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SERVICE MANUAL, FIRE BOSS

1. 13 Ia SCOOP SYSTEM 14 1 5 FOAM 5 8 4154040 tt tt tt tt tt tt tto 14 1 6 VENT AND OVERFLOW 20444 4040 15 1 7 HARD LANDING AND DAMAGE INVESTIGATION csssccssscssssessssesssetessseesseeees 16 17 1 10 MEANS FOR LEVELING 18 2 0 MAIN AND NOSE GEAR OPERATION REMOVAL AND 5 18 2 1 DESCRIPTION AND OPERATION cette 18 2 2 SERVICE NOSE GEAR 19 2 3 NOSE BOX TRACK WERAR ed ted b p ated eas 19 2 4 SERVICE MAIN WHEELS AND 19 2 5 SERVICE MAIN GEAR OLEO 20 2 6 SERVICE NOSE AND MAIN GEAR 5 26 AC ADJUSIBNETEBRS 26 NOSE GEAR e e G 26 2 7 2 MAIN GEAR ttt ttt ttt ttt ttt tt ttt 27 2 7 3 BLEEDING HYDRAULIC SYSTEM AFTER SERVICE 27 2 7 4 HYDRAULIC ACCUMULATOR 5 27 2 8 MAIN AND NOSE GEAR REMOVAL AND DISASSEMBLY 28 2 8 1 REMOVAL OF MAIN GEAR OLEO
2. 28 2 8 2 REMOVAL OF MAIN GEAR RETRACTION 28 1002545 Rev K Page 5 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 2 8 3 REMOVAL OF MAIN GEAR DRAG LINK ee 28 2 8 4 REMOVAL OF NOSE GEAR TROLLEY ASSEMBLY FROM NOSE BOX 28 2 8 5 REMOVAL OF NOSE GEAR 0 0 28 2 8 6 REMOVAL OF LOWER NOSE GEAR FROM PIVOT BLOCK 28 2 8 7 REMOVE THE NOSE GEARS sic 29 FIGURE 2 1 HYDRAULIC SYSTEM SCHEMATIC 30 FIGURE 2 2 SCHEMATIC ELECTRICAL SYSTEM eem 32 FIGURE 2 3 LAYOUT MAIN GEAR REL D e Petr et ae ep 32 FIGURE 2 4 CARRIAGE ASSEMBLY MAIN 33 FIGURE 2 5 ASSEMBLY MAIN GEAR SHOCK 34 FIGURE 2 6 ASSEBLY MAIN GEAR ASSEMBLY 35 FIGURE 2 7 ASSEMBLY MAIN GEAR DRAG LINK 36 FIGURE 2 8 ASSEMBLY MAIN GEAR WHEEL AND BRAKE 37 FIGURE 2 9 ASSEMBLY NOSE GEAR BOX AND RETRACTION 38 FIGURE 2 10 ASSEMBLY NOSE GEAR LOWER 39 3 0 HYDRAULIC PUMP SYSTEM DISASSEMBLY AND SERVICE 40 3 1 OPERATION 5
3. 211 5 SKIN ndi 5 20 USE 70 OR AO NM56 NM RIVETS IN lt iz te a Ri M ma DIMENSIONS 5 70 o SEALANT ARON PATCH EDG d AMSE ADA RIVETS 010 00000 So 9 9 0 040290 3 30 Ed SPAC I 8 3 Rivet in place Page 72 of 91 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 FIGURE 14 1 TYPICAL SKIN REPAIR 1002545 Rev FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 2 SEALANT ARUUND PATCH dur ae X E IN SKIN of USE ANO UR AN436 A04 RIVETS 30 SEALANT ARDUND PATCH 2 HOLE IN SKIN 35 E SPACE LO 1 00 MAX ERI USE AN470 UR AN4a6 A04 RIVE 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 S FIGURE 14 2 TYPICAL SKIN REPAIR 1002545 Rev K Page 73 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 32 30
4. 58 AS tnt ta e Mam 59 FIGURE 13 0 SCHEMATIC AUXILIARY INSTRUMENT 60 FIGURE 13 1 SCHEMATIC CIRCUIT BREAKER 61 FIGURE 13 2 SCHEMATIC INSTALLATION ANGLE OF ATTACK 62 FIGURE 13 3 AOA FLAP CALIBRATION READINGS 63 FIGURE 13 4 SCHEMATIC INSTALLATION FOAM TANKS PUMPS 64 FIGURE 13 5 SCHEMATIC INSTALLATION BILGE PUMPS 65 FIGURE 13 6 SCHEMATIC INSTALLATION SCOOP FILL SYSTEM 66 FIGURE 13 7 SCHEMATIC INSTALLATION PROBE POSITION 67 FIGURE 13 8 SCHEMATIC INSTALLATION PDR 60 68 FIGURE 13 9 SCHEMATIC INSTALLATION ITT EXCESS POWER LIGHT 69 FIGURE 13 10 SCHEMATIC INSTALLATION WATER IN FLOAT SENSORS 70 14 0 REPAIRING FLOAT HULL SHEET METAL BULKHEADS AND OTHER AREAS 71 14 1 DESCRIPTION 1002545 Rev K Page 7 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 14 2 REPLACEMENT onerat poitrine Se opas tene bu ie 71 FIGURE 14 1 TYPICAL SKIN REPAIR iit 72 FIGURE 14 2 TYPICAL SKIN REPAIR 73 FIGURE 14 3 TYPICAL SKIN REPAIR ws 74 14 4 BULKHEAD ACCESS HOLES
