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Model 3000 &3450 Service Manual

1. D o Q MERGENCY FITTING REF 956 CHO SAND 59 FWD FITTING REF LIP LP Pp p Hox roH Hos NOSE GEAR RAMS DOWN DOWN DOWN DOWN MAIN GEAR RAMS O 4Q FIGURE 5 10 SCHEMATIC HYDRAULIC SYSTEM MAULE AIRCRAFT Page 20 of 79 1002550 Rev E WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL DETAIL F L E i Figure continues I ret J n FIGURE 5 2 SCHEMATIC ELECTRICAL SYSTEM 1002550 Rev F Page 21 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL Figure continued from previous page gt 952 gt FIGURE 5 2 SCHEMATIC ELECTRICAL SYSTEM 1002550 Rev F Page 22 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 6 0 MAIN GEAR REMOVAL AND OPERATION 14 lt 6 1 REMOVAL AND DISSASSEMBLY OF MAIN GEAR Jack and block aircraft per Section 4 You may do one gear at a time or both if float is properly blocked After load is off landing gear pull circuit breaker and move hand pump selector to up then to down and back to neutral to relieve hydraulic pressure Remove all three 3 access cove
2. ANASB ADA RIVE 5 30 TYP SEALANT AROUND PATCH L HOLE IN SKIN NE 2 20 ra 1 00 p rus c Or wo USE AN470 RIVE 5 Trim hole as shown by dotted line Patch material to at least same thickness as original skin Prime all bare surfaces Seal between patch and skin Rivet in place FIGURE 11 2 TYPICAL SKIN REPAIR 1002550 Rev E Page 67 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 3 20 30 p 0 3 20 SPACED a Que rm ca NU DC 100 SEALANT AROUND PATCH USE AN470 OR AN456 AD4 RIVETS HULE IN SKIN 4 20 EB SPACED SEALANT AROUND PATCH i ER mer E SS QU p 4 20 2 Ces 3 0 MX SPACED DS NUM ET 1004 J O USE AN470 OR AMSG ADA RIVETS HOLE IN SKIN Prime all bare sur DIT I Rivet in place Page 68 of 79 Trim hole as shown by dotted line Patch material to at least same thickness as original skin faces Seal between patch and skin FIGURE 11 3 TYPICAL SKIN REPAIR 1002549 Rev NINIWIIV 91 1909 IVI831VN
3. 6 HJ133S WON m WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL dAl C IVNSS31X3 WVAS SIT 195 JjsvHJOalld LOVANNV WON FIGURE 11 4 GUNWALL EXTRUSION REPAIR 1002550 Rev E Page 69 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL R 030 al 74 080 amp 06I TE ALUMINUM SPLICE SEAM EXTERNAL FIGURE 11 5 FORWARD CHINE EXTRUSION REPAIR Page 70 of 79 1002549 RevE WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 10 38 79 E qb MATERIAL 6061 6 ALUMINUM CE SEAM EXTERNAL im INSTALLATION INSTRUCTI STALLING WEAR STRIP 1 POSITION WEAR STRIP OVER MAIN KEE 2 DRILL 29 DIA HOLE CLOSE EACH END AND BETWEEN EACH IEAD US D WEAR STRIP FOR APPROX LOCATIONS 3 MAIN K 8 32 THRU 4 DRILL WEAR STRIP TO 17 DIA amp C SIN 1007 5 APPLY AT SEALANT 892 BR BETW STRIP AND SECURE STRIP KEE
4. s o dow WHY LOVeL3MH H3OVdS FIGURE 6 11 VIEM 1 16 CUSHION GEAR UP ADD SPACER AND WASHER FOR ADJUSTMENT Page 44 of 79 1002550 Rev E WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL y FIGURE 6 12 VIEW OF HYDRAULIC CYLINDER 1002550 Rev E Page 45 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 7 0 NOSE GEAR 7 1 DESCRIPTION The nose gear is a reinforced fiberglass spring that is attached at the upper end to a trolley block This trolley moves fore and aft hydraulically in tracks that are part of the nose box sides This trolley is guided in the tracks by nylon slide blocks A down stop is located on the forward end of the trolley The lower end of the spring is attached to a pivot block Inside the block is a castering pin that is attached to the nose wheel fork This pin in normal taxiing is free castering In the air the pin is locked so wheel trails in landing position The up lock is on the lower bearing plate opposite side of pivot block The slot in this plate mates in the upper 1 4 inch diameter bolt near top of the nose box A tow lug is provided on the lower end of each spring refer to Figure 7 1 Nose tires are standard 10 X 3 50 4 ply inflated to 50 5 psi CAUTION Tow on hard surface only 7 2 NOSE GEAR REMOVAL FROM BOX ASSEMBLY 1 Jack and block aircraft per Section 4 2 Remove top most forward access cover 3 Remove round inspection
5. TAN 40 310 c U 2 9 z FIGURE 6 5 OUTSIDE VIEW SHOWING DRAG LINK AND COUPLING NUT Page 38 of 79 1002550 Rev E WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL GEAR TRACKS Levit D 7 n 6 a SHOCK STRUT DRAG LINK NOTE POSITION FIGURE 6 6 VIEW LOOKING UP INTO WHEELWELL FROM OUTSIDE 1002550 Rev E Page 39 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL TRACK SPREADER RETRACT ZERK FITTING PLATE YOKE POSITIONING ROLLER SHOCK STRUT tie FUL LL FIGURE 6 7 ASSEMBLED TRACK ASSEMBLY REMOVED FROM FLOAT Page 40 of 79 1002550 Rev E WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL SHOCK STRUT ZERK PIN POSITIONING 3 WW RETRACT YOKE NOTE POSITION FIGURE 6 8 POSITION OF RETRACT YOKE TO SHOCK STRUT 1002550 Rev E Page 41 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL RETRACT YOKE 1 4 BOLTS SECURING RETRACT TRACK YOKE TO RETRACT ARM 2 MUD FLAP TRACK SPREADER PLATE FIGURE 6 9 VIEW LOOKING DOWN THROUGH TOP ACCESS HOLE Page 42 of 79 1002550 Rev E WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL CYLINDER ROD END RETRACT ARM FIGURE 6 10 VIEW SHOWING 1 16 CUSHION GEAR DOWN ROD END ATTACHMENT 1002550 Rev E Page 43 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL
6. FIGURE 6 1 MAIN GEAR RETRACTION eene emen 34 FIGURE 6 2 MAIN GEAR WHEEL ASSEMBLY 35 FIGURE 6 3 DRAG LINK INSTALLATION mmn 36 FIGURE 6 4 VIEW OUTBOARD ACCESS HOLE CYLINDER IINSTALLATION 37 FIGURE 6 5 OUTSIDE VIEW SHOWING DRAG LINK AND COUPLING NUT 38 FIGURE 6 6 VIEW LOOKING UP INTO WHEELWELL FROM OUTSIDE 39 FIGURE 6 7 ASSEMBLED TRACK ASSEMBLY REMOVED FROM FLOAT 40 FIGURE 6 8 POSITION OF RETRACT YOKE TO SHOCK STRUT 41 FIGURE 6 9 VIEW LOOKING DOWN THROUGH TOP ACCESS HOLE 42 FIGURE 6 10 VIEW SHOWING 1 16 CUSHION GEAR DOWN ROD END ATTACHMENT e a ue 43 FIGURE 6 11 VIEM 1 16 CUSHION GEAR UP ADD 5 AND WASHER FOR ADJUSTMENT iei ERE a EE np 44 FIGURE 6 12 VIEW OF HYDRAULIC CYLINDER 45 FO NOSENGEAR i 46 4 52 Cut shan hiki qve ibo ei t gare IUE 46 7 2 NOSE GEAR REMOVAL FROM BOX ASSEMBLY 46 7 3 REASSEMBLE NOSE GEAR TO NOSE 46 7 4 REMOVAL OF NOSE WHEEL FORK FROM PIVOT ASSEMBLY 47 7 5 NOSE BOX REMOVAL FROM 47 7 6 NOSE BOX TRACK WEAR irren
7. Rust Protection Boeshield T9 Rust Protection Boeing Company ACF 50 Rust Protection Corrosion X Corrosion Technologies Corp Tef Gel Ultra Safety Systems Inc Float Sealant 890 B2 or B4 Pro Seal Company PR 1440 C PPG Aerospace 1422 B2 B4 or B6 Pro Seal Company RTV Silicones General Electric SIKAFLEX 201 or 252 Sika Manufacturing Telflon Spray 6P 730A Comet Industries 1002550 Rev G Electrical Insulating Compound Dow Corning 4 4 Dow Corning Corporation Hydraulic Fluid Mil H 5606 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 should 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 Ibs 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 T
8. X X Page 60 of 79 1002549 Rev E WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL INSPECTION TIME INTERVALS HOURS Landing Gear Systems General Main and Nose Gear Tracks Lubricate Nose Gear Pivot Blocks and Forks Inspect for condition lubrication corrosion and paint Details Clean Fork for Inspection Check Fork Tension 8 10 Ibs 25 50 100 200 RT LT INSP Nose Gear Box Block Tracks measured at slide route for wear 020 inches or less wear tolerance Nose and Main Wheel Bearing Grease zerk fittings X Wheels and Tires Inspect for wear pressure condition Brake Assemblies Inspect for wear corrosion leakage Hydraulic Fluid Screen Clean and inspect Note If floats sit for extended periods of time i e if removed during winter months screen should be cleaned before putting floats back into service Hydraulic fluid in reservoir should be checked for moisture or other contaminates and changed if necessary Clean and Inspect Hydraulic Fluid Level X X Main and Nose Gear Actuator Assemblies Inspect for condition lubrication leakage corrosion and cleanliness Clean and Lube Nose and Main Gear Tracks Nose Gear Springs Scotchply springs inspect for cracks delamination and paint Main Gear Drag Link Inspect for condition lubrication corrosion check atta
9. pick up aircraft at the front spar lifting rings Arm of lifting rings at the aircraft station 433 58 Level the aircraft by placing weight on the float deck to balance Record tare weight and arm 1002550 Rev E Page 77 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL WEIGHING PROCEDURES FOR MAULE FLOATPLANE Level the aircraft as per the weight and balance section of the landplane handbook Place the scales under all 4 wheels Place whatever blocking is required under the mail gears to level the aircraft Drop a plumb bob from the wing leading edge and mark the floor with a line This line is the datum 0 0 in the calculations Measure the distance from 0 0 to each nose wheel center This is X1 and X2 Measure the distance from 0 0 to each main wheel center This is Y1 and Y2 If the floats are seaplane floats the scales go under the step point in the rear and a point towards the front of the float These distances are measured and become the same X and Y as for the amphibian Use this table for the calculations Scale Reading Distance from 0 0 Weight x Arm Weight Moment Left Front X1 Right Front E x2 Y Left Rear Y1 Right Rear Y2 Totals Notes 1 Zero out or deduct tare weights at the Y arm 3 If using overhead hoist and weight load cell pick up aircraft at the front spar lifting rings Arm of lifting rings at the aircraft station 433 58 Level the
