nose tires are standard 5 00 x 5 10 especially saltwater Tracks and blocks should ply inflated to 60 5 psi All tires must be approved to TSO C62 type III be cleaned and left dry or alternately cleaned and wiped with a rag with dry silicone spray on it Je J p DETAIL C L 2 pw Av FIC P j LI l gt NOS w DETAIL B 1 SIDE ONLY FIGURE 3 2 NOSE WHEELGREASING Revision D Page 35 of 109 P N 1004646 Doc No
39. 00 AMPHIBIOUS FLOATS 3 4 NOSE GEAR ASSEMBLY Items refer to areas on Figure 3 3 Insert the Ram Assembly Item 6 into the Flange Assembly Item 3 if removed during disassembly 2 Slide the Trolley Item 12 with installed blocks and rollers into nose box track from bottom 3 Pull forward on the Link still attached to the Rod End Item 5 to place the rollers Item 14 into the down lock pocket on the nose box track 4 Thread the Ram Assembly Item 6 onto the Rod End Item 5 until the ram piston contacts the Flange Assembly Item 7 while at the same time the rollers are seated in the down lock pocket Both the piston and the rollers need to bottom out against their respective mating parts at the same time 5 Tighten the AN316 10R jam nut against the rod end Revision D 6 Install the Nose Ram Item 2 onto the Flange Assembly Item 3 being careful not to nick T Seals on bolt holes Fasten with NAS1103 2 bolts and necessary washers 7 Oil felt wiper through oil cup on the Flange Assembly Item 3 8 Connect hydraulic lines to cylinder and cycle gear to fill cylinder with fluid 9 Service hydraulic system with Mil H 5606 if necessary Page 37 of 109 P N 1004646 Doc No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS NOSE WHEEL amp BOX POCKET DOWN LOCK FIGURE 3 3 NOSE GEAR ITEMS Revision D Page 38 of 109 P N 1004646 No W7001 24 01 SERV
40. 411008611 27 H3QNI1AO 3A VA H3Q0VHHOS aa 57785 dd3dNITA9 d31 nO gr NOISId H3GNITA9 HINNI ONIH O 9 8 5 1 2c 82782SN dvo FIGURE 4 8 MAIN SHOCK STRUT P N 1004646 No W7001 24 01 Page 60 of 109 Revision G SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS 4 5 EMERGENCY GEAR OPERATION An emergency hand pump is provided in case of total electric pump failure or loss of fluid The emergency hand pump draws hydraulic fluid from the bottom of the hydraulic power pack reservoir The hydraulic power pack electric pumps have fluid pickup tubes that do not reach the bottom of the hydraulic fluid reservoir This prevents the electric pump from being able to pump all the fluid out of the system Revision G Page 61 of 109 The remaining small reserve quantity of fluid below the electric pump pickup tube is then reserved exclusively for the emergency hand pump The quantity of reserve fluid below the electric pump pickup tubes is sufficient to raise or lower the landing gear with the hand pump alone P N 1004646 Doc No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS CHAPTER 5 HYDRAULICS Revision G Page 62 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS 5 0 HYDRAULIC SYSTEM BASIC DESCRIPTION A pressure of between 500 psi and 700 psi in the DOWN position
41. 646 No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS OLEO SHOCK STRUT BRAKE CALIPER GREASE INSERT AND PADS O RING SEALS MAIN GEAR ASSY WHEEL ASSY AXLE NUT FIGURE 4 2 MAIN GEAR LOWER Revision D Page 43 of 109 P N 1004646 Doc No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS 4 1 MAINGEAR RETRACTION DESCRIPTION Refer to Figures 4 1 4 2 4 3 4 4 4 4 4 5 and 4 6 for visual reference Retraction and extension of the main gear is accomplished with a hydraulic rack and pinion type actuator The actuator consists of two opposing pistons connected by a geared rack with a rotating pinion gear in the middle Hydraulic fluid is transferred from one piston to the other using an electrically reversible hydraulic pump located in the empennage of the aircraft The differential pressure build up causes the piston to move pushing the rack and rotating the pinion gear and its attached drive shaft Attached to each end of the drive shaft are actuating arms that drive separate rod linkages with adjustable rod ends The drive shaft and actuating arms have a keyway to prevent slippage on the rotating drive shaft The rod linkages push and pull on the Main Gear Top Arm Assembly causing it to pivot around a fixed point Also attached to the actuators drive shaft is a visual gear position indicator Revision G Page 44 of 109 This indicator
42. 9 MAIN WHEEL AND TIRE REMOVAL remove each main wheel Remove brake caliper 2 Cut cotter pin and remove axle nut 3 Pull wheel off of axle Each main wheel is a split type rim To remove the tire Remove air from tire 2 Remove 3 bolts that hold wheel together 3 Split rim and remove tire and tube Main gear tires should be replaced when the tread is worn through in any area Reinstallation is the reverse of removal for tires wheels and brakes 0 100 IN 2 54 mm MINIMUM 0 100 IN M lt 2 54 mm MINIMUM 0 100 2 54 mm MINIMUM PRESSURE BACK PLATE PLATE FIGURE 4 1 MINIMUM BRAKE LINING THICKNESS P N 1004646 Doc No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS MAIN GEAR WHEELALIGNMENT There is no way to adjust the alignment within each main gear wheel set If the tires are showing signs of abnormal asymmetric wear some component has likely been worn bent Starting with the axle examine each main gear component and mounting point for signs of damage deformation Replace damaged components once found If no gear bulkhead components are found to be damaged use the following procedure to align left and right floats 1 Move aircraft to level surface 2 Check float alignment by measuring boxing wire lengths horizontal cross wires between spreader bars 3 If not equal loosen both wires until there is no tension 4 Start wit
43. DN DN PILOTED CHECK VALVES 270 PSI MIN BREAKING AFT FUSELAGE MOUNTED POWER PACK WITH PUMPS PREASURE SWITHCES AND CHECK VALVES L CROSS FITTINGS LOWER FUSELAGE UNION FITTINGS IN EMERGENCY FOR WHEEL FLOAT K HAND PUMP s PET SWAP LO IN CABIN Ne N B ES N b UP UP NOSE GEAR RAMS WIPOSITION SWITCHES DOWN DOWN DOWN DOWN MAIN GEAR RAMS W PROXIMITY HYDRAULIC RAMS SWITCHES LOCATED IN FLOATS UP UP FIGURE 5 1 HYDRAULIC SCHEMATIC Revision G Page 64 of 109 P N 1004646 Doc No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS E ya w tt TOP VIEW HYDRAULIC ROUTING 915 E
44. ESCRIPTION The water rudder retract system is manually operated by a lever through a system of cables and pulleys Water rudder retract handle with lock pull finger lock to move handle FIGURE 6 1 WATER RUDDER RETRACTION amp EMERGENCY GEAR PUMP HANDLES Steering is directed from the aircraft rudder Water rudders should be centered when the air steering system The controls are rudder is centered by adjusting turnbuckles interconnected and seamless to the operator There is no left or right rigging adjustment aside from retraction and extension of the water related to the maximum travel of the water rudder rudder system Verify air rudder rigging has been modified for floatplane operation per WATER RUDDER RIGGING drawing 1002632 All cables in the water rudder steering and retract system should be rigged to 30 5 lbs The downward travel on the water rudder should be set according to drawing 1004211 Revision G Page 69 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS r WATER RUDDER r RUDDER PEDALS RIGGINGISTEERING x po PON 0 WI RUDDER FIGURE 6 2 WATER RUDDER CABLE ROUTING Page 70 of 109 P N 1004646 No W7001 24 01 Revision G SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS THIS PAGE INTENTIONALLY LEFT BLANK Revision G Page 71 of 109 P N 1004646 Doc W7001 24 01 SERVICE MANUAL amp I C A