5. R 2 RELAY Poe 3 11 3 H2 PLMP 2 18 185A BOA 1 R H FLOAT FIGURE 13 5 SCHEMATIC INSTALLATION BILGE PUMPS Page 65 of 91 1002545 Rev K FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 1070 JILVW3HOS M TINVW Z NId OL BIN JLLVWZHUS INI HISLWY 3332 68 DH 6 OL 038 WALSAS 19915 AV H r o dd uny TWINVN HILIMS FIGURE 13 6 SCHEMATIC INSTALLATION SCOOP FILL SYSTEM 1002545 Rev 66 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL SCOOPS 1 GREEN SEE AUX INSTR PANEL DWG 7B3 4368 FOR WIRING SCHEMATIC NOTE AIRCRAFT S N EFFECTIVITY 29 194 199 HY DRAULIC PRESSURE SWITCHES FIGURE 13 7 SCHEMATIC INSTALLATION PROBE POSITION Page 67 of 91 1002545 Rev K BOSS CONVERSION ON 10000 SERVICE MANUAL 3111 53 1 I EF I8L ONIMVA 355 01 3LVIANTINNV NI 43148 69 7 INIMVeK 33S v x 1 2 TANVd DIITIV 19 M v1 H HIHN 16 281 ONO 338
6. 995 NIVW WIR NVA 301715 DL ONTLIANNOD 0 331 835 SOSNAS N wv ASSIS Aa SAO 9 9 ADIS 135 HYLLY 1708 eM NOSNAS L3NEIVW AS 133 22071 MDS 13 Od FIGURE 2 4 CARRIAGE ASSEMBLY MAIN GEAR Page 33 of 91 1002545 Rev FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL E 6227 14 O RING METERING PIN Ber LOWER CAP 4115B01TP037 T SEAL PISTON 4115B001TP037 T SEAL OUTSIDE RETAINER PISTON OUTER CYLINDER 4115B001TR035 T SEAL INSIDE RETAINER 5 2 METERING TUBE RETAINER CAUTION REMOVE PRESSURE VALVE BEFORE DIASSEMBLY BEARING 1 OK UPPER CAP 5 AN622789 FILL PLUG 2 4115 001 035 T SEAL A FIGURE 2 5 ASSEMBLY MAIN GEAR SHOCK STRUT 1002545 Rev Page 34 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL SC ZCCBNV AJANI TAI LaQdallS V3H3 IIB 3DNV H SHONITTMO 13V NILLI 17183 NIN 0 vcC LCCDNY CAVANDA 3UNV H VIE SLLBCSW elddIM NOTAN DNILLId Sant 29m WALNd8 5011 05 1 30115 X30 DH 30115 LYASNI FIGURE 2 6 ASSEBLY M
7. e 5 0 2 8 gt gt d eo 2 3 z wo lt 8 zl N N 8 m e a IOS S m 2 65 58 A 25 2 5 6 a 6 A 5 NMOG LSNray 38084 1snrav FIGURE 4 2 ASSEMBLY CYLINDER PROBE JACK 1002545 Rev K Page 47 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 5 0 FOAM DELIVERY SYSTEM OPERATION REMOVAL AND SERVICE 5 1 DESCRIPTION AND OPERATION Full operating information of the entire foam system is described in Introduction Section 1 7 The foam system schematic is shown in figure 5 The main 18 gallon firewall foam tank that feeds the hoppers is stock Air Tractor system The 18 gallon firewall tank has been modified to allow foam from the float tanks to refill that tank A fluid level gauge also has been added Each float has a 30 gallon tank that pumps into the firewall tank 5 2 ADJUSTMENT AND TEST No adjustment is necessary for this system When pumps are running a pump on light is located on the auxiliary instrument panel 5 3 REMOVAL OF FOAM SYSTEM To remove tank from float disconnect electrical plug and hose coupling from tank edges Lift from center handle and the tank from the float through top deck Tank should have small amount of foam in for ease of removal The tank floor may now be removed through top deck The 18 gallon firewall tank is a standard A