10. 3000 3450 FLOAT SERVICE MANUAL 13 0 REPLACING SIDE SKIN STIFFENERS Side skin stiffeners located between bulkheads are secured by a special adhesive This adhesive and stiffeners are available from our Parts Department Each stiffener has a specific location and contour See parts manual for stiffener part number and location The end stamped T goes to gunwall 14 0 REPAIRING HEAT TREATED PARTS Main landing gear drag link shock strut and actuation parts are heat treated These parts are not to be welded without reheat treatment Return to factory for repair and heat treatment 1002550 Rev E Page 65 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 30 20 SPAC E IN SKIN j EN SPAL ED HOLE IN SKIN o o TRIM HOLE 1 CV SEALANT AR 40 TYP Page 66 of 79 FIGURE 11 1 TYPICAL SKIN REPAIR 1002549 Rev E PATCH USE AN470 OR AN436 AD4 RIVETS DIMENSIONS UND PATCH EDG LISE AN470 AN456 AD4 RIVETS WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL ND PATCH AR E IN SKIN
11. PLATE Ses MS21044N4 NUT ANS 11A BOLT 2 3000 ANS 124 BOLT 2 3450 GREASE ZERK NAS1148F0563P WASHER 4 MS21044N5 NUT 2 3A06602 00 THRUST WASHER 21106605 002 PLUNGER AN6227 9 D RING M52 350 SPRING 21406213 006 TOW ANS 7A 2 3000 ANS 104 BOLT 2 3450 NAS1149F0563P WASHER 4 MS21044N5 NUT 2 CLEVELAND P N D 30380 NOSE WHEEL ASS Y 21406318 001 PIVOT BLOCK NOSE GEAR 10 X 3 50 4 PLY TIRE 30A06000 024 ASS Y NOSE GEAR FIGURE 7 1 NOSE GEAR RETRACTION SYSTEM Page 48 of 79 1002550 Rev WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL REMOVE ROD END AT THIS LOCATION gt lt o lt ACCESS HOLE FIGURE 7 2 NOSE BOX ACCESS LOCATION 1002550 Rev E Page 49 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL FOR NOSEBOX REMOVAL REMOVE FW D 8 BOLTS ON NOSE BULKHEAD AND 2 BOLTS ON BULKHEAD ON AFT BOX SIDE PLAY ADJUSTMENT BOLTS REMOVE THIS BOLT FOR NOSE GEAR REMOVAL FIGURE 7 3 FRONT VIEW NOSE BOX 1002550 Rev E Page 50 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL AATIONL H3 LN3O OL 13S33O 1 NOILISOd ALON 7 642018 38175 A311O31 SMOVMH L HOd ISON A311O31 SNOI1VOO1 FIGURE 7 4 POSITION OF TROLLEY TO NOSE BOX Page 51 of 79 1002550 Rev E WIPLINE
12. WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL Verification and Remedy a Reset circuit breaker b Short across pressure switch leads and see if motor runs If motor operates replace pressure switch c Short across solenoid pressure switch leads and see if motor runs If motor operates replace solenoid pressure switch d Ifc above does not produce results and it is verified that voltage was actually applied to motor it can be assumed motor is bad or not properly grounded e Check motor ground Select hand pump to up and down position to relieve pressure Return to center and select gear PROBLEM Power pack does not shut off after gear reaches position a Faulty pressure switch b Faulty or dirty pressure relief valve allowing insufficient pressure buildup Remedy a Replace pressure switch b Clean and check relief valve PROBLEM Power pack shuts off before gear reaches position Probable Cause a Binding or jammed gear retractor which causes pressure to build up and stay up and pressure switch shuts off power pack Remedy a Repair retractor PROBLEM Power pack cycles on and off after gear is in position Probable Cause a Internal hydraulic leak b External hydraulic leak 1002550 Rev E Page 53 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL Remedy a Verify leak is not external by checking fluid level in reservoir and looking at couplings for oil leaks If no
13. aircraft by placing weight on the float deck to balance Record tare weight and arms Page 78 of 79 1002549 Rev E WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL WEIGHING PROCEDURES FOR BUSHHAWK FLOATPLANE Level the aircraft as per the weight and balance section of the landplane handbook or use the cabin floor laterally and longitudinally Place the scales under all 4 wheels Place whatever blocking is required under the mail gears to level the aircraft The aircraft datum is the landing gear beam centerline This mark is 0 0 in the calculations Measure the distance from 0 0 to each nose wheel center This is X1 and X2 Measure the distance from 0 0 to each main wheel center This is Y1 and Y2 If the floats are seaplane floats the scales go under the step point in the rear and a point towards the front of the float These distances are measured and become the same X and Y as for the amphibian Use this table for the calculations Scale Reading Distance from 0 0 Weight Arm Weight Moment Left Front 4 X1 Right Front E x2 Y Left Rear Y1 Right Rear Y2 Totals Notes 1 Zero out or tare weights at the Y arm 2 If using overhead hoist and weight load cell pick up aircraft at the front spar lifting rings Arm of lifting rings at the aircraft station 433 58 Level the aircraft by placing weight on the float deck to balance Record tare weight an
14. bracket to cylinder body Install indicator rod and cable through top access Grease all zerk fittings bolt heads nuts bolt shafts that are exposed Grease wheel bearings Final gear check and inspection Caulk and replace side access covers Install top indicator cover 6 1 2 DISSASSEMBLY OF SHOCK STRUT Shock strut requires no maintenance except if urethane blocks seem sloppy or spin around easily or on unloaded aircraft it seems to squat excessively To dissemble remove cotter pin in top retaining pin and remove pin If replacing urethane blocks pressure must be applied by a press to compress strut and install retaining pin Assemble in reverse order of removal of Figure 6 1 and Section 6 1 Shock strut may be returned to the factory for maintenance Page 26 of 79 1002550 Rev E WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 6 1 3 REPLACING AND SERVICING HYDRAULIC CYLINDERS Wipaire Inc has created a new design to replace the previous unserviceable main and nose gear actuators for the 2100 2350 3000 and 3450 amphibious floats and is detailed in Service Letter 97 available on our website or from our customer service department The actuators are fully serviceable The older style non repairable units can be identified by the stainless steel shiny outer cylinder with non removable aluminum end caps If these units leak or will not hold pressure they should be replaced with new units The new units will be the repairab
15. cover on nose box top from above access refer to Figure 7 2 4 Remove nose bumper by removing attaching screws 5 With hand pump retract gear partially so rod end of cylinder is exposed in round access cover on nose box top 6 Loosen jam nut and unscrew cylinder rod end from end of cylinder 7 Remove long 4 inch diameter bolt on lower end of nose gear fork refer to Figure 7 3 8 Nose gear assembly now may be removed from nose by pulling complete nose gear forward from nose box 9 Clean and inspect nose box tracks for wear 10 Replace or inspect trolley axles and nylon blocks on nose gear trolley Assemble in reverse order of removal and 7 3 7 3 REASSEMBLE NOSE GEAR TO NOSE BOX 1 If installing rod end and trolley link to trolley note position of grease hole it has to be positioned up refer to Figure 7 4 2 Before inserting trolley in nose box take care to position nylon slide blocks Position as noted on Figure 7 1 and Figure 7 4 3 Slide trolley into nose box and reconnect to cylinder refer to Figure 7 2 4 The gear down position is set by adjusting the cylinder rod end so that the over center knuckle brass rollers bottom out in the Nose Fork Tracks without preload on the cylinder rod Tighten lock nut 5 The gear up position does not require adjusting as long as the Up Stop has engaged the Up Stop Pin 6 Bring gear to down and locked position and set side play adjustment These are the two 2 long i
16. cycles check for external leaks If pump cycles on and off during gear cycle it may be necessary to select hand pump to UP Cycle gear up with electric pump Then select to gear DOWN hand pump and cycle gear down with electric pump Repeat if necessary This manually bleeds system NOTE Fluid level in reservoir in UP position is full DOWN position reservoir is half full Don t over fill in DOWN position 1002550 Rev E Page 15 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 5 3 LANDING GEAR MALFUNCTION PROCEDURES Landing Gear Fails to Retract or Extend Battery Switch ON Landing Gear Switch RECHECK IN DESIRED POSITION Landing Gear Motor Circuit Breaker CHECK IN Hand Pump Position Selector CHECK in NEUTRAL POSITION Gear Lights 4 BLUE for gear UP 4 GREEN for gear DOWN 6 Gear Position CHECK VISUALLY If gear still in improper position 7 Landing Gear Switch RECYCLE 8 Landing Gear Motor CHECK RED LIGHT ON 9 Airspeed REDUCE to minimize airloads on gear If pump is running intermittently gear is not moving 10 Hand Pump Position Selector PLACE IN SAME POSITION as Landing Gear Switch NOTE Hand Pump Position Selector must be aligned for the same position as the Landing Gear Switch 11 Gear Operation VISUALLY VERIFY If above procedure still fails to position landing gear as desired 12 Landing Gear Motor Circuit Breaker FULL 13 Landing Gear Switch D
17. each side of the upper shock arm so that the gear proximity switches should not require re adjustment after the gear is re assembled Remove the 2 lower drag link pivot bolts P N 1005734 At this time you can remove the drag link shock strut and upper shock arm assembly as one component The shock strut can be separated from the assembly by removing the grease zerk fitting in the center of the upper and lower pivot pins This fitting and the retainer bushing center the pivot pins There is also a notch on the flange of the retainer that aligns with a roll pin that positions the grease fitting zerk so that it is accessible for periodic lubrication when the float is assembled Remove the actuator arm P N 1005280 from the actuator shaft P N 1005277 Disconnect the up and down hydraulic lines from the actuator Page 30 of 79 1002550 Rev F 10 11 12 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL Remove the 3 AN4 mounting bolts that hold the actuator housing to the wheel well sidewall Now the actuator should slide out of the float If itis necessary to remove the side support plates start by removing the proximity switches P N 1005724 Remove the 8 AN4 mounting bolts that secure the support plates to the wheel well sides and it will slide out as a 3 piece assembly 6 2 3 DISASSEMBLY OF THE HYDRAULIC ACTUATOR The actuator cylinder tubes P N 1005272 can be removed by removing the internal snap ring retainer usi