45. FOR THE 7000 AMPHIBIOUS FLOATS CHAPTER 7 ELECTRICAL Revision G Page 72 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS 7 0 ELECTRICAL SYSTEM BASIC DESCRIPTION For detailed information regarding the electrical system refer to Installation Drawing 1004472 The following electrical systems are added with the installation of Wipline 7000 floats on the Quest Kodiak 100 24V DC Hydraulic pumps 2 each pump with its own dedicated circuit breaker 2 Gear selector head for changing pump flow directions to actuate the landing gear up and down and indicated gear position 3 Emergency Trim Timer Override System ETTOS for bypassing the aileron trim timer if primary aileron system fails ELECTRIC HYDRAULIC PUMPS The installed 24V DC electrically reversing hydraulic pumps are wired independently to allow failure of one pump without affecting the other pump The pump is electrically shut off in the up and down directions by a fluid pressure switch that cuts pump power when sufficient hydraulic pressure is obtained in the gear system Gear swings should take less than 45 seconds with both pumps operating If the gear cycle time is greater than 45 seconds it is likely that one pump is not pumping Revision G Page 73 of 109 This can be verified by pulling each pump breaker to see if the system functions on one pump but not the other GEAR SELECTOR HEAD The
46. FT BLANK Revision G Page 79 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS CHAPTER 9 RECOMMENDED PROCESSES PRODUCTS AND INSP CHECKLISTS Revision G Page 80 of 109 P N 1004646 Doc No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS 9 0 SERVICING INSTRUCTIONS As coded in the Inspection Time Limits chart in this section there are items to be checked each 25 50 100 and 200 hours Also there are notes on special items which may require servicing at more frequent intervals When conducting an inspection at 25 hours all items marked for 25 hours would be accomplished at 50 hours the 25 and 50 hour items would be accomplished at 100 hours the 25 50 and 100 hour items would be accomplished at 200 hours the 25 50 100 and 200 hour items would be accomplished A complete inspection Annual Inspection would include all 25 50 100 200 hour items Below is a list of recommended lubricants and protection products when servicing float hull amphibious components This lists products used by Wipaire during assembly of the floats There may be equivalent products just as satisfactory for protection However it is recommended if trying different products to inspect them frequently so as to determine their effectiveness Protection of nuts bolts hydraulic lines metal surfaces or electrical connections Dinitrol AV30 Dinol
47. Group CRC SP400 Soft Seal CRC Industries General Lubricants LPS 1 LPS 2 and LPS 3 LPS Industries Revision G Page 81 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS Wheel Bearings Main Gear Retract Mechanism Nose Gear Pivot and Rod Ends HCF Grease P N 605 HCF Industries Aeroshell 22 Shell Global Solutions Green Grease Multi Purpose Green Grease Inc Aviation Grease SHC 100 ExxonMobil Aviation Lubricants If existing grease cannot be identified you must lubri flush all float grease fittings until visibly exhausting all old grease and new grease is coming out Additionally if you cannot determine existing grease in wheel bearings completely clean and repack bearings with new grease Metal Corrosion Protection Boeshield T9 Rust Protection Boeing Company Corrosion X Corrosion Technologies Corporation ACF 50 Rust Protection Tef Gel Ultra Safety Systems Inc Float Sealant 890 B2 or B4 Pro Seal Company PR 1440 C PPG Aerospace RTV Silicones General Electric SIKAFLEX 201 or 252 Sika Manufacturing Teflon Spray 6P 730A Comet Industries Hydraulic Fluid Mil H 5606 Revision J Page 82 of 109 Electrical Insulating Compound Dow Corning 4 DC4 Dow Corning Corporation Bolt Torque Bolts in Critical Areas For common correct torque when installed or when visual inspection indicates a need for a torque check Nut torque sh
48. H FRONT VIEW usa s sottotitoli SA 15 FIGURE 1 2 TOP isq 16 FIGURE 1 3 FLOAT TERMINOLOGY ib 17 FIGURE 1 4 MAINTENANCE ACCESS POINTS retinet test rooster aus runapaq aasan kusa 18 FIGURE 1 5 20 FIGURE 1 6 FLUID TYPES AND QUANTITIES patte ea ida pine etu ti 20 FIGURE 3 I NOSE WHEEL amp BOX peut NE NUR 33 FIGURE 3 2 NOSE WHEEL GREASING 5 aan s ua 35 FIGURE 3 3 NOSE GEAR ITEMS ted tas Ue 38 FIGURE 4 1 MINIMUM BRAKE LINING THICKNESS eese en enne 41 PIGUREA 2 MAIN GEAR LOWER 43 FIGURE4 3 MAIN GEAR GREASING 45 FIGURE 4 4 MAIN GEAR ADJ DOWN 47 FIGURE 4 4B MAIN GEAR ADJ 48 PIGUREA 5 MAIN GEAR ADI UP L PAR Ane Ee 49 FIGURE 4 6 MAIN GEAR DOWN STOP AD J 50 FIGURE 4 77 ROTARY ACTUATOR iini ui seines 59 5 MAIN SHOCK STRUCT
49. ICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS THIS PAGE INTENTIONALLY LEFT BLANK Revision D Page 39 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS CHAPTER 4 MAIN LANDING GEAR BRAKES amp GEAR RETRACTION Revision D Page 40 of 109 P N 1004646 Doc W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS 4 0 GENERAL The main landing gear incorporated within the amphibious floats are retractable quadricycle type with four main wheels in a dual tire formation Air oil shock struts on the two main landing gear assemblies provide shock absorption The main landing gear has dual 6 00 x 6 8 ply tires All tires must be approved to TSO C62 type III The gear system is hydraulically actuated and driven by two hydraulic pumps Brakes are hydraulic and there is a caliper on each main wheel BRAKE REMOVAL amp INSPECTION Each main wheel has a dedicated brake caliper To remove the brake caliper 1 Remove two mounting bolts on each caliper 2 Compress the caliper piston using a c clamp 3 Slide caliper off of the brake disc Brake pads should be replaced when the minimum section thickness is less than 0 100 see Figure 4 1 Generally the brake discs should be checked for wear grooves deep scratches and excessive pitting Pitting deeper than 0 015 or thickness below 0 327 is cause for replacement Revision D Page 41 of 10