8. 403 vecv 13L SMO JAS FIGURE 13 10 SCHEMATIC INSTALLATION WATER IN FLOAT SENSORS 1002545 Rev K Page 70 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 14 0 REPAIRING FLOAT HULL SHEET METAL BULKHEADS AND OTHER AREAS 14 1 DESCRIPTION The float hull is manufactured from the following aluminum alloys Forward Top skins 040 in thick 6061 T6 aluminum Side skins 040 in thick 6061 T6 aluminum Center Top and Side skins 063 in thick 6061 T6 aluminum Aft Top and Side skins 040 in thick 6061 T6 aluminum Bottom skin sister keel to keel 063 in thick 6061 T6 aluminum Bottom skin sister keel to chine 050 in thick 6061 T6 aluminum Nose Bulkhead 100 in thick 6061 T6 aluminum Bulkhead aft wheel well 063 in thick 6061 T6 aluminum All remaining bulkheads 040 in thick 6061 T6 aluminum Main strut panel 125 in thick 6061 T6 aluminum All hull external and internal parts may be purchased from Wipaire parts department Damage to any of the sheet metal including but not limited to skins and bulkheads may be repaired per Figures 10 1 through 10 3 or any acceptable repair method listed in FAA Advisory Circular 43 13 14 Any float hull sheet metal or part thereof can be purchased from Wipaire to aid in repair To simplify repairs the skins may be ordered precut Skins may be reattached to extrusions by method shown in figures 10 1 through 10 3 NOTE There are many ways to
9. Sa 0 AROUND PATCH i T 20 QU A ix y Eg SPACED lt 2 0 MAX ap MEINE L 0 USE 48470 OR AN456 AD4 RIVETS IN SKIN 4 20 40 TYP EB SPACED SEALANT AROUND PATCH 1 0 00 122 2234 72 4 QU ut 4 20 x OK 3 0 SPACED 17s DENM 2100 USE AN470 AN456 AD4 RIVETS HOLE IN SKIN 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 TS SENEC FIGURE 14 3 TYPICAL SKIN REPAIR Page 74 of 91 1002545 Rev K FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 14 4 BULKHEAD ACCESS HOLES During extensive float maintenance it may be desirable to cut an access hole in a solid bulkhead to enable replacement of neighboring float structure This type of access hole can be cut and then repaired according to figure MIN 6x D A o ALLOWABLE AREAS TO CUT MAINTENANCE ACCESS HOLE MAX 2 ACCESS HOLES PER BULKHEAD NOTE S 1 ACCESS HOLES MAY BE CUT FOR THE PURPOSE OF MAINTENANCE 2 MAX 2 ACCESS HOLES PER BULKHEAD 3 RIVET PATCH OVER ACCESS HOLE ONCE MAINTENANCE IS COMPLETE 4 PATCH MUST BE OF THE SAME OR STRONGER ALLOY 6061 T6 OR 2024 T3 WITH THE SAME THICKNESS
10. BS lt lt 5 am ae gt J m FIGURE 14 5 GUNWALL EXTRUSION REPAIR 1002545 Rev K Page 77 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL Es IVIGHLVN JdalvdIM 91 1909 VIBS3IVN DS ne I 1 SL C IVN3d1X4 WSS JJI 5 FIGURE 14 6 FORWARD CHINE EXTRUSION REPAIR 1002545 Rev Page 78 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL LJ dAL S SL108 V8 ENV HLIM NIVW OL 051708 SI 41315 ASHSVM 01 096 JaIVdIM WDIBH 5 38 AVW dIALS ASHSVM 107 08BNY 081 0 WANIWITIY 91 1909 OL T 0671 451 FIGURE 14 7 MAIN KEEL EXTRUSION REPAIR 1002545 Rev K Page 79 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 1 2 5 m LANI gt 2 3 mm Ln EN wm m D lt l U m f gt SPLICE SEAM EXTERNAL ha CYP FIGURE 14 8 KEEL EXTRUSION REPAIR Page 80 of 91 1002545 Rev K FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL WAS JJI 145 CAL SL