18. external leaks are found disconnect and cap off the hydraulic actuators one at a time and find the leaky one by process of elimination b If isolating entire system still indicates internal leak power pack check valve located in pressure port of pump is bad and needs replacement or reseating c Visually inspect lines cylinders and hoses and replace as necessary 5 PROBLEM Power pack cycles on and off during gear cycle 6 Probable Cause a Binding in retraction unit b Pressure switch cut off limit too low Remedy a Investigate for free operation Check gear that retracts last b Replace pressure switch PROBLEM Slow gear operation cycle considerably longer than 30 seconds Probable Cause a Plugged oil screen b Poor electrical connection to motor Check ground c Poor motor d Worn pump gears Remedy a Clean intake screen located inside reservoir tank b Connect motor direct to 12 24 volt source and note operation poor motor needs overhaul Covered in b above d Replace pump Page 54 of 79 1002550 Rev E WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 7 PROBLEM Circuit breaker pops during cycle Probable Cause a Wire connections bad or corroded b Bad motor brushes c Bad circuit breaker Remedy a Clean and protect terminal with grease b Overhaul motor c Replace circuit breaker 8 PROBLEM Power pack does not cycle up or down Probable Cause
19. making this adjustment These adjustments must be made with pressure on the cylinder to be sure that the internal components are properly seated in both positions when checking the alignment Shop air can be used if plumbed to the cylinder hydraulic fittings or it can also be done using the aircraft hydraulic system by hooking the up and down lines to both cylinders outside of the float and making the adjustments before re installing them in their proper location On newer float models the adjustment tool 1006709 will not be required The shaft and the gear housing will have the timing marks permanently machined at the outside end of the shaft 6 2 6 ASSEMBLY OF THE MAIN GEAR COMPONENTS Page 32 of 79 1002550 Rev F WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 1 If removed re install side support plates into the wheel well in reverse order of disassembly making sure to align upper and lower pivot points using the upper pivot shaft and lower pivot bolts to aid alignment 2 Atthis point the hydraulic actuator can be bolted in place This is the time when the mounting bolts are the easiest to access Although the actuator can be reinstalled at any point from here on Re assemble the drag link shock strut and upper by replacing the pivot pins retainers and grease fitting Align the shock so that the center retainer flange positioning roll pins are toward the left side of the assembly 4 Install the adjustable actuator l
20. to the up and down positions To remove the axle and wheel remove the brake pads from the caliper so that the caliper can be slid from the torque plate and rotor Remove the 2 AN5 bolts that hold the anti rotation plate P N 1005855 to the side arm of the landing gear drag link Remove the cotter pin from the axle retaining bolt P N 1005374 and remove the Castle nut so the axle retaining bolt can be removed Once the bolt is removed pry the Axle Hubs P N 1005378 and 1005389 from each drag link arm by inserting a screw driver in the slot provided and pry out the retaining bushings Now the Wheel and axle assembly should be free to slide out of the Drag Link Arms The Axle is removed by sliding the locking ring off P N 1004281 so that the bearing retention nut P N MS21025 24 and the seal spacer P N 6 04093 002 can be removed The axle can now be slid from the wheel 6 2 2 REMOVAL OF THE MAIN GEAR COMPONENTS Remove the left and right access covers on the sidewalls of the float Remove the gear indicator P N 30A05000 027 to prevent damage to it and remove the grease fitting from the hole in the upper shock arm This fitting must be removed in order to slide the upper pivot shaft P N 1005733 out Unbolt the actuator linkage rod from the actuator arm P N 1005280 Remove the cotter pin and castle nut from one end of the upper pivot shaft P N 1005733 7 8 diameter rod and slide it out Note where washer shims are located on
21. 18 FIGURE 5 10 SCHEMATIC HYDRAULIC SYSTEM CESSNA 206 19 FIGURE 5 10 SCHEMATIC HYDRAULIC SYSTEM MAULE AIRCRAFT 20 FIGURE 5 2 SCHEMATIC ELECTRICAL SYSTEM 21 6 0 MAIN GEAR REMOVAL AND OPERATION teen 23 6 1 REMOVAL AND DISSASSEMBLY OF MAIN 23 6 1 1 INSTALLATION AND ASSEMBLY OF MAIN 24 6 1 2 DISSASSEMBLY OF SHOCK STRUT 26 6 1 3 REPLACING AND SERVICING HYDRAULIC 27 6 1 4 HAND PUMP AND SELECTOR VALVE 28 6 TB GEAR SELECTOR SWITCH mec ittm lateat e atit 29 29 6 2 ALUMINUM MAIN GEAR RETRACTION DESCRIPTION RACK AND PINION ACTUATOR corea e co LN me 29 6 2 1 MAIN GEAR ASSEMBLY REMOVAL SETUP AND ADJUSTMENT 30 1002550 Rev F Page 3 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 6 2 2 REMOVAL OF THE MAIN GEAR 30 6 2 3 DISASSEMBLY OF THE HYDRAULIC 31 6 2 4 DISASSEMBLY AND ASSEMBLY OF THE SHOCK STRUT 31 6 2 5 ASSEMBLY OF THE ACTUATOR ene ere n nenas 32 6 2 6 ASSEMBLY OF THE MAIN GEAR 32 6 2 7 ASSMEBLY OF THE WHEEL AND 33
22. 35 7 SEALING WASHER gt SK ZERK 3 30404000 100 3000 ws 34A04000 101 3450 SHOWN NAS114901016 WASHER V ASS Y SHOCK STRUT NAS6210 52 BOLT 4 30405702 016 BOLT DATAS P ge NASI 149F 1063P WASHER MS21083N10 NUT 30404475 005 AS BLISHING 30A04000 091 LH DPP 30A04000 090 RH SHOWN ASS DRAG LINK BUSHING 2 30A04574 001 COUPLING FIGURE 6 1 MAIN GEAR RETRACTION Page 34 of 79 1002550 Rev CLEVELAND P N 30 241 MAIN BRAKE ASS Y WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 69 gt gt 5 SS C lt lt mi Lust WI IL Z FIGURE 6 2 MAIN GEAR WHEEL ASSEMBLY 1002550 Rev E Page 35 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL TIVLSNISY IVO IH M20 18 1887 S9OM1 ASSHL dO ALON HOVLIV LNYLS MOOHS MYAZ ASVAYO ANNT OVE NIV ASSV JAVY FIGURE 6 3 DRAG LINK INSTALLATION Page 36 of 79 1002550 Rev E WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL TENSION SPRING RETRACT ARM CYLINDER ROD END BUSHING amp WASHERS NOTED ON ITEM 28 ON INSTALL FIGURE 6 4 VIEW OUTBOARD ACCESS HOLE CYLINDER IINSTALLATION 1002550 Rev E Page 37 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 2 YALLOO AYM INO AINO STIVLSNI TIVI SNISH
23. 5 degrees past the locking position in both directions This provides an over center lock in both directions The actuator arm is attached to the upper shock arm by a linkage rod with adjustable swivel rod ends In the gear down position there is also another over center locking feature that provides a double locking condition and positions the shock strut to direct the landing gear forces up to the upper shock arm and transfers these forces through the side gear support plates and wheel well sidewalls There are two proximity sensors P N 1005724 that sense the position of the upper shock arm in both up and down positions The proximity sensors have a built in LED to indicate when they are sensing the gear position This feature greatly aids in the adjustment of their sensing positions 1002550 Rev F Page 29 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 6 2 1 MAIN GEAR ASSEMBLY REMOVAL SETUP AND ADJUSTMENT Place aircraft on jacks to allow the 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 REMOVAL OF THE MAIN GEAR TIRE AND WHEEL 1 Disconnect battery ground terminal or pull the circuit breaker to stop electrical power to the electrically driven hydraulic pump Bleed pressure off the hydraulic lines by moving the emergency gear position selector
24. 70 FIGURE 11 6 MAIN KEEL EXTRUSION 71 FIGURE 11 7 AFT KEEL EXTRUSION REPAIR 72 FIGURE 11 8 AFT CHINE EXTRUSION ee 73 15 0 WEIGHT AND BALANCE kieren Eee icti eer 74 WEIGHING PROCEDURES FOR CESSNA 185 FLOATPLANE 74 WEIGHING PROCEDURES FOR CESSNA 206 75 WEIGHING PROCEDURES FOR CESSNA 182 FLOATPLANE 76 WEIGHING PROCEDURES FOR CESSNA 180 77 WEIGHING PROCEDURES FOR MAULE FLOATPLANE 78 WEIGHING PROCEDURES FOR BUSHHAWK 79 1002550 Rev F Page 5 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL LOG OF REVISION REV NO PAGES DESCRIPTION DATE A 30 44 Added an inspection time limit and tolerances for the Nose Block 4 18 06 Track wear B 29 Added information and a picture of new serviceable hydraulic 10 1 07 cylinders 50 52 V UR pics C 63 68 Checklist changed format Added weighing information 5 1 08 D 11 12 13 Section 5 1 amp 5 2 information has changed Instructions in 6 2 6 25 08 22 23 24 Instructions changed for 6 4 E ALL Reformat of entire document incorporated new aluminum main gear 4 12 2013 procedures add green grease as approved grease Replaced Elec
25. ER OPERATIONS ARE STRONGLY LINKED TO CORROSION AND MUST BE ADDRESSED PROACTIVELY 2 3 HARD LANDING AND DAMAGE INVESTIGATION After a thorough cleaning of the suspected damaged area all structural parts should be carefully examined to determine the extent of damage Frequently the force causing the initial damage is transmitted from one member to the next causing strains and distortions Abnormal stresses incurred by shock or impact forces on a rib bulkhead or similar structure may be transmitted to the extremity of the structural member resulting in secondary damage such as sheared or stretched rivets elongated bolt holes or canned skins or bulkheads Points of attachment should be examined carefully for distortion and security of fastenings in the primary and secondary damaged areas at locations beyond the local damage 1002550 Rev E Page 11 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 3 0 CORROSION Corrosion is a reaction that destroys metal by an electrochemical action that converts metal to oxide Corrosion is accelerated when in contact with dissimilar metals such as aluminum and steel or any material which absorbs moisture like wood rubber or dirt The primary means of detection of corrosion is visual The most obvious sign is a corrosive deposit of white powder Other signs are discoloration of the metal surface or bubbles and blisters under the painted surface Light corrosion may be removed by light hand sa