50. IWIPAIRE INC WIPLINE FLOATS SKIS MODIFICATIONS AIRCRAFT SALES AVIONICS INTERIOR MAINTENANCE PAINT REFINISHING SERVICE MANUAL amp ICA for the WIPLINE 7000 AMPHIBIAN FLOAT on the QUEST MODEL 100 KODIAK Ave Fleming Field KSGS South St Paul MN 55075 Ph 651 451 1205 Fax 651 457 7858 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS THIS PAGE INTENTIONALLY LEFT BLANK Revision G Page 2 of 109 P N 1004646 W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS LOG OF REVISIONS Acceptance 7 premo ico zs se screen ifs 2788 e preso oos Sina p Eco 22090 see Doc w7001 34 03 Lf E Update to cover page logo added instructions and G1000 See List Land floatplane software configuration to float removal and Re install checklists added 3 blade propeller maintenance section Added Green Grease as an 4 18 2013 approved grease Updated Fig 1 6 for new oleo updated Fig 4 4A Fig 4 6 and ood ba his 5 30 2014 rigging procedures remaining paged repaginated minor changes to float install and removal instructions Added shear torque chart PR 1440 C Sealant and Tef Gel removed H See List warranty claim form Corrected 5 26 2015 1200 was 1000 1400 was 1150 and 1900 was 1300 Added Dow Corning DC4 and Mobil See List Aviation Grease SHC 100 to approved 7 29 2015 product list update exhaust
51. N 1004646 No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS CHAPTER 10 TROUBLESHOOTING Revision G Page 102 of 109 P N 1004646 No W7001 24 01 uonoy 3A291109 s asneg YOUMS 159 YAMS 159 noid jesoy Bulpuey 3591 JOU op sjojeoipur Buipue1 eoe doeu 2 eoe deu seusniqjojou q eseaJD 1291044 pue 199 409 Suonoeuuoo JO e oKo Buunp sdod 1exeeuJg eoejdeu D eoejdeu 2 1004 9 1284109 J eui amod pz JOJOW 0 uonoeuuoo 1004 piSu pejeoo 9 e 7 spuooes og 5 MOS
52. RS3 NOSEGEARZ ua has retta tis a Ed mS pd a maq h sak es 32 30 NOSE GE AN 32 ADJUSTMENT TEST NOSE GEAR dave pte bt Betta 34 3 2 NOSE GEAR BASIC SERVICING uu saan Wise nenne au ene una dean ga 35 BS NOSE GEAR DISASSEMBLY 36 NOSE GEAR ASSEMBLY 37 CHAPTER 4 MAIN LANDING GEAR BRAKES amp GEAR RETRACTION 40 4O GENBENL am kusam east ama aa asi ua E mek mesa 41 4 1 MAIN GEAR RETRACTION DESCRIPTIOLN 44 4 2 MAIN GEAR ASSEMBLY SETUP AND ADJUSTMENT esee nenne 51 4 3 ADJUSTING THE GEAR UP POSITION doctore eo onte 56 4 4 ADJUST MAIN GEAR UP AND DOWN POSITION SWITCHES eee 57 4 5 EMERGENCY GEAR OPERA TION ies esi Sedo te 61 CHAPTER 5 HYDRAULICS GO pA UV EYE OON PER A IN QUNM IE 62 5 0 HYDRAULIC SYSTEM BASIC DESCRIPTION 63 3 1 BLEEDING THE HYDRAULIC S TS DENIS x tuens aee ue DI tcv est tea 66 Revision D Page 7 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS CHAPTER WATERK RUDDER 68 6 0 BASICDESCRIPTION
53. Revision D Page 25 of 109 P N 1004646 Doc No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS 1 4 FLOAT HANDLING amp JACKING To jack the floats for servicing tires brakes or doing retraction tests it is recommended that a floor type jack three ton minimum be used These jacks are commonly used for truck repair The jack should be positioned on the keel centerline on the first bulkhead forward of the step The jack should contact the keel squarely and if room permits slip a board between the jack and keel CAUTION Due to critical angle of aircraft when single float jacking check that wing fuel tank valves are confirmed closed if possible use wing tie rope from float side to be jacked and tie off to tug Raise the float slowly making sure the aircraft stays balanced After raising block up the keel in several places and lower the jack Raise only one float at a time with the opposite float wheels Revision D Page 26 of 109 chocked Position a sawhorse under main and after body keel to keep aircraft from tipping fore and aft TOWING When towing the amphibian aircraft two lugs are provided on the lower forward side of the nose spring A rigid V frame can be fabricated to attach to these lugs for towing the aircraft with a tractor Wipaire Parts has this tow bar available for purchase HOISTING Hoisting the aircraft can be performed using a lifting apparatus that att
54. Step 30 Page 56 of 109 P N 1004646 No W7001 24 01 4 4 ADJUST MAIN GEAR UP AND DOWN POSITION SWITCHES 1 With the aircraft still on Jacks position the gear in the UP position This allows access to the gear down proximity switch 2 Loosen the jam nut on the Gear Down Proximity Switch located on the back of the Main Gear Top Mount Thread the Gear Down Proximity Switch in or out until the face of the sensor is flush with the face of the Main Gear Top Mount Reference Figure 4 4B Tighten the jam nut on the proximity switch to 10 3 inch pounds 3 Thread out the Set Screw Adjustment Item 6 located on the Top Arm Assembly Item 2 4 Position the gear in the DOWN position With the aircraft master switch on thus providing power to the proximity switch thread the Set Screw Adjustment located on the Top Arm Assembly in until the LED light built into the proximity switch initially illuminates with the gear arm in the full down over center locked position then thread the set screw in an additional half turn 5 Reposition the gear to the UP position SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS 6 Loosen the jam nuts on the gear up proximity sensor 7 Adjust the gear up proximity sensor switch to have between a 0 030 0 060 gap between the proximity sensor plate and the proximity sensor Tighten the jam nuts on the proximity sensor to 10 3 inch pounds 8
55. TER AND THEIR ENVIROMENTS ARE STRONGLY AND DIRECTLY LINKED TO CORROSION AND MUST BE HANDLED PRO ACTIVELY Even without direct contact with saltwater this hydraulic pump in the aircraft fuselage has severely corroded due to being in a saltwater environment without being kept clean Page 23 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS Forward strut attach point under cosmetic fairing on aircraft fuselage CORROSION HOT SPOTS DISSIMILAR METAL CONTACT LIKE LANDING GEAR FLOAT ATTACH POINTS AND OTHERS ENCLOSED SPACES THAT STAY MOIST LIKE LANDING GEAR FLOAT INTERIORS SKIN LAP JOINTS AND OTHERS CONTAMANINATES ON THE METAL LIKE DIRT SALT ENGINE EXHAUST AND OLD OR OTHERWISE COMPRISED GREASE Badly corroded fly wire fitting Revision D Page 24 of 109 1 3 CORROSION Corrosion is the process by which metals are turned into oxides It is a natural and ultimately unavoidable chemical reaction that is accelerated by dissimilar metals in contact with each other and enclosed spaces and contaminants like dirt and exhaust deposits that hold moisture against the metal If that moisture is salt water or fresh water that is polluted it conducts the electrolytes better and the process of corroding is faster Most aircraft and most floats are made out of aluminum due to its strength to weight ratio and its ability to withstand fatigue and remain fiel
56. aches to the aircraft with nylon straps under the wing strut attach points Contact Wipaire Parts for details if necessary Hoisting the aircraft should only be necessary to remove or install floats LEVEL The level reference for the Quest Kodiak is the seat track Weight and balance information should be taken with the aircraft in a level attitude The float deck is at a 4 degree incidence from the aircraft level reference P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS 1 5 MOORING For land operations the aircraft is equipped with three fixed mooring points Two are located on the outboard edge of the wing struts and the other is located on the underside of the tail section of the atrcraft Mooring Procedure on Land 1 Position the aircraft near mooring location and 1t point into the wind 2 Setthe parking brake and or chock the main wheels 3 Install the aircraft control column lock 4 Install the flight control gust lock 5 Tie down the aircraft to anchor points on the ground 6 Install provided engine inlet covers pitot tube covers and propeller anchor assembly 7 Attach a static ground cable to one of the aircraft tie down eyelets and the ground anchor point Revision D Page 27 of 109 For water operations the floats are equipped with two deck cleats on each float one forward near the pilot copilot doors and one aft near the cargo