11. FIRE BOSS SERVICE MANUAL For FIRE BOSS AT 802A CONVERSION on WIPLINE 10000 MODEL FLOATS 1700 Henry Ave Fleming Field South St Paul MN 55075 U S A PHONE 651 209 7191 Mobile 651 253 7172 Fax 651 457 7858 EMAIL info firebossllc com www firebossllc com FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL THIS PAGE BLANK Page 2 of 91 1002545 Rev K FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL LOG OF REVISION No PAGES DESCRIPTION DATE A 2 3 38 39 Added info to 10 2 added alternate inst panel updated 05 25 04 Table of Contents B 39 46 Added info on AOA system maintenance and figure 9 4A 11 16 04 15 16 19 29 3 Changed some p n in drawings added instructions for 12 5 05 2 50 solenoid valve service and modified drawings D 11 66 Added an inspection time limit and tolerances for the Nose 4 18 06 Block Track wear E 23 Figure 2 5 Main Gear Shock Strut changed to reflect use 5 12 06 of T Seals instead of O rings F 16 21 Added main gear oleo shock strut servicing information 1 1 08 5 6 14 15 18 Revised oleo shock strut information Added enhanced 6 25 09 23 float cleaning and corrosion information H 68 72 Added information regarding rivet replacement to Section 11 22 10 12 Added guidance and Figure 11 7 regarding allowable maintenance holes in the float bulkheads J Cover page Updated cover page telephone numbers 10 8 12 79 81 82 83 Changed 200 hr Insp
12. NDVI 1IHJMIJ V S Dl 21 ead 09 ed Sd FIGURE 13 8 SCHEMATIC INSTALLATION 60 AUDIO 1002545 Rev K Page 68 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL SEE DWG 701 4254 LITE INSTALLATION 2 5 L PRESS TEST LIGHT ENGINE CR YAUN D TED e CHPLE AL RED 10 AUDIO WARNING POR 60 5 A WARN ANN ITT FACTORY SUPPLIED INSTALLATION ITT EXCESS POWER LIGHT FIGURE 13 9 SCHEMATIC Page 69 of 91 1002545 Rev BOSS CONVERSION ON 10000 SERVICE MANUAL II Ed OL 97 dAV divin T I Dae peer eS 8 1 1 s 1 09 l 1 B I e L T I 1 I N 1 I 1 I Nan 2 V I AY Ha 1YOH IUS 1 4 1 1 1 1 1 1 1 1 I I 1 1 1 BAD SS EI E TI 1831 DL 5538 4 2 Kt its imu 181 IRIS 1431 NIH 82 9 9 17 9 WEW __ 5 099091 LIVTIVISNI 3111 c ADSNAS 1
13. ei 75 FIGURE 14 4 BULKHEAD ACCESS HOLES eee 75 14 5 REPAIRING FLOAT HULL EXTRUSIONS KEEL CHINE ETC 76 FIGURE 14 5 GUNWALL EXTRUSION REPAIR eee 77 FIGURE 14 6 FORWARD CHINE EXTRUSION REPAIR 78 FIGURE 14 7 MAIN KEEL EXTRUSION 79 FIGURE 14 8 KEEL EXTRUSION een 80 FIGURE 14 9 AFT CHINE EXTRUSION 47 81 15 0 CONTINUED AIRWORTHINESS 5 ic orbs Pei 82 SERVICE SCHEDULE toast 82 16 0 WEIGHING PROCEDURES FOR THE AT 802 FIRE BOSS AMPHIBIAN 90 Page 8 of 91 1002545 Rev K FIRE BOSS CONVERSION 10000 SERVICE MANUAL INTRODUCTION This manual describes the general servicing and maintenance for the Model 10000 float on the Air Tractor AT 802A aircraft It includes hull landing gear and scooping systems For services and repairs not covered by this manual contact Wipaire Customer Service 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 technical support or parts sales call write or email Wipaire Inc Customer Service 1700 Henry Avenue Fleming Field South St Paul MN 55075 651 306 0459 Fax 651 306 0666 Website www w