26. ESIRED POSITION 14 Hand Pump Position Selector PLACE IN DESIRED POSITION 15 Emergency Hand Pump PUMP until resistance becomes heavy may be 100 or more cycles 16 Gear Position CONFIRM VISUALLY WARNING Do not attempt to land on water unless all four wheels are fully retracted 17 Refer to Section 5 4 for more detailed troubleshooting Page 16 of 79 1002550 Rev E WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL AFT FITTING REF FITTING CREF HYDRALLIC PLHP ASSY FIGURE 5 1A SCHEMATIC HYDRAULIC SYSTEM CESSNA 182 1002550 Rev Page 17 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL HYD PLIMP fo FIREWALL REF EMERGENCY HAND PUMP FITTING REF FWD FITTING REF 2o NOSE GEAR RAMS DOWN DOWN D C MAIN GEAR RAMS UP FIGURE 5 1B SCHEMATIC HYDRAULIC SYSTEM CESSNA 180 185 Page 18 of 79 1002550 Rev E WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL HYDRALLIC PLMP ASSY EMERGENCY HAND PUMP AFT FITTING REF FWD FITTING REF NOSE GEAR RAMS MAIN GEAR RAMS UP UP FIGURE 5 1C SCHEMATIC HYDRAULIC SYSTEM CESSNA 206 1002550 Rev E Page 19 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL HYDRAULIC PUMP ASSY
27. L WITH ANSO7C832 8 SCREWS ANSBO 8 WASHERS AN365 632 Page 71 of 79 FIGURE 11 6 MAIN KEEL EXTRUSION REPAIR 1002550 Rev E WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL RNAL SEAM 10 38 SPL II 75 2 94 FIGURE 11 7 AFT KEEL EXTRUSION REPAIR Page 72 of 79 1002549 RevE 5051 7165 ALUMINUM RIAI MAT WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL C WV3S 3917145 SZ WIASLVW e WIINIWTIV 91 1909 FIGURE 11 8 AFT CHINE EXTRUSION REPAIR 1002550 Rev E Page 73 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 15 0 WEIGHT AND BALANCE WEIGHING PROCEDURES FOR CESSNA 185 FLOATPLANE Level the aircraft as per the weight and balance section of the landplane handbook Place scales under the nose and main gear wheels Place blocking under right and left main gear wheels to level aircraft Drop a plumb bob from the face of the firewall and mark the floor This mark is the datum station 0 0 Measure the distance from 0 0 to each nose wheel This is X1 and X2 Measure the distance from 0 0 to each main wheel This is Y1 and Y2 If the floats are seaplane floats the scales go under the step point in the rear and a point towards the front of the float These distances are measured and become the same X and Y as for the amphibian Us
28. MODEL 3000 3450 FLOAT SERVICE MANUAL 8 0 HYDRAULIC PUMP DISASSEMBLY AND SERVICE Pump may be returned to factory for service Electric pump motor may be returned to factory for service 1 2 3 1 Remove return line on lower reservoir and drain oil Remove screw on bottom of reservoir for tank removal After tank removal pick up filters to be pulled off friction fit and cleaned Refer to Figures 8 1 amp 8 2 Replace tank reinstall lower hose and fill with clean hydraulic oil Mil H 5606 Fill by removing breather and filler stand pipe 8 1 SETTING THERMAL AND PRESSURE RELEIF VALVES These are preset at the factory Thermal relief is set at 1100 100 0 PSI and pressure relief at 800 100 0 PSI If adjusting refer to Figure 8 2 for location of relief valves Loosen jam nut on relief valve to be changed Turn clockwise to increase and C clockwise to lessen Do not exceed factory settings noted above 8 2 TROUBLESHOOTING HYDRAULIC SYSTEM PROBLEM Power pack does not run after gear selection RED pump light OFF Probable cause Circuit breaker has tripped Pressure switch not pulling in at low cut in Solenoid switch not pulling in Motor not properly grounded Pressure buildup on both sides of up and down lines PROBLEM Power pack does not run after gear selection RED pump light ON Probable cause a Faulty pump motor Page 52 of 79 1002550 Rev E 2 3 4
29. TE Do not over tighten lugs will bend Position by hand gear to the Up lock Install coupling nut NOTE Nut must be installed in same position as removed or cotter keyholes will not line up 18 19 20 21 23 Tighten outboard nut first and align cotter keyhole Tighten inboard and align cotter keyhole Install two 2 cotter keys Cycle by hand from top access up to down Inspect and feel for any binding and rollers going to each stop end of track Reinstall tire and brake NOTE Cotter key axle and safety wire brake bolts Through access holes clean out bottom of float Grease all zerk fittings and head of nuts on all bolts exposed Install lower cylinder 3 8 inch bolt NOTE Position of washers one 1 each side of cylinder and remove any excess Loctite from hole in 5 8 inch bolt head before installing 3 8 inch bolt Apply to Loctite 3 8 inch bolt before installing Visually inspect bolt for proper installation Reconnect ground wire screw If cylinder was replaced cylinder must be re indexed at this time Using the aircraft pump move the cylinder to the gear up position From the top access hole hold the gear in the gear up retracted position by hand Adjust the rod end clevis so the hole in it is 1 32 1 16 inch below the hole in the retract 1002550 Rev E Page 25 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 27 35 36 37 arm refer to fi
30. WIPAIRE INC aa WIPLINE FLOATS SKIS MODIFICATIONS AIRCRAFT SALES AVIONICS INTERIOR MAINTENANCE PAINT REFINISHING SERVICE MANUAL and INSTRUCTIONS FOR CONTINUED AIRWORTHINESS for the WIPLINE MODEL 3000 3450 AMPHIBIOUS AND SEAPLANE FLOATS Revised December 20 Fleming Field KSGS South St Paul MN 55075 12 651 451 1205 Fax 651 457 7858 www wipaire com WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Page 2 of 79 1002550 Rev E WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL TABLE OF CONTENTS SECTION PAGE 6 NEW CUSTOMER INFORMATION 7 Lo 9 S haha ha RE 10 2OTEOAT HUL MAINTENANCE u 11 Du 11 OO CLEANING 11 2 3 HARD LANDING AND DAMAGE 11 CORO SION Z n ae ELLE 12 4 0 FLOAT HANDLING JACKING AND AIRCRAFT TOWING 13 5 0 RETRACT SYSTEM OPERATION AND MAINTENANCE 14 5 1 DESCRIPTION AND OPERATION tte 14 ADJUSMMENT TEST LED M Lu Lr 15 5 3 LANDING GEAR MALFUNCTION PROCEDURES 16 FIGURE 5 1 SCHEMATIC HYDRAULIC SYSTEM CESSNA 182 17 FIGURE 5 18 SCHEMATIC HYDRAULIC SYSTEM CESSNA 180 185
31. a Pressure build up in both sides of up and down lines Remedy a Select hand pump to up and down position to relieve pressure Return to center and select gear 1002550 Rev E Page 55 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL PUMP MOTOR BREATHER RING MOTOR TO BASE FILLER TUBE JAM NUT ADJUSTING SCREW EXTENSION TUBES FILTERS RESERVOIR SEAL PICKUP TUBE HAND PUMP RESERVOIR ATTACH FIGURE 8 1 HYDRAULIC PUMP RETLIRN Page 56 of 79 1002550 Rev E WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL FILTER UP THERMAL RELIEF VALVE PRESSURE SWITCH DOWN THERMAL RELIEF VALVE DOWN PRESSURE RELIEF VALVE PICK UP TUBE HAND PUMP UP PRESSURE RELIEF VALVE FIGURE 8 2 INTERNAL VIEW HYDRAULIC PUMP 1002550 Rev E Page 57 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 9 0 CONTINUED AIRWORTHINESS As coded in the Inspection Time Intervals 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 When conducting an inspection at 50 hours the 25 and 50 hour items would be accomplished When conducting an inspection at 100 hours the 25 50 and 100 hour items would be a
32. block needs to be measured for the amount of wear The tolerance for wear is 020 inches If the wear is or is less than the limit it can still be used If the wear in the track is greater than 020 inches the block must be replaced This check should be done every 200 hours and is part of the maintenance checklist On the 3000 8 3450 Series Floats Gear Track P N 2107349 003 LT 004 RT 1002550 Rev E Page 47 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 21A0 399 194 ANGLE AN4 7A BOLT 2 ASI 149F0463P WASHER 4 S21044N4 2 AN4 53 BOLT 2 NAS1149F0432P WASHER 4 MS21044N4 2 21407094 002 END AN316C5R NUT 21407032 005 LINK 21407509 007 AXLE 3A07930 001 BEARING 5100 45 H SNAP RING 21A07349 003 LH 21A07349 004 RH TRACK NOSE E AN4 5A BOLT 4 NAS1149F0463P WASHER 8 MS21044M4 4 30407323 002 NOSE BOX 21407187 008 TROLLEY 34A07309 008 AXLE 2 3A07604 001 SLIDE BLOCK 4 P MEME 30A07000 017 ASS Y NOSE BOX e E AED di NOTE WIDE OFFSET BE TOWARD BOLT 2 3000 CENTER DF TROLLEY AS SHOWN ANS IBA BOLT 2 3450 DETAIL 4 NAS1140F0563P WASHER MS21083NS NUT 4 D EB194 4 22 pum i HYDRAULIC ACTUATOR REF BEARING PLATE UPPER 55 1 P 30 08655 001 SPRING 3000 1 30 06856 001 SPRING 3450 DA UT REF 1406237 01 22 NASIL49F0432P 2 WASHER BEARING
33. can be slid apart The bushings should all be inspected for wear If worn they can be pressed out and replaced The center tube should also be checked for wear or galling To reassemble properly position the urethane blocks in the position as shown in figure below 1002550 Rev F Page 31 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL SHOCK STRUT ASSEMBLY 4 Be sure to position the aluminum plate 04 over the head of the center bushing to act as a retainer plate 5 Carefully slide components together over the center tube making sure that the center tube is locked into place in the counter bore of the top shock end 6 With both shock ends in place install the stainless steel retainer washers and a new AN365 8 lock nut Align both ends with the pin axis as close to parallel as possible Ensure that both retainer locator roll pins are on the same side Torque the AN365 8 lock nut to 120 ft pounds It is critical in the assembly that the center tube is tightly retained between the top shock end and the stainless steel retainer 6 2 5 ASSEMBLY OF THE ACTUATOR 1 Assemble in reverse disassembly order 2 Liberally apply grease to rack and pinion 3 Position the keyway on the shaft correctly using template tool 1006709 by aligning the keyway with the notches in the tool in both and down positions If end stop adjustment is required loosen and remove the locking nut on the end caps Always use a new o ring if