57. ackage is comprised of the forward struts main pylons rear cross wires and front cross wires or flying wires The streamlined struts are made from extruded aluminum alloys The main pylon is built from machined aluminum trusses internal ribs and skinned with aluminum sheet WATER RUDDERS The floats are equipped with water rudders attached at the rear of the float structure These rudders steer when the floats are in the water Rudder controls are integrated into the existing aircraft rudder system and should move in the same direction as the air rudder Water rudders are extended and retracted with a handle installed to the right of the pilot seat Water Rudder amp Spring Revision D Page 21 of 109 P N 1004646 W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS OPTIONAL EXHAUST SYSTEM The Kodiak amphibian can be equipped with an optional exhaust system designed to deflect the engine exhaust plume away from the aircraft This exhaust system is applicable to the floatplane and landplane The optional exhaust system consists of a left and right hand waterline cut exhaust stack The optional heat shield is only installed to assist in cooling of exhaust gases across the left side of the cowling and fuselage Operation of the aircraft is unchanged when the optional exhaust system is installed Specific data related to the performance of the aircraft with this option insta
58. ater 2 Hartzell Propeller Owner s Manual Manual No 139 revision 10 or later 3 Pratt amp Whitney Maintenance Manual Part No 3021242 P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS 8 1 MAINENANCE PRACTICES For general maintenance practices installation and removal maintenance schedule testing troubleshooting and inspection reference Kodiak 100 Maintenance Manual 490770 and or Hartzell Propeller Owner s Manual No 139 For installation of this propeller on the Kodiak 100 the propeller governor must be limited to 2150 RPM For governor adjustment reference Pratt amp Whitney Maintenance Manual P N 3021242 Blade angle settings can be found on drawing 1005260 and are Low pitch 17 0 0 1 Reverse 15 0 0 5 Feather 87 0 1 0 Blade angles should be adjusted per Hartzell Manual 139 page 4 3 See Table 1 for locating additional maintenance information FOUND IN Subject Kodiak Mainenance Manual 490770 Hartzell Manual No 139 System Operation Page 61 9 Chapter 2 Installation and Removal Page 61 19 Chapter 3 Testing check inspection Page 61 22 Chapter 4 Chapter 5 Special Tools Page 61 8 Page 3 3 TABLE 1 MAINTENANCE INFORMATION IN KODIAK AND HATZELL MANUALS Revision G Page 78 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS THIS PAGE INTENTIONALLY LE
59. by sliding a 3 inch wide piece of paper in See Figure 4 4B and photo on this page then moving gear to down and locked position If paper is tight gear is rigged correctly If paper is able to slide out then the Top Arm and Top Mount are not making proper contact and need further adjustment Reattach spring Revision G Page 54 of 109 c 30 Loosen the Fig 4 6 Item 1 Jam nut on the Main Gear Down Stop Assembly and screw in the NAS 428 adjustment bolt Fig 4 6 Item 2 Verify the bolt does not touch the Top Arm when gear is in the down position When the aircraft is off the jack stands and the weight of the aircraft fully on the wheels adjust the NAS 428 bolt to lightly make contact with the Main Gear Top Arm when the gear is in the full down position then turn the bolt one and a half turns in so that the bolt no longer makes contact with the Top Arm Gap should be about 0 050 inches Tighten the jam nut P N 1004646 No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS Note There are three over center locks on the main gear when the gear is down The firstis the over center rod linkages that are adjusted in the above steps The second is from the spring pulling on the actuator arm when the gear is in the down position The spring prevents the actuator from moving in the event of a loss of hydraulic pressure The third comes in the form of the angle between the
60. d repairable Steel is used for strength in hardware and landing gear parts and these are often areas where these dissimilar metals cause corrosion Areas where moisture and dirt mix and stay wet against metal are common sites of oxidation Float strut attach points water rudders and skin joints are examples of areas where this occurs P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS 1 3 CORROSION CONT Cladding plating anodizing painting greasing and waxing are all processes used to help protect metal from corrosion Wipaire uses all these techniques during manufacture But due to the rugged way our floats are used and the environment these surface sealers become abraded or wear away leaving the metal exposed Removal of corrosion is detailed more fully in Chapter 8 but there are a few things an owner can do to stop the spread of corrosion and minimize the damage Aside from the already detailed cleaning and inspection procedures an anti corrosion spray like Corrosion X or its equivalent should be used liberally Because it has the ability to displace moisture and contaminants it can be used when the floats are still wet or when they are dry Periodically hardware should be covered with waterproof grease Especially in a salt water environment bolts should be removed at least once a year and grease applied to the shafts bolt screw heads and nuts
61. e blade propeller replaces the originally installed 96 inch four blade propeller on the Quest Kodiak 100 airplane DECRIPTION The installed propeller is a constant speed full feathering reversible hydraulically actuated propeller The propeller and blade model is HC B3TN 3D T10282NS Upon installation the propeller governor is adjusted to regulate maximum propeller speed to 2150 RPM This propeller has been shown to achieve equal or better performance in takeoff and climb compared to the standard four blade propeller OPERATION Propeller operation is unchanged from the original aircraft with the exception of limiting maximum propeller speed to 2150 RPM See original Quest Kodiak Pilot s Operating Handbook and Approved Airplane Flight Manual Note no gauge re marking is associated with Revision G Page 77 of 109 the change in maximum propeller speed therefore there are no software changes for the G1000 REFERENCE DOCUMENTS The following Wipaire Inc documents must be attached to this ICAW document and are provided for both the operator and maintenance technician Document revision levels are current and hardcopy attached at the time of installation Drawing number 1005260 Installation 3 blade 102 propeller The following reference documents are required and are available from the companies Kodiak 100 Maintenance Manual Part No 490770 specifically Chapter 61 revision 1 or l