14. however they provide a good reference for different flap settings in ensuring the flap sensor is calibrated 10 0 AIRCRAFT WING AND CONTROL SURFACE MODIFICATIONS 10 1 DESCRIPTION AND OPERATION The wing leading edge and the leading edge of the horizontal stabilizers have vortex generators installed Each wing leading edge has 63 generators and each horizontal stabilizer has 21 generators If one falls off replace it according to the drawing instructions The horizontal stabilizer is modified for installation of vertical finlets Each stabilizer has 2 finlets one on the topside and one on the lower side a total of 4 per aircraft The elevator servo tab has been modified to add 1 0 inch to the cord of the tab 10 2 MAINTENANCE VORTEX GENERATORS Inspect wings and horizontal tail for missing vortex generators No two adjacent generators may be missing on any wing or horizontal stabilizer Any missing generators must be replaced as soon as possible FINLETS 50 hrs Perform a visual inspection of auxiliary finlets and struts if installed Clean the area inspect auxiliary finlet installation for missing gaskets and loose bolts or cracks in attach fittings if struts are installed inspect the strut and attach fittings for loose bolts or cracks inspect the area of the stabilizer around mounting holes and doublers for cracks or loose rivets Page 54 of 91 1002545 Rev K FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL is accepta
15. 1002545 Rev K FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 6 3 HEMOVAL OF THE SYSTEM s inated o pere ie 50 6 4 SERVICE BILGE SYSTEM Hed to a REM E 50 7 0 VENT AND OVERFILL PROTECTION SYSTEM 50 7 1 DESCRIPTION AND OPERATION tea een ee 50 1 2 ADJUSTMENT ANB TES n T Ue oet 50 7 3 SERVICE OVERFILL VENT SYSTEM eir re hte ptr re 50 8 0 FLOAT STEERING AND RETRACT SYSTEM eene 51 8 1 DESCRIPTION AND OPERATION eno tr u 51 8 2 ADJUSTMENT uiii eet oaa dt 51 8 3 REMOVAL AND ACCESS ril Precor een bene te Eae MERE 51 8 4 SERVICE OF STEERING AND RETRACT SYSTEM 51 FIGURE 8 WATER RUDDER STEERING AND RETRACTION SYSTEM 52 9 0 ANGLE OF ATTAGK SYS asua a Pee ed 54 CNET pull c DU 54 9 2 MAINTENANCE sineta tet tL et pesto 54 10 0 AIRCRAFT WING AND CONTROL SURFACE MODIFICATIONS 54 10 1 DESCRIPTION AND OPERATION 54 10 2 54 11 0 AUXILIARY INSTRUMENT PANEL eem 56 11 1 DESCRIPTION AND OPERATION rorem rete 56 FIGURE 11 1 INSTRUMENT PANEL ide oret ote denote aem tee rta ced 57 FIGURE 11 1 INSTRUMENT PANEL CIRCIUT BREAKER
16. 2 and LPS 3 LPS Industries Page 82 of 91 1002545 Rev J FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL Wheel Bearings Main Gear Retract Mechanism Nose Gear Pivot and Rod Ends HCF Grease P N 605 HCF Industries Green Grease Multi Purpose Green Grease Inc Aviation Grease SHC 100 ExxonMobil Aviation Lubricants Rust Protection Boeshield T9 Rust Protection Boeing Company ACF 50 Rust Protection Corrosion X Corrosion Technologies Corporation 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 Telflon Spray 6P 730A Comet Industries Hydraulic Fluid Mil H 5606 Electrical Insulating Compound Dow Corning 4 DC4 Dow Corning Corporation 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 1002545 Rev M Page 83 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL INSPECTION TIME INTERVALS 15 2 HOURS MECHANIC INSP 2550 100 ANN Float Float General Placards Hulls amp Float Installation Float exterior Inspect for damage Struts wrinkled metal corrosion p