34. ccomplished When conducting an inspection 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 and 200 hour items Below is a list of recommended lubricants and protection products when servicing float hull and 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 or metal surfaces Zip D 5029NS Corrosion Inhibiting Compound Zip Chemical Company CRC 5 400 Soft Seal CRC Industries General Lubricants LPS 1 LPS 2 and LPS 3 LPS Industries Page 58 of 79 1002550 Rev E WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 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 f 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
35. ch bolts for wear Main Gear Shock Strut Inspect for evidence of corrosion pitting cleanliness and security Check lower attach bolt for wear Hydraulic Lines and Fittings Inspect for leaks condition and security AV 30 or Grease Fittings Hydraulic Manifolds if equipped Inspect for condition security and leaks HOURS RT LT INSP 1002550 Rev E Page 61 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL Page 62 of 79 1002549 Rev E inspect 25 50 100 200 X Brake System Plumbing Inspect for leaks condition and security Perform Retraction Test Main Gear Inspect up and down for X proper engagement Nose Gear Trolley Inspect for proper X travel Nose Gear Inspect for excessive side X play in the down position Perform emergency gear Extension X hand pump Nose and Main Wheel Bearings Disassemble and X WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL As general inspection guidelines each of the following areas should be inspected for their own unique attributes Movable Parts For lubrication servicing security of attachment binding excessive wear safetying proper operation proper adjustment correct travel cracked fittings security of hinges defective bearings cleanliness corrosion deformation sealing and tension Fluid Lines and Hoses For leaks cracks dent
36. d arms 1002550 Rev E Page 79 of 79
37. e is recommended The brakes need no special care other than to maintain the brake disc free of rust which causes premature brake lining wear Bleeding is carried out in the usual manner from the bottom up Main wheel tires are standard 6 00 x 6 8 ply Type III aircraft tires inflated to 50 5 psi refer to Figure 6 2 6 2 ALUMINUM MAIN GEAR RETRACTION DESCRIPTION RACK AND PINION STYLE ACTUATOR Retraction and Extension of the main gear is accomplished with a hydraulic rack and pinion type actuator The actuator consists of two opposing pistons pushing a geared rack with a rotating pinion gear in the center The center gear housing is lubricated when assembled at the factory and also has a grease fitting for periodic lubrication of the rack gear and pinion This actuator should only require servicing at 100 hour or annual type inspections The housing is not sealed so seepage of grease residue is not cause for alarm However leakage of red 5606 hydraulic fluid from the housing indicates piston seal leakage in one or both actuator cylinders These rack and pinion actuators are located internally on the right side of the float on both the left and right floats They must be accessed by removing the access cover on the sidewall of the float The drive shaft extends into the center wet bay to actuate the gear A single keyed actuator arm rotates approximately 192 degrees to actuate and lock the gear in both directions by traveling approximately
38. e this table for the calculations Scale Reading Distance from 0 0 Weight x Arm Weight Moment Left Front X1 Right Front P _ x2 _ Left Rear Y1 Right Rear Y2 Totals Notes 1 Zero out or deduct tare weights at the Y arm 2 If using overhead hoist and weight load cell pick up aircraft at the front spar lifting rings Arm of lifting rings at the aircraft station 433 58 Level the aircraft by placing weight on the float deck to balance Record tare weight and arm Page 74 of 79 1002549 Rev E WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL WEIGHING PROCEDURES FOR CESSNA 206 FLOATPLANE Level the aircraft as per the weight and balance section of the landplane handbook Place scales under the nose and main gear wheels Place blocking under right and left main gear wheels to level aircraft Drop a plumb bob from the face of the firewall and mark the floor This mark is the datum station 0 0 Measure the distance from 0 0 to each nose wheel This is X1 and X2 Measure the distance from 0 0 to each main wheel This is Y1 and Y2 If the floats are seaplane floats the scales go under the step point in the rear and a point towards the front of the float These distances are measured and become the same X and Y as for the amphibian Use this table for the calculations Scale Reading Distance from 0 0 Weight x Arm Weight Moment Lef
39. emaining threads and tighten both ends On the main gear actuators the in and out fittings must be indexed so that they Face approximately the same direction If adjustment add or remove shims under the end cap 6 1 4 HAND PUMP AND SELECTOR VALVE OPERATION For normal gear operation electrical power pack the handle is in the neutral position handle pointed to the neutral position If electrical pump should not operate select to gear up handle pointed forward or gear down handle pointed aft Insert stow away handle in pump and pump gear to desired position If pump should leak remove snap ring under handle and pull out inner cylinder Replace rings and reinstall Page 28 of 79 1002550 Rev E WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 6 1 5 GEAR SELECTOR SWITCH The gear selector is an electrical switch that changes pump direction of the electro power pack for gear up or down The red light on panel indicates the pump has power supplied to it The four 4 green lights indicate the landing gear is down The four 4 blue lights indicate the gear is up for water landing The top two lights of each cluster refer to the nose gear position The bottom two refer to the main gear BLUE GEAR UP WATER GREEN GEAR DOWN LAND 6 1 6 MAIN WHEELS AND BRAKES Grease zerks are provided on all wheels and bearings and should be greased every 25 hours or after an extended period of time in the water Water heat resistant greas
40. ero out or deduct tare weights at the Y arms 2 If using overhead hoist and weight load cell pick up aircraft at the front spar lifting rings Arm of lifting rings at the aircraft station 33 58 Level the aircraft by placing weight on the float deck to balance Record tare weight and arm Page 76 of 79 1002549 Rev E WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL WEIGHING PROCEDURES FOR CESSNA 180 FLOATPLANE Level the aircraft as per the weight and balance section of the landplane handbook or use the upper door sill Place the scales under all 4 wheels Place whatever blocking is required under the mail gears to level the aircraft Drop a plumb bob from the face of the firewall and mark the floor with a line This line is 0 0 in the calculations Measure the distance from 0 0 to each nose wheel center This is X1 and X2 Measure the distance from 0 0 to each main wheel center This is Y1 and Y2 If the floats are seaplane floats the scales go under the step point in the rear and a point towards the front of the float These distances are measured and become the same X and Y as for the amphibian Use this table for the calculations Scale Reading Distance from 0 0 Weight x Arm Weight x Arm Moment Left Front X1 Right Front u x2 2 Left Rear 1 Right Rear Y2 Totals Notes 1 Zero out or deduct tare weights at the Y arms 2 lf using overhead hoist and weight load cell
41. gure 6 11 This adjustment must be accomplished by adding or removing washers under the rod end lock nut The in and out adjustment of the rod end on the threads is not critical at this time as long as the lock nut is snug against the Rod End Clevis Again using the aircraft pump move the piston rod to the gear down extended position Then position the gear in the gear down position and hold in place through the top access hole in the float Align the hole in the Rod End Clevis with the hole in the Retract Arm Adjust the Rod End Clevis so that the hole in it is 1 32 1 16 above the hole in the retract arm and tighten the lock nut refer to figure 6 10 NOTE Add spacer washers under jam nut as necessary to achieve 1 16 inch cushion see Figure 6 11 Install upper cylinder bolt to attach cylinder rod end to retract arm attach tension spring refer to Figure 6 4 Check retract for operation by aircraft hydraulic system Set gear position switch by sliding bracket on outside of hydraulic cylinder body by running gear to down position slide switch bracket up so lights green are illuminated on selector head refer to Figure 6 12 By running gear to up position slide switch bracket down so lights blue are illuminated on selector head NOTE If lights have a double flash on off on move switch brackets further to outer ends so lights come on just once After switch brackets are positioned apply bead of RTV silicone to secure