62. ecessary if there is critical loss of strength in parent metal and depends on location and other factors xiii E Pylon before repair Revision G Page 83 of 109 Pylon fully repaired After removing the corrosion restore the area to the original finish like prime and enamel or coat the metal with a waterproof grease CORROSION X or equivalent should also be applied to stop corrosion and repel moisture and contaminants Corrosion Limits Allowable thickness loss Bottom Skins 30 Side Skins fwd of Step 30 Side Skins aft of Step 20 Top Deck 30 Machinings 0 015 Struts 0 030 NOTES 1 Maximum surface area for skin corrosion to the maximum depth shall not exceed one 1 square inch and must be separated by at least 14 inches from any other skin corrosion damage 2 For machined fittings struts and pylons corrosion limits are provided as maximum pitting depths Corroded surface area for these limits shall not exceed 0 5 square inches and must be separated by at least 5 inches from any other corrosion damage FIGURE 9 1 CORROSION LIMITS P N 1004646 Doc No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS 9 2 MAINTENANCE CHECKLIST Revision G Page 84 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS X X s sou jo Bunnoi pue Ajunoes
63. ed placard using MIL H 5606 red hydraulic fluid The fluid level placard Figure 1 5 is installed on the forward hydraulic Reservoir Revision G FIGURE 1 5 HYDRAULIC FLUID LEVEL PLACARD The nose wheels are fully castoring for maneuverability while the airplane is under engine power or being towed The main landing gear has dual 6 00x6 8 ply tires and the nose gear has a single 5 00x5 10 ply tire All tires must be approved to TSO C62 type III Differential use of the main wheel brakes steers the aircraft on land Item Fluid Type Qty Main Gear Shock MIL H 5606 975 20 mL Strut 33 0 750z Main Gear Shock Nitrogen or 425 25 psi Strut Air Main Gear Tires Nitrogen or 60 0 5 psi Air Nose Gear Tires Nitrogen or 60 5 psi Air Hydraulic Pump MIL H 5606 per placard reservoir FIGURE 1 6 FLUID TYPES AND QUANTITIES Page 20 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS LANDING GEAR CONTINUED Grease zerks are provided in many locations that have pivoting joints Greasing is recommended at 25 hour intervals or more often depending on operating environment with HCF Grease or equivalent See Figure 3 2 for nose gear grease zerk locations See Figure 4 3 for main gear grease zerk locations STRUT PACKAGE The strut package attaches the floats to the aircraft The strut p
64. ervice points on the main In addition to the over center locking provided by landing gear to pay attention to during the rod linkages and actuator arm for the gear m maintenance Grease zerks are located on the extended position a second down locking method pivots of the main gear draglinks each wheel is provided as well The geometry of the main gear axle top and bottom pivot points on the oleo drag link oleo pneumatic shock strut and the top pneumatic shock strut and the rotation point arm assembly provide an additional over center of the top arm assembly see figure 4 3 The locking method n adjustable rod end bearings are permanently The force vector from the oleo directed in line sealed and do not require servicing Inspect with the centerline of the oleo assembly rotates the the rod ends for freedom of movement and contacting face on the top arm assembly into corrosion Replace the rod ends when contact with the main gear top mount at all necessary Depending on the operating positions of oleo stroke This transfers the landing environment greasing requirements may vary load into a structure designed to withstand the Highly corrosive environments such as salt generated landing forces as well as prevents the water may require more frequent inspections top arm from rotating and collapsing the main Regardless the gear should be inspected landing gear visually at least
65. es Item 3 when setting the over center up adjustment 2 Rotate the actuator rotation arm fully toward the gear up position 3 When the actuators internal piston contacts the UP adjustment setscrew check to make sure all the linkages have rotated past Top Dead Center TDC by pushing and pulling on the Top Arm Assembly The UP adjustment screw Item 10 should not need to be adjusted if properly set using Wipaire Tool 1004800 during the actuator maintenance If it is found that one can reverse drive the rotary actuator and pull the gear down by hand the rod linkage and the actuator arms have not moved past TDC Re check the position of the UP stop using Wipaire Tool 1004800 If the UP position is found to be correct look for signs of damage in the floats as something is out of position preventing the stop setting using Tool 1004800 from being correct Call Wipaire s Customer Service Department for specific instructions Revision G 4 Bleed air from hydraulic system by actuating the gear several times with the electric hydraulic pumps See Chapter 5 Section 5 1 for specific bleeding instructions 5 If it is necessary to adjust gear up and down position switches proceed to next section If not lower gear and reattach oleo shock strut to top arm assembly When aircraft weight is fully on the wheels remember to set the NAS 428 bolt on the Main Gear Down Stop Assembly refer to Section 4 3
66. every 25 hours for cleanliness and proper lubrication There are two proximity switches on each main gear unit One for sensing gear up position and the other for gear down position These are easily replaceable and can essentially be adjusted during maintenance see figure 4 4A and 4 5 The proximity sensors have a built in LED to indicate when they are sensing the gear position This feature greatly aids in the setup and servicing of the sensors Revision G Page 46 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS 3 ROD LINKAGE TOP ARM 2 DOWN ADJUSTMENT JAM NUT 8 DOWN ADJUSTMENT SCREW PROXIMITY SWITCH SET SCREW ADJUSTMENT PROXIMITY SWITCH DOWN LIGHT FIGURE 4 4A MAIN GEAR ADJ DOWN P N 1004646 Doc No W7001 24 01 Page 47 of 109 Revision G SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS 39 3 1OV1NOO WHY dOL LNIWLSNFAY NMOG e LAN IN3W1S nr dV NMOG QOY FIGURE 4 48 MAIN GEAR ADJ DOWN P N 1004646 No W7001 24 01 Page 48 of 109 Revision G SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS 1N3W1Snrov an AN WYF 1N3W1Snrav V 58 CR cd 7 5 I INNON 01 2 QOY wav 2 FIGURE4 5 MAIN GEAR ADJ UP Revision G Page 49 of 109 P N