17. 2 dalIVdIM 80 WINIWIIV 91 1909 18 Wa dalvdlM FIGURE 14 9 AFT CHINE EXTRUSION REPAIR 1002545 Rev K Page 81 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 15 0 CONTINUED AIRWORTHINESS 15 1 SERVICE SCHEDULE As coded in the Inspection Time Intervals chart in this section there are items to be checked each 25 50 100 hours and annual 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 accomplished When conducting an Annual inspection the 25 50 100 and Annual items would be accomplished Below is a list of recommended lubricants and protection products when servicing float hull amphibious components and fire bombing equipment This lists products used by Wipaire during assembly of the floats There may be equivalent products just as satisfactory for protection However it is recommended if trying different products to inspect them frequently so as to determine their effectiveness Protection of nuts bolts hydraulic lines or metal surfaces Dinitrol AV30 Dinol Group CRC SP400 Soft Seal CRC Industries General Lubricants LPS 1 LPS
18. 40 4 0 SCOOP SYSTEM OPERATION REMOVAL AND 43 4 1 DESCRIPTION AND 43 4 2 ADJUSTMENT AND TEST u rre rer rrt eite t wen th aychan 43 4 3 REMOVAL OF SCOOP AND FILL 6 43 44 SERVICE SCOOP SYSTEM s ite ga t RE bebe ha teer uet en 44 4 5 SERVICE OF SELONOID VALVE SCOOP 44 4 6 SERVICE OF IN LINE FILTERS SCOOP RETRACTION 44 FIGURE 4 1 ASSEMBLY SCOOPING SYSTEM COMPLETE 45 FIGURE 4 ASSEMBLY SCOOPING SYSTEM 46 FIGURE 4 2 ASSEMBLY CYLINDER PROBE 47 5 0 FOAM DELIVERY SYSTEM OPERATION REMOVAL AND SERVICE 48 5 1 DESCRIPTION AND OPERATION Ree ctt t et et es 48 5 2 ADJUSTMENT AND TEST been bx 48 5 3 REMOVAL FOAM SYSTEM i eror etr eur een ee eu ERE ERE oA 48 54 SERVICE FOAM SYSTEM wis eet eode paite to 48 FIGURE 5 SCHEMATIC PLUMBING FOAM SYSTEM 49 6 0 FLOAT SYSTEM OPERATION REMOVAL AND SERVICE 50 6 1 DESCRIPTION AND OPERATION 50 62 ADJUSTMENT AND TEST 50 Page 6 of 91
19. AS THE ORIGINAL PANEL OR ONE GAGE THICKNESS GREATER 4 USE SOLID RIVETS OF SAME DIAMETER AS EXISTING RIVETS OR 1 SIZE LARGER ALTERNATELY USE CHERRY MAX OR EQUIVALENT FASTENER OF SAME DIAMETER OR 1 SIZE LARGER KEY D DIAMETER RADIUS FIGURE 14 4 BULKHEAD ACCESS HOLES 1002545 Rev K Page 75 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 14 5 REPAIRING FLOAT HULL EXTRUSIONS KEEL CHINE ETC All extrusions in the float hull are formed 6061 T6 aluminum alloy All extrusions may be repaired by splicing as shown in figures 11 1 through 11 5 Sections of extrusion for splicing may be purchased from Wipaire in any length needed Skins may be purchased pre cut to simplify repairs There are many ways to repair Wipline floats and each method depends on the degree and location of the damage The following figures are examples of some repairs For additional help contact the Wipline float factory at 651 451 1205 Page 76 of 91 1002545 Rev K FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL SL 4 T m me eg ea H gt m zm 79 I m 2 gt 2 lt Tu 556 gt gt ii T1 UJ 79 IT 70 s E 5 2 24 a 00 70 m LJ CO lt m iR 70 70 70