42. he 2 AN5 bolts 6 Tighten and install cotter pin in the axle retainer bolt 7 Re install brake caliper and pads Bleed the brakes if required 09 The Drag link is 3 piece unit not meant to be disassembled unless it is determined that they must be inspected for corrosion Upon reassembly clean thoroughly and liberally apply sealer between the parts to prevent moisture from entering the joint and install new hardware In highly corrosive conditions it is recommended that the assembly be re primed and painted after assembly 1002550 Rev F Page 33 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 1400051 21405925 008 MS21044N5 SPRING NAS1149F0563P WASHER 30405000 039 LH SHOWN 30405000 040 RH DPP ASS Y RETRACT ARM 30404454 007 AN5 12A BOLT SHAFT 30405460 001 LEVIS RETRACT ARM 30405252 001 SPACER NAS1149D0863J WASHER HYDRAULIC CYLINDER AN6 13A BOLT ASLIAGFOG32P WASHER AST 14901016 WASHER 30A05558 001 MODIFIED BOLT 837834035 SEALING WASHER 30A05000 027 ASS Y ARM GEAR INDICATOR ANG204 17 BULT ASL 149F0463P WASHER 4 S21083M NUT 2 PLACES 095641 ZERK 2 30A05000 042 ASS Y RETRACT YOKE NCLUDES INDICATUR ARM 1085K43 21405520 003 2 NOTE INSTALL WITH LARGE C 30405114 003 LH DPP RADIUS FACING TRACK 30405114 004 RH SHOWN TRACK 9378340
43. i Retraction cables should be rigged such that the rudder blade is in the up position and that the cables are just slack in the down position 11 0 REPAIRING FLOAT HULL SKINS The float hull is manufactured from the following aluminum alloys Top skins 025 inch thick 6061 T6 aluminum Side skins 025 6061 T6 aluminum Bottom skin 040 inch thick 6061 T6 aluminum Nose bulkhead 080 inch thick 6061 T6 aluminum All remaining forward bulkheads 032 inch thick 6061 T6 aluminum Afterbody skin 025 inch thick 6061 T6 aluminum All afterbody bulkheads 032 inch thick 6061 T6 aluminum Damage to the skins may be repaired per Figures 11 1 11 2 11 3 or any acceptable repair method listed in FAA Advisory Circular 43 13 14 Any float hull skin or part thereof can be purchased from Wipaire to aid in repair To simplify repairs the skins are precut and drilled except forward bottom skins NOTE Forward side skins are stretched formed and may be purchased from factory 12 0 REPAIRING FLOAT HULL EXTRUSIONS KEEL CHINE ETC Refer to Figures 11 4 through 11 8 for repair schemes for repairing hull extrusions Outside hull extrusion may be purchased from Wipaire in any length Internal splices may be purchased from Wipaire or fabricated per sketches shown in figures Any repair to hull not shown in this manual to be per FAA Advisory Circular 43 13 1A Page 64 of 79 1002549 Rev E WIPLINE MODEL
44. inkage rod with the female rod end in the upper arm 5 Reposition the assembly into the float and insert the upper pivot pin and the lower pivot bolts Make sure that the upper shock arm is positioned on the upper pivot so it is centered between the side support plates and shimmed so that there is less than 010 play This is critical so that the upper shock arm cannot move away from the proximity switches more than 010 in normal use 6 Make sure all pivots operate freely 7 Adjust the linkage rod in the Gear Down position only It must be adjusted so that there is approximately 1 4 to turn of preload in the down position Too much preload puts high stress on the actuator components Tighten all locking nuts 6 2 7 ASSMEBLY OF THE WHEEL AND BRAKE 1 the Wheel Bearings require replacement reassemble the wheel per the wheel manufacturers instructions 2 Assemble the wheel onto the axle with the seal spacer and axle nut opposite of the brake rotor side of the wheel After setting the bearing preload install the locking ring to prevent the axle nut from rotating Slide the wheel and axle assembly into the drag link and insert the retainer bushings Insert the axle retainer bolt from the side opposite the brake but do not tighten 5 the anti rotation plate was disassembled from the brake torque plate re assemble them so the brake caliper is rotated as far up as it can go without hitting the drag link arm Install and tighten t
45. k strut with each other is important Refer to Figure 6 7 for positions Before installing track assembly clean out wheel well area of dirt excess grease etc Reinstall track assembly from bottom of float NOTE Position of track spreader plate It goes to the up position refer to Figures 6 6 6 9 Position track assembly in wheel well area and start lower 5 8 inch diameter removed in step 16 one 1 each side NOTE This positions track assembly Do not install coupling nut or tighten at this time refer to Figure 6 6 Page 24 of 79 1002550 Rev E 10 11 14 15 2 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL Pivot track around 5 8 inch bolts to align 3 16 inch bolt and each side to wheel well Do not tighten Temporarily install retract arm through to 5 8 inch hole in tracks without going through retract yoke Tighten all 3 16 inch bolts four 4 each side on tracks After tightening 3 16 inch side bolts eight 8 remove retract arm and install through retract yoke upper bushing Reinstall two 2 1 4 inch diameter bolts in retract yoke to retract arm and tighten refer to Figure 6 9 NOTE Temporarily tie shock strut to the up position so 5 not in the way when reinstalling drag link clean and inspect drag link Install drag link so shock strut lugs are up Install one 1 5 8 inch diameter bolt on each side Untie shock strut and attach to drag link 5 8 inch bolt NO
46. land is accomplished by differential braking The nose wheels are full castering Access to the float interior is accomplished by removing covers on the top deck side skins and two covers inside the wheel well When necessary water inside the float hulls may be removed through pumpout cups located on the outboard edge of each float top skin Page 10 of 79 1002550 Rev E WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 2 0 FLOAT HULL MAINTENANCE 2 1 GENERAL The float structure side top skins and bottom skins are 6061 T6 aluminum and extrusions are 6061 T6 aluminum keel chine etc Skins are alodined and primed after being cleaned and acid etched Exterior is finished with a urethane color paint or equivalent 2 2 CLEANING The outside of the float should be kept clean by washing with soap and water with special care taken to remove engine exhaust trails water line marks and barnacle deposits as these are all linked to corrosion After saltwater operation washing with fresh water should be done daily with special attention to hard to reach places such as seams wheel well etc The float interior should be flushed if salt water enters the compartments it s easy to tell by the smell inside the float lockers At night or when the floatplane is in storage the inspection and or baggage covers should be opened so the interior has a chance to dry out THE ABOVE CLEANING TECHNIQUES ARE VITAL FOR KEEPING CORROSION TO A MINIMUM SALTWAT
47. le type The sealed units can also be upgraded to the repairable type at any time in accordance with Service Letter 97 Repairable units new products will have the repairable type cylinders These can be identified by their all aluminum construction and grey color These units can be disassembled and repaired according to the following instructions Repair Kits include all replacement O rings and Quad rings and Rod Wiper 2000 Series Floats Cylinder Part Numbers Repair Kit Number Nose 1002572 1002578 Main 1002573 1002577 If servicing beyond the usual cleaning and inspection use Section 6 amp 7 amp 8 to remove the main and nose gears respectively Once cylinders are removed from the floats 1 The end caps must be removed they are secured with medium strength Loctite Always clamp the tube in such a way as to not damage or deform the outer cylinder 2 Once the end caps are removed remove the rod and piston from the main cylinder 3 Remove the two quad rings off the piston then remove the O rings off the end caps 4 Remove the two O rings from the front rod end cap located on the inside portion of the rod end cap and the plastic wiper ring All parts must be thoroughly cleaned of any residue of Loctite and hydraulic fluid NOTE Be sure to look at all seals closely so they can be re installed correctly 1002550 Rev E Page 27 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL Reassembly 1 2 To reasse
48. 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 up and down position the pressure switch deactivates the solenoid and the pump motor stops Figure 5 2 shows the electrical schematic of the system 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 oil back to the pump reservoir when the line pressure exceeds 800 psi The system also has an internal relief valve to protect against thermal expansion when line pressure exceeds 1100 psi The selection of gear up or gear down is accomplished by a cockpit mounted control panel Each float gear has individual indicator lights on the control panel allowing the pilot to confirm that each gear has fully retracted or extended At the top of each float deck just forward of the step a visual indicator is provided for the main gear Nose gear up and down may be determined visually for position An emergency hand pump is provided in case of total electric pump failure or loss of fluid The reservoir has additional hydraulic fluid available only to the hand pump The main gear has an over center lock in both up and down positions Retraction takes place when pressure is exerted on the actuator piston driving the actuating arm along the slide track see Figure 5 3 A reverse p