67. ght Drop a plumb bob from the face of the firewall This is station 0 0 Draw another line between the nose wheel centers and a 4th line between the main wheel centers Measure the distance from 0 0 to the nose wheel line This is X1 and X2 Measure the distance from 0 0 to the main wheel line This is Y1 and Y2 Scale Reading Distance from 0 0 Weight x Arm Weight x Arm Moment Left Front X1 Right Front X2 Left Rear To Y2 Right Rear Totals Notes 1 Zero out or deduct tare weights at the Y arm Revision G Page 99 of 109 P N 1004646 Doc No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS 9 4 WIPAIRE FLOATS SPECIAL TOOLS 1 1004800 Main Gear Rigging tool referred to in Chapter 4 is a tool that will be given to customers as part of the float purchase If it gets lost or broken a replacement can be purchased by contacting Wipaire Customer Service 2 The tow bar mentioned in Chapter 1 is available in several models Contact Wipaire Customer Service for details 3 The lifting rig also mentioned in Chapter 1 is also available for purchase Contact Wipaire Customer Service for details Fax 651 306 0666 Phone 651 306 0459 CustomerService wipaire com Revision G Page 100 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS THIS PAGE INTENTIONALLY LEFT BLANK Revision G Page 101 of 109 P
68. h long wire and tighten until both wires measure the same length 5 Tighten the remaining lose wire until snug BLEEDING BRAKE SYSTEM Whenever the hydraulic brake lines are disconnected and reattached the brake system should be bled To bleed the brake system Check that all lines are properly attached between the brake calipers and brake master cylinders 2 Check brake fluid reservoir level and fill Revision D Page 42 of 109 to MAX line located on the pilot side of the engine compartment mounted to the firewall 3 Depress brakes using pilot pedals brakes will likely be spongy and need significant travel to build braking force 4 Loosen hydraulic fitting at one brake caliper just enough to let fluid and air seep out when brakes are actuated 5 While one person actuates the brakes a second person should watch the brake caliper with the loose fitting 6 If air is in the system actuating the brakes will cause bubbles in the fluid coming out of the loosened brake caliper fitting 7 Actuate the brakes through full travel several times until all the bubbles have been released and fluid is being expelled at the loose caliper without signs of air 8 Tighten the loose caliper fitting 9 Check fluid level in brake fluid reservoir and refill to MAX line as necessary 10 Repeat procedure at each caliper 11 When complete brakes should not feel soft or spongy when actuated P N 1004
69. he 4 wires coming off of the timer box to 4 pin molex connector J227E Bi Disconnect the molex connector and insert the molex connectors from the pre wired bypass switch PN 1004634 4 Route the wires for the guarded switch to the panel 25 Install switch in panel below and to the left of the control yoke per drawing 1004469 Revision G Page 74 of 109 See drawing 1004472 for specific connector schematic Removal is the reverse of installation Install cover into any holes in the panel To check the function of this system the switch should be activated and the trim rocker switches depressed If the aileron trim indication on the PFD and the trim tab move continuously the system is functioning correctly If the trim indicator or tab do not move continuously the switch and associated connections should be checked This system should be checked for proper function at every 100 hour inspection and annual P N 1004646 No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS THIS PAGE INTENTIONALL Y LEFT BLANK Revision G Page 75 of 109 P N 1004646 Doc W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS CHAPTER 8 HARTZELL 3 BLADE PROPELLER Revision G Page 76 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS 8 0 HARTZELL 3 BLADE PROPELLER DESCRIPTION AND OPERATION GENERAL The Hartzell 102 inch thre
70. installed gear selector head is similar to units used in several other models of Wipline floats This selector head switches current directions to the electric pumps reversing their pumping direction It also indicates gear positions using four blue and four green incandescent lights The lights for the nose gear are turned on with a magnetic switch that senses a magnet in the hydraulic cylinder piston The lights for the main gear position are triggered by inductive proximity switches that are triggered by metal flags on the main gear arm Lights area cartridge style and can be replaced by pulling them out from the bezel P N 1004646 Doc No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS EMERGENCY TRIM TIMER OVERRIDE SYSTEM ETTOS The ETTOS system consists of a guarded switch that when activated bypasses the timer on the aileron trim system This allows the aileron trim tab to move as long as the trim switch is depressed When the system is not activated the trim tab stops moving after 1 second and requires the pilot to depress and then release the trim rockers to get trim motion in discrete steps The emergency trim timer override system is easily installed and removed from the Quest Kodiak aileron trim system To install the bypass switch 1 Locate aileron trim timer the underside of the panel that the aileron trim switch is mounted It is a square box about 2in x 2in x O 5in 2 Follow t
71. ircraft 3 Install AN525 pan head screws in all attachment locations 4 Place allloose parts and fasteners in bag and zip tie to removed strakes Waterline Cut Exhaust System Removal reference drawing 1004690 1 Remove Waterline Cut Exhaust System Wipaire PN s 1008398 and 1008399 2 Install Standard Quest Exhaust Ducts in accordance with Quest Service Letter SL 007 dated 5 06 09 or later revision Quest PN s 100 178 1001 amp 100 178 1002 or 100 178 1003 amp 100 178 1004 Revision J Page 96 of 109 P N 1004646 Doc No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS OPTIONALLY REMOVED FLOAT KIT ITEMS the following items by be removed when the aircraft is removed from floats but it is recommended for ease of float reinstallation that they be left in place MECHANIC INSP THIS IS INTENDED AS A GENERAL GUIDE EACH INSTALLATION MAY HAVE SUBTLE DIFFERENCES ALWAYS USE THE INSTALLATION DRAWINGS AS THE FINAL REFERENCE ALL WORK SHOULD BE DONE BY CERTIFIED AIRCRAFT TECHNICIANS Hydraulic Power Pack in tailcone 1 Disconnect cap and secure hydraulic lines that run forward under the floor 3 lines 2 Disconnect and secure electrical power lines and gear position connector from power pack 3 Unbolt power pack mounting plate from installed hardpoints and remove 4 Pull and secure electric motor breakers on fwd breaker panel
72. is STC f 2 FAA APPROVED 2 D DATE c u jo Revision D Page 30 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS THIS PAGE INTENTIONALLY LEFT BLANK Revision D Page 31 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS CHAPTER 3 NOSE GEAR 3 0 NOSE GEAR The nose gear consists of composite fiberglass beams that are attached at the bottom to blocks that caster Inside the block is a castering pin that is set into the machined fork assembly The castering pin allows the nose wheel to pivot in a complete circle The geometry is such that no shimmy dampers are necessary The nose gear has an over center down lock Retraction occurs when pressure is applied to the forward face of the actuator piston and the carriage is drawn along the tracks in the nose box Gear position light proximity switches are closed when the piston containing the magnetic material has reached either end of its travel Refer to Figure 3 1 for visual reference The nose gear has single 5 00 x 5 10 ply tire All tires must be approved to TSO C62 type III Revision D Page 32 of 109 NOSE WHEEL AND TIRE REMOVAL To remove each nose wheel 1 Cut cotter pin and remove axle nut 2 Remove the bolt securing the opposite side of the axle 3 Pull Push the axle through the side plate either direction taking care to set