20. GEAR REMOVAL AND DISASSEMBLY 2 8 1 REMOVAL OF MAIN GEAR OLEO Jack the aircraft by method described in section 1 2 With main wheels off the ground both sides run the gear up so that the main carriage is approximately 2 inches forward of down lock position This must be accomplished to remove the top oleo bolt In order to remove the lower bolt it is necessary to remove the wheel on the head side the 2 8 2 REMOVAL OF MAIN GEAR RETRACTION CYLINDER Relieve pressure in system place gear selector handle in neutral position lever between up and down and remove hydraulic lines Remove end cap from end of cylinder Drain fluid Remove forward end of cylinder from bulkhead flange Remove both cylinder support rings from the bulkhead NOTE Piston to be in the up position for cylinder removal Remove cylinder from piston and up through top float inspection cover To remove piston remove top inspection cover on top forward end of gear tunnel accessible from top float inspection cover forward of step Pull back piston to expose top of carriage in center of access cover Remove 25 dia retention bolt Remove piston by pulling aft See figure 2 6 for part breakdown 2 8 3 REMOVAL OF MAIN GEAR DRAG LINK Remove drag link from trunnions on step bulkhead Axle is heat shrunk to drag link and is not removable 2 8 4 REMOVAL OF NOSE GEAR TROLLEY ASSEMBLY FROM NOSE BOX Gear must be in down position Unbolt the spring from the trolley
21. TEST LITE WATER BRT DIM SWITCH IN FLOAT SWITCH FOAM FILL LEVEL SELECT THIS PANEL FOR AIR TRACTOR S N 172 AND LOWER LITE ENGINE POWER ANGLE OF ATTACK DISPLAY LITE ASYMMETRICAL SCOOP AOA DIM SWITCH LITE WATER IN FLOAT 61 1245 SWITCH 25F 1535 LITE GREEN 25F1536 LITE AMBER 3 11 404 MOM SWITCH 1 1250 BRT DIM SWITC 61 1248 SWITCH SCOOP POS SWITCH RHEOSTAT 2312 0001 FILL SYSTEM DISPLAY C312 0003 OUTPUT CABLE C312 D002 BREAKOUT CABLE STANDARD COMPASS LOCATION 2SF1536 LITE AMBER 2 23 307 SWITCH FOAM THIS PANEL FOR AIR TRACTOR S N 173 AND UP FIGURE 11 1 INSTRUMENT PANEL 1002545 Rev K Page 57 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL RT FOAM PUMP LT FOAM PUMP LT BILGE PUMP RT BILGE PUMP ITT WARNING ANNUN LT FLOAT WATER SENS AOA RT FLOAT WATER SENS SCOOP SYSTEM FIGURE 11 1 INSTRUMENT PANEL CIRCIUT BREAKER Page 58 of 91 1002545 RevK FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 13 0 ELECTRICAL 13 1 Figures 13 0 through figure 13 1 show the electrical schematic for the auxiliary instrument panel along with electrical schematics for each noted system 1002545 Rev K Page 59 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL _ PANEL LILIES NWMLI
22. X Water Perform Retraction Test For probe down position inspect for proper Pickup seating and alignment of tubes Probes X Inspect for speed of retraction approximately one second X Inspect for any leaks in probe jack cylinder X Inspect float area around probe opening for any damage X Auxiliary Finlets Remove and inspect per Section 10 2 X Visual Inspection per Section 10 2 X 1002545 Rev K Page 87 of 91 FIRE BOSS CONVERSION ON 10000 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 dents 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 1002545 Rev K Page 88 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL Bolts in Critical Areas For corrosion correct torque when installed or when visual inspection indicates a need for a torque che