49. ly 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 landing wheels chocked Position a sawhorse under main and after body keel to keep aircraft from tipping fore and aft For raising the aircraft for float installation and removal use the lifting rings if provided or lift at front wing attach points Aircraft may be lifted by spreader bars with a launching dolly WITH CAUTION lift on both spreader bars as close to float hull as possible When towing the amphibian aircraft tow lugs are provided on the lower forward side of the nose spring A rigid V frame can be fabricated to attach to these lugs and aircraft towed with a tractor Wipaire Parts has this tow bar available A lifting apparatus that will pick the aircraft up by the lifting rings at wing attach points from a ceiling hoist to be fabricated Contact factory for details if necessary 1002550 Rev E Page 13 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 5 0 RETRACT SYSTEM OPERATION AND MAINTENANCE 5 1 DESCRIPTION AND OPERATION Retraction and extension of the main and nose landing gear is effected by a hydraulic actuation system shown schematically in figure 5 1 The gear system is hydraulically actuated and driven by one reversible electric pump A pressure of between 500 psi and 700 psi in the up and down position is maintained in the supply
50. mble first make sure you are using Mil H 5606 hydraulic fluid and lubricate all the new quad and O rings not the wiper with it Thread the end cap onto the cylinder tube a couple threads Waiting to add a drop of medium strength Loctite until this point helps to keep it from contaminating the cylinder Then finish carefully tightening the end cap Following that slide the piston down into the cylinder being careful of the quad rings Check the top of the cylinder when this is done for flakes of rubber to indicate any damage from installation Clean the threads and install the quad rings into the rod end cap NOTE Make sure that quad rings are not twisted and are Seated in the grooves If they are compromised in Any way they will not seal or hold pressure properly Install the new seal ring and lubricate all the quad and O rings with hydraulic fluid and insert the threaded end of the rod making sure of the end of the rod is clean and free of any sharp edges that will damage the quad ring Once this is slid past the flats in the threaded ends check again for any evidence of seal damage by looking for flakes of rubber If there is ANY damage to any of the seals they must be replaced NOTE When sliding the rod end cap over the threaded rod SLOWLY work the rod end cap down on the rod You should feel the rod pass thru each quad ring Thread the rod end cap into the cylinder tube Start threads and then add a drop of Loctite on the r
51. nch bolt that refer to Figure 7 3 are horizontal through the nose fork 7 Reinstall cover on Figure 7 2 8 Reinstall nose bumper Page 46 of 79 1002550 Rev E WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 9 Set proximity switches or check so when gear is down green lights on selector head are on When gear is up blue lights are on Set by sliding switch brackets on cylinder shaft When set apply RTV silicone to secure to cylinder 7 4 REMOVAL OF NOSE WHEEL FORK FROM PIVOT ASSEMBLY 1 Remove bolt NOTE This is a heat treated bolt Entire pivot shaft on nose fork will drop down for service Assemble per Figure 7 1 Axle bolt is modified for grease service A special anti rotation washer is under bolt head to keep axle from turning DLD 7 5 NOSE BOX REMOVAL FROM FLOAT 1 Nose gear must be removed 7 2 2 Remove the eight 8 1 4 inch bolts from nose bulkhead Plate nuts on inside of nose bulkhead 3 Hydraulic cylinder to be removed by unscrewing from back nose box flange NOTE Keep washers on cylinder for reinstallation Remove two 2 bolts holding nose box to float bulkhead angles 5 Slide entire nose box forward NOTE Nose box may be removed by just removing hydraulic lines elbow fittings and proximity switches Then slide box out with cylinder attached 7 6 NOSE BOX TRACK WEAR Due the wear over time the roller slide block places on the track as the gear are retracted the
52. nding or chromic acid Moderate and severe corrosion blistering flaking and pitting may be removed by heavy sanding or grinding and applying chromic acid No more than 1 3 the thickness of skin material should be removed before complete replacement or reinforcement of an area is necessary After removing the corroded area restore area to original finish prime and enamel BOESHIELD Corrosion X or ACF 50 may also be applied to stop corrosion Refer to manufacturer s instructions for application instructions Maintaining the float inside and outside finishes by washing after saltwater operations will help protect the float from corrosion Periodically all hardware should be covered with a waterproof grease or paralketone Under saltwater conditions bolts should be removed at least once a year and grease reapplied to the shafts heads and nuts Page 12 of 79 1002550 Rev G WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 4 0 FLOAT HANDLING JACKING AND AIRCRAFT TOWING jack the floats for servicing tires brakes doing retraction tests it is recommended that a floor type jack one ton minimum be used These jacks are commonly used for auto repair The jack should be positioned on the keel centerline on the first bulkhead forward of the step Example is shown to the left of this text The jack should contact the keel squarely and if room permits slip a board between the jack and keel Raise the float slow
53. ng the proper sized snap ring pliers Note or mark the tubes so that they can be re assembled on the side from which they were removed The end caps P N 1005273 can also be removed by removing the hydraulic line fitting and the internal snap ring retainer once the cylinder tube is removed from the center housing P N 1005275 Again note or mark the tubes and end caps to reassemble in the same location By marking these components you may eliminate the need to re adjust the end stops if all the same parts are to be re used The piston P N 1005276 is a free floating piston and will simply slide out Remove the 2 screws in the face of the housing so that the housing top P N 1005274 can be slid off the shaft P N 1005277 If the actuator is to be re assembled with the same components mark the rack gear and pinion with timing marks so that it can be reassembled without requiring adjustments to the end stops Now the shaft and pinion gear P N 1005282 will also slide out The shaft and pinion have a keyway for alignment and the pinion has a set screw that holds the pinion from sliding on the shaft The bushings in the housing should never require replacing but if they do they are pressed into the housing from the inside 6 2 4 DISASSEMBLY AND ASSEMBLY OF THE SHOCK STRUT With the strut removed from the gear assembly loosen and remove the AN365 8 elastomeric self locking nut from the center retaining bolt The strut at this time
54. op access remove four 4 3 16 inch diameter bolts holding track to side panels 21 From inboard access remove four 4 3 16 inch diameter bolts holding track to side panels 22 From under float slide out the entire track assembly Position on bench Refer to Figure 6 7 1002550 Rev F Page 23 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 23 24 25 26 27 on Remove shock strut assembly from track assembly by spreading track panels apart Leave track spreader plate intact Clean and inspect track To remove shaft from upper shock strut remove the two 2 outside grease zerk fittings refer to Figure 6 8 For shock strut service shock strut must be compressed before disassembly NOTE Shock strut maybe returned to the factory for service Clean and inspect all parts 6 1 1 INSTALLATION AND ASSEMBLY OF MAIN GEAR Assemble track assembly before installing in float refer to Figure 6 7 Lay shock strut on bench with grease zerk facing up Install retract yoke to shock strut upper end with roller shaft NOTE Holes in shaft to match holes in shock strut bushing Grease zerks position shaft to shock strut bushing refer to Figure 6 8 Install bushing to lower shock strut Grease Grease shaft and install rollers to each end NOTE Radii on bushings to be on outboard side Install tracks over this assembly NOTE Position of tracks retract yoke and shoc
55. or removing washers under the rod end lock nut The in and out adjustment of the rod end on the threads is not critical at this time as long as the lock nut is snug against the Rod End Clevis Again using the aircraft pump move the piston rod to the gear down extended position Then position the gear in the gear down position and hold in place through the top access hole in the float Align the hole in the Rod End Clevis with the hole in the Retract Arm Adjust the Rod End Clevis so that the hole in it is 1 32 1 16 above the hole in the retract arm and tighten the lock nut Nose and main gear proximity switches are set by sliding the mounting clips on the cylinders to a position such that the light goes out when the cylinder piston is about 1 8 inch from the bottomed position while traveling in the up direction It should come on about 1 8 inch from the bottomed position while traveling in the down direction The system automatically bleeds provided sufficient oil is maintained in the reservoir To check the fluid level fill the reservoir with hydraulic oil and cycle the gear If the reservoir empties i e fluid disappears in sight glass stop the cycle by pulling the circuit breaker on the control panel 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 up and down positions If the fluid level continues to decline during gear
56. orm Prep E reds 47 FIGURE 7 1 NOSE GEAR RETRACTION 48 FIGURE 7 2 NOSE BOX ACCESS LOCATION mn 49 FIGURE 7 3 FRONT VIEW NOSE tiom Stereo eon 50 FIGURE 7 4 POSITION OF TROLLEY TO NOSE BOX 51 8 0 HYDRAULIC PUMP DISASSEMBLY AND 52 8 1 SETTING THERMAL AND PRESSURE RELEIF VALVES 52 8 2 TROUBLESHOOTING HYDRAULIC 5 5 52 FIGURE 8 1 HYDRAULIC PUMP iioii eR et Ponte 56 Page 4 of 79 1002550 Rev F WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL FIGURE 8 2 INTERNAL VIEW HYDRAULIC enm 57 9 0 CONTINUED AIRWORTHINESS t 58 10 0 WATER RUDDER RETRACTION AND STEERING SYSTEM 64 11 0 REPAIRING FLOAT HULL SKINS 64 12 0 REPAIRING FLOAT HULL EXTRUSIONS KEEL CHINE 64 13 0 REPLACING SIDE SKIN STIFFENEHRS 2 ir ttti toit trece one 65 14 0 REPAIRING HEAT TREATED 65 FIGURE 11 1 TYPICAL SKIN BEPAIRB iier ERE a 66 FIGURE 11 2 TYPICAL SKIN 67 FIGURE 11 3 TYPIGAL SKIN 68 FIGURE 11 4 GUNWALL EXTRUSION 69 FIGURE 11 5 FORWARD CHINE EXTRUSION