73. lled can be found in the Airman s Flight Manual Supplement Doc No W7001 25 01 latest revision Revision J Optional Left Exhaust Stack with optional Heat Shield Optional Right Exhaust Page 220f 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS 1 2 CLEANING The outside of the float should be kept clean by washing with fresh water and soap Special care should be taken to remove engine exhaust trails water line marks and barnacle deposits After salt water operations washing with fresh water should be done daily with special attention paid to hard to reach places like skin seams wheel well areas float attach points hardware Alternatively water taxiing in fresh water at step speed can help flush the entire system The float interior should be flushed out especially if salt water or polluted water gets inside the compartments If the floats are being stored inside a building either installed on the aircraft or not it is strongly recommended to remove the inspection covers so the interior of the floats can dry out Revision G OPERATORS IN SALT WATER ARE STRONGLY CAUTIONED RINSING THE AIRCRAFT AND FLOATS WITH FRESH WATER AT THE END OF EACH DAY IS CRITICAL ADHERING TO THESE CLEANING RECOMMENDATIONS ARE VITAL FOR KEEPING CORROSION TO A MINIMUM FAILURE TO CLEAN THOROUGHLY CAN SEVERLY SHORTEN THE LIFE OF THE FLOATS SALT WATER POLLUTED WA
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75. ould be applied depending on the hardware application unless the torque is specified for a certain joint in this manual or installation drawings Tension Application Nut Bolt Size Torque Limits in lbs Min Max 8 36 12 15 10 32 20 25 1 4 28 50 70 5 16 24 100 140 3 8 24 160 190 7 16 20 450 500 1 2 20 480 690 9 16 18 800 1 000 5 8 18 1 100 1 300 3 4 16 2 300 2 500 7 8 14 2 500 3 000 1 14 3 700 4 500 1 1 8 12 5 000 7 000 1 1 4 12 9 000 11 000 Shear Application Nut Bolt Size Torque Limits in Ibs Min Max 8 36 7 9 10 32 12 15 1 4 28 30 40 5 16 24 60 85 3 8 24 95 110 7 16 20 270 300 1 2 20 290 410 9 16 18 480 600 5 8 18 600 780 3 4 16 1 300 1 500 7 8 14 1 500 1 800 1 14 2 200 3 300 1 1 8 12 3 000 4 200 1 1 4 12 5 400 6 600 A Torque of 80 should be used when Tef Gel is applied to the bolt P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS 9 1 CORROSION REMOVAL Corrosion is usually detected visually which is why Wipaire strongly recommends the previous cleaning and inspection procedures It can appear as a white or pale green powder discoloration of the metal surface or bubbles and blisters under the surface of the paint Light corrosion is removed by gentle sanding or chromic acid Moderate and severe corrosion blistering flaking and pitting can be removed by heavier sanding or grinding Reinforcement or replacement of affected areas may be n
76. qI09 v SV G3GN31NI SI SIHL SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS dSNI JINVHOIN SAI OOQHOO Id SNOLLOQLESNI P N 1004646 Doc No W7001 24 01 Page 95 of 109 Revision G SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS AUXILARY FIN FINLET STRAKE amp EXHAUST STACK REMOVAL MECHANIC INSP THIS IS INTENDED AS A GENERAL GUIDE EACH INSTALLATION MAY HAVE SUBTLE DIFFERENCES ALWAYS USE THE INSTALLATION DRAWINGS AS THE FINAL REFERENCE ALL WORK SHOULD BE DONE BY CERTIFIED AIRCRAFT TECHNICIANS Right Left Finlet Removal reference drawing 1004099 1 Remove screws near horizontal stabilizer on both the upper finlet and lower finlet 8 screws total 4 forward 4 aft 2 Slide lower finlet down to remove from horizontal 3 Slide upper finlet up to remove from horizontal 4 Unbolt attachment clips from forward upper forward lower aft upper and aft lower attach points and remove from horizontal stabilizer 5 Install forward upper forward lower aft upper and aft lower cover plates using AN525 pan head screws 6 Place all loose parts in bag and zip tie to removed finlets Strake Removal reference drawing 1004500 1 Unscrew all fasteners from strake mounting flanges upper horizontal stab lower horizontal stab fuselage 2 Pull strake forward and outboard to remove from a
77. sod 1292 72 X X S 51591 uoisu x3 sSuo 1081 li Jeoc AoueBieur3 Jo pue y ye pue uonisod eui ul SI ul ejd 10 12edsu ayeoipul sluBi 9 10 93 s Buisn uonisod NAAOG 1299 paes Jo pue eui 1e pue SUBJ ul SI Jedoud 10 sou 1o dsul 5161 p 1edoud 10 JOjo9Jos umop pue dn j12edsu Buisn uonisod 1295 paes YOUMS 191589 UO WNL spue s uo pue SIOH L X X SMOJ O Se 51591 Au uonoedsui 1 02 291 Ayoedeo 22 se JO peoiues X X Sc S c Sd Jepul eq eu eunsseud 9096 Jedoud pue uoisseidwoo esn peJinbaJ s J 5 10 YOOUD 71 ooc 01 OS 95 E1ouot dSNI 9JINVHO3IN SNOILONUYLSNI P N 1004646 Doc No W7001 24 01 Page 89
78. spacers aside as they are removed 4 Wheel will drop out between side plates once axle has been moved a sufficient distance Each nose wheel is a split type rim To remove the tire Remove air from tire 2 Remove 6 bolts that hold wheel together 3 Split rim and remove tire and tube Nose tires should be replaced when the tread is worn through in any area Reinstallation is the reverse of removal P N 1004646 Doc No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS BRASS KNUCKLE NOSE GEAR PROXIMITY SWITCHES ROLLER SLIDE BLOCKS 4 NOSE WHEEL EXTENDED MAGNET FOR SWITCH STROKE ADJUSTMENT UP STOP PIN DOWN STOP PIN NOSE WHEEL RETRACTED FIGURE 3 1 NOSE WHEEL amp BOX Revision D Page 33 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS 3 1 ADJUSTMENT TEST NOSE GEAR Refer to Figure 3 1 for visual reference Adjustment of actuator stroke is provided at the ends of the piston rods The length of the nose gear rod is adjusted such that the over center knuckle brass rollers just bottom out on the down side and the piston just bottoms out on the mounting flange The up stops nests in the up stop pin Nose gear proximity switches are located on clips that are mounted on the outer cylinder body one on each end most forward switch is for the gear down lights and most aft is for the gear up