57. orque of 8096 should be used when Tef Gel is applied to the bolt Page 59 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL INSPECTION TIME INTERVALS HOURS RT LT INSP General Details 25 50 100 200 General Placards Hulls 4 Float Installation Float exterior Inspect for damage X Struts wrinkled metal corrosion paint loss etc Struts amp attach fittings X Spreader bars X Float Structure interior X Baggage Compartment Covers and Seals X Inspect for condition security operation excessive wear Pumper Tube Installation Inspect for condition X security routing of hoses Water Water Rudder Hinges Inspect freedom of Clean and Inspect Lube with 2 X Rudder rotation System Water Rudder Steering and Retract Systems X Inspect the following cables for broken wire cable fittings for cable slippage cracks and distortion cable pulleys for freedom of rotation and cable guard pins for presence rigging Water Rudder Blades and Posts Inspect for Clean and Inspect Lube with LPS 2 X damage security of attachment corrosion paint rigging Electrical Pump and Indicator Light Wiring Inspect for X System chafing broken or loose terminals and general condition Solenoids Inspect wiring mounting and general X condition Pressure Switches Inspect wiring mounting X and general condition Pump Motors Inspect wiring mounting and general condition
58. rocess effects extension Gear position light proximity switches are closed when the cylinder piston containing the magnetic material is adjacent to the switch The nose gear has an over center down lock Retraction occurs when pressure is applied to the forward fact of the actuator piston and the carriage is drawn along the tracks in the nose box as shown in Figure 5 4 Gear position light proximity switches are closed when the piston containing the magnetic material has reached either end of its travel Page 14 of 79 1002550 Rev E WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 5 2 ADJUSTMENT TEST Adjustment of the hydraulic actuator stroke is provided at the ends of the piston rods on the nose and main gear Nose The gear down position is set by adjusting the cylinder rod end so the over center knuckle brass rollers bottom out in the Nose Fork Tracks without preload on the cylinder rod The gear up position does not require adjusting as long as the Up Stop has engaged the Up Stop Pin Mains With the Retract Arm disconnected from the Rod End move the cylinder to the gear up retracted position using the aircraft pump Then position the gear in the gear up position and hold in place through the top access hole in the float Align the hole in the Rod End Clevis with the hole in the Retract Arm The hole in the clevis should be 1 32 1 16 below the hole in the retract arm This adjustment must be accomplished by adding
59. rs 1 top and 1 each side of wheel well area Remove putty around side access jambs Remove brake caliber Do not disconnect hydraulic lines so it s not necessary to bleed on reinstall Remove axle cotter pin wheel nut and tire refer to Figure 6 3 Through top access remove gear indicator shaft and cable Through outboard side access remove upper bolt on hydraulic cylinder NOTE Position of tension spring refer to Figure 6 4 Remove ground electrical wire screw Remove bolt on lower end hydraulic cylinder Through top access bring gear to the up lock position by moving gear by hand Under the float remove cotter pin on coupling nut 2 Use tie strap to tie cylinder forward for ease of bolt removal of gear NOTE Before removing mark nut inboard or outboard for ease of reinstalling refer to Figure 6 5 Hold coupling nut with 1 inch wrench while removing bolt on outboard side then inboard side NOTE Just remove coupling nut leave bolts through gear tracks for now 15 Through top access unlock gear and by hand move to the down position Under the float remove bolt on drag link holding the lower shock strut end Through side access finish removing main drag link 5 8 inch bolts and remove drag link 18 Through top access remove two 2 1 4 inch diameter bolts on retract yoke refer to Figure 6 9 19 From outboard access remove retract arm by pulling outboard From outboard and t
60. s kinks chafing security corrosion and deterioration Metal Parts For security of attachment cracks metal distortion broken welds corrosion condition of paint and any other apparent damage Wiring For security chafing burning defective insulation loose or broken terminals corroded terminals Bolts in Critical Areas For corrosion correct torque when installed or when visual inspection indicates a need for a torque check Some additional general maintenance areas are as follows Nose and Main Gear Tracks Clean and then lubricate with a dry Teflon coating spray Joints Spray all joints with light penetrating oil such as LPS 3 to ensure lubrication at all times Electrical Connections Apply SP 400 SOFT SEAL or LPS 500 to all electrical connections to prevent corrosion Hydraulic Fluid For use in all hydraulic systems including brakes MIL H 5606 1002550 Rev E Page 63 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 10 0 WATER RUDDER RETRACTION AND STEERING SYSTEM Description The water rudder retract system is manually operated by a lever through a system of cables and pulleys Steering is directed from the aircraft rudder steering system Adjustment Rigging of the water rudder steering cables is accomplished by centering the airplane rudder and adjusting the turnbuckles such that both rudders trail with the float centerline Cables should be tensioned to 10 pounds 5 ps
61. s manual contact Wipaire Customer Service Department The service products referred to throughout this manual are described by their trade name and may be purchased from the Wipaire Parts Department To contact Wipaire for service assistance or parts sales call email or write Wipaire Inc 1700 Henry Avenue Fleming Field South St Paul MN 55075 Telephone 651 306 0459 Fax 651 306 0666 Website www wipaire com Email CustomerService wipaire com 1002550 Rev E Page 9 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL 1 0 GENERAL The Model 3000 3450 seaplane or amphibious float is an all aluminum constructed float with watertight compartments The actual displacement in fresh water for each float is 3301 pounds Model 3000 and 3776 pounds Model 3450 buoyancy for the seaplane and 3125 pounds Model 3000 and 3600 pounds Model 3450 buoyancy for the amphibian The amphibious float is geometrically the same as the seaplane except for the addition of landing gear and internal structure for the landing gear The water rudder steering and retract system is cable operated with ball bearing pulleys Water rudder cables tie into the existing aircraft rudder system The main landing gear has a 6 00 x 6 8 ply tire and the nose landing gear has a 10 X 3 50 4 ply tire The gear system is hydraulically actuated and driven by one reversible electric pump Brakes are hydraulic and have a caliper on each main wheel Steering on
62. t Front X1 Right Front 0 2 2 Left Rear 4 4 Y1 4 Right Rear 2 Totals Notes 1 Zero out or deduct tare weights at the Y arm 2 If using overhead hoist and weight load cell pick up aircraft at the front spar lifting rings Arm of lifting rings at the aircraft station 433 58 Level the aircraft by placing weight on the float deck to balance Record tare weight and arm 1002550 Rev E Page 75 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL WEIGHING PROCEDURES FOR CESSNA 182 FLOATPLANE Level the aircraft as per the weight and balance section of the landplane handbook Place the scales under all 4 wheels Place whatever blocking is required under the mail gears to level the aircraft Drop a plumb bob from the face of the firewall and mark the floor with a line This datum line is 0 0 in the calculations Measure the distance from 0 0 to each nose wheel center This is X1 and X2 Measure the distance from 0 0 to each main wheel center This is Y1 and Y2 If the floats are seaplane floats the scales go under the step point in the rear and a point towards the front of the float These distances are measured and become the same X and Y as for the amphibian Use this table for the calculations Scale Reading Distance from 0 0 Weight Arm Weight Moment Left Front 4 X1 Right Front 4 2 x2 Left Rear Y1 Right Rear 2 Totals Notes 1 Z
63. trical Schematic figure revised instructions for F 22 23 29 disassembly and re assembly of aluminum main gear Added Shear 5 26 2015 33 59 Torque chart PR 1440 C Sealant Tef Gel and full contact info Removed Warranty Claim Form G 6 12 59 Added Dow Corning DC4 Corrosion X and Mobil Aviation Grease 12 4 2015 SHC 100 to approved product list Modified torque limit section Page 6 of 79 1002550 Rev G WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL m OM INC NEW 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 FedEx and or UPS account number if applicable Please return to Wipaire Customer Service Fax 651 306 0666 Phone 651 306 0459 CustomerService wipaire com 1002550 RevE Page 7 of 79 WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Page 8 of 79 1002550 Rev F WIPLINE MODEL 3000 3450 FLOAT SERVICE MANUAL INTRODUCTION This manual describes the general servicing and maintenance for the Model 3000 3450 float hull landing gear systems installation and control parts For services and repairs not covered by thi

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Model 3000 &amp;3450 Service Manual

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Model 3000 &3450 Service Manual