79. stem is installed m D Auxiliary Vertical Fins are added Horizontal Strakes added 6 Vortex generators are added to the vertical stabilizer 7 The elevator trim servo tabs incorporate a 1 5 inch chord extension Operational information is detailed in the Airplane Flight Manual Supplement Actual displacement for each float in fresh water 18 Amphibian at 100 Buoyancy 6946 pounds at 80 Reserve 7717 pounds Page 19 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS LANDING GEAR The landing gear incorporated within the amphibious floats is a retractable quadricycle type with two swiveling nose or bow wheels and four 4 two 2 dual sets of main wheels Shock absorption is provided by air oil shock struts on the two main landing gear assemblies and composite flat springs on the nose gear assemblies Each main wheel is equipped with a hydraulically actuated disc brake Landing gear extension and retraction is accomplished by two 2 electrically driven hydraulic pumps and four 4 hydraulic actuators one 1 for each gear The hydraulic pumps are located in the aircraft empennage and can be accessed by removing the aft cabin bulkhead The hydraulic actuators are located adjacent to each gear Hydraulic system fluid level should be checked at 25 hour intervals and should be serviced to levels in accordance with the install
80. system Revision J Page 3 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS THIS PAGE INTENTIONALLY LEFT BLANK Revision G Page4 of 109 P N 1004646 W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS LIST OF EFFECTIVE PAGES PAGES REVISION PAGES REVISION PAGES REVISION Revision J Page 5 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS THIS PAGE INTENTIONALLY LEFT BLANK Revision G Page 01109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS TABLE OF CONTENTS SECTION PAGE LOGORREVISIONS sorora Rave acu rra e busua Qhasa fut 3 PEISE OE EFFECTIVE PAGES s sa namn sau s u e 5 TABLE OF CONTENTS a huahua 7 TIS TOR FIGURES AND TA BL BS sta aaa 10 CHAPTER 1 INTRODUCTION AND GENERAL 14 LOIN TT RODUC DOIN PME 14 LI GENERAL FLOAT INFORMA TION RII SENSE Eee 19 iom bI gsm 29 24 L4 FEOAT HANDLING amp JACKING 26 dues di SP S 27 CHAPTER 2 AIRWORTHINESS LIMITATIONS 28 CHAPTIE
81. the steering cables amp water rudder retract cables 30lbs 5 24 Functionally check water rudder rigging with water rudders down as follows Move air rudder to the right confirm water rudder moves to the right Move air rudder to the left confirm water rudder moves to the left Insure system moves freely in both directions with no catching or binding 25 Install step struts 26 Install brake lines and bleed for air bubbles 27 Install elevator down spring if required by exhaust configuration 28 Install fairings for main pylon nose gear cover panel and wing root fairings 29 Inflate main gear tires to 60 Ibs 5 Ibs nose tires to 60 Ibs 5 Ibs 30 Remove aircraft from stands Check for proper main oleo extension gt 3 of chrome should be visible at static deflection 31 Check aircraft placards against the drawings for accuracy 32 Install cover over pilot and co pilot step holes 33 Make logbook entry amp check for proper placarding Revision G Page 98 of 109 P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS Weighing procedures for Quest Kodiak on Wipaire 7000 Amphibian Floats Level aircraft per the manufacturer s instructions Place scales under the right and left main and nose gears Place blocking under the right and left main gears to level aircraft Draw lines on the floor from the centerline main wheels and centerline nose wheel left to ri
82. uator Rotate the actuator shaft fully to the DOWN position If the two keyway slots do not line up when the actuators internal piston contacts the DOWN adjustment set screw Item 8 the actuator needs adjustment It may be necessary to use one of the actuator arms removed in step 5 to help rotate the actuator To adjust the DOWN position loosen the DOWN adjustment screw jamb nut Item 9 and back off the adjustment screw Revision G 12 Align the keyway on the actuator shaft 13 14 15 16 Page 52 of 109 Item 4 with the keyway on Wipaire Tool 1004800 Insert the parallel key removed in step 5 into the aligned keyways Thread in the Down Adjustment setscrew until light contact is made between the setscrew and the actuators internal piston Do not over tighten as the actuator cannot rotate with Wipaire Tool 1004800 and the key installed Over tightening can damage the face of the actuator piston With setscrew positioned against the piston face tighten the adjustment screw jamb nut Item 9 Repeat steps 10 14 for setting the UP position setscrew See figure 4 5 Install actuator in float by reversing steps thru 7 Safety wire 5 16 18 bolts when installed Outer face of actuator arms should be flush to actuator shaft It is recommended to leave the spring disconnected during gear rigging P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR
83. ue Fleming Field South St Paul MN 55075 Telephone 651 306 0459 Fax 651 306 0666 Website www wipaire com Email CustomerService wipaire com Page 14 of 109 In this service manual we have worked hard to include many repair scenarios in addition to the recommended products practices and routine maintenance required to keep your floats in working order When a float part is significantly changed or an additional inspection is recommended or required often a service letter and or kit is issued If a warranty is issued most commonly it is for an 18 month time period so it is crucial to check for service letters specific to your float model at each periodic inspection to be eligible Service Manuals and the installation prints included are also revised periodically and also to be kept updated Service letters Service Kits and Service Manuals are available on our web site at no charge WWW Wipaire com NOTE IT IS CRITICAL TO CHECK FOR MANUAL UPDATES EACH TIME AN INSPECTION IS EXECUTED P N 1004646 Doc No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS FIGURE 1 1 FRONT VIEW Revision D Page 15 of 109 P N 1004646 Doc No W7001 24 01 SERVICE MANUAL amp I C A FOR THE 7000 AMPHIBIOUS FLOATS je Ei E
84. w Item 8 should be turned out to allow more rotation If the angle is greater than required the actuator is over rotating and the adjustment screw should be turned in One turn of the adjustment screw changes the angle by approximately 2 If adjustments have been made to the Down Adjustment Screw the Rod Linkage Item 3 may need to be shortened or lengthened so that the Top Arm Contact Face Item 15 still makes contact with the Top Mount Repeat steps 22 through 24 until angles measure within tolerance With setscrew positioned against the piston face tighten the adjustment screw jam nut Item 9 P N 1004646 No W7001 24 01 SERVICE MANUAL amp LC A FOR THE 7000 AMPHIBIOUS FLOATS 27 28 29 Preload the rod linkages by shortening each rod by 1 2 turn after the contact faces touch on the Top Arm and Top Mount Tighten the Rod Linkage jamb nuts Check the operation of the over center down lock As the actuator rotates causing the contact faces to touch the actuator arm should continue to rotate and snap past Top Dead Center TDC Make sure that there is preload on the linkage rods so that contact faces remain touching past TDC Push and pull on the Top Arm Assembly Item 2 to ensure it is locked over center The Top Arm Assembly needs to be contacting the Top Mount Item 7 when the gear is extended to properly transfer the landing loads Ensure Top Arm and Top Mount are making contact

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