23. a small amount of lost motion of the actuator rod Retraction takes place when pressure is exerted on the actuator piston driving the collar along the slide tube The lock is tripped when the follower slides up the contoured track in the actuator as shown in figure 2 4 A reverse process causes extension Gear position light proximity switches are closed when the appropriate hook containing the magnetic material nests over the locking bar Page 18 of 91 1002545 Rev K FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL Shock absorption for the main landing gear is provided by a hydraulically dampened air spring Figure 2 5 shows the main components The oil and air share a common chamber When the oleo is collapsed the oil is forced through the main orifice compressing the air in the upper cylinder Extension reverses this process The extended oleo is initially set at the factory to 250 psi no load In field adjustment of air pressure and oil volume is described in section 2 2 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 as shown in figure 2 9 Gear position light proximity switches are closed when the piston containing the magnetic material has reached either end of its travel The nose gear consists of composite fiberglass beams that are attached at the bottom to castering blocks Inside the block is a
24. 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 A spring loaded ball rides in a groove machined in the castering pin This groove has a round pocket on the back face with the result that the cam provides retention of the pin the block and self centering of the wheel A thrust bearing is on top of the castering pin along with a lower bearing 2 2 SERVICE NOSE GEAR The nose gear pivot assembly should be cleaned and greased every 25 hours or more frequently whenever in water for extended period of time Nose gear tracks to be lightly greased Apply grease to a cloth on a stick or rod and run along tracks inside of the nose box both sides The nose gear pivot bearings are matched to bearing and race If replacement is necessary replace entire bearing The nose wheels contain grease zerks for the wheel bearings They should be greased every 25 hours Nose tires are standard 6 00 x 6 8 ply inflated to 50 5 psi 2 3 NOSE BOX TRACK WEAR Due to the wear the roller slide block places on the track as the gear are retracted the block needs to be measured for the amount of wear The tolerance for wear is 070 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 070 inches the block must be replaced This check is to be done every 200 hours and
25. is part of the maintenance checklist On the 10000 Series Floats Gear Track P N 13A07104 001 LT 002 RT 2 4 SERVICE MAIN WHEELS AND BRAKES Grease nipples 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 grease is recommended The dual piston 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 Although since the line is T ed to the double 1002545 Rev K Page 19 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL brake one must remember to bleed one segment of the Y first then finish the entire job through the remaining segment Main wheel tires are standard 8 50 x 10 8 ply type Ill aircraft tires inflated to 50 5 psi Refer to figure 2 10 2 5 SERVICE MAIN GEAR OLEO Oil Level The correct level is best set by draining and refilling with the correct quantity of fluid 1900 ml This should be done with the oleo removed from the float CAUTION Release air pressure and remove air valve before attempting to service oleo After filling refit valve and cap then pressurize to 250 psi Note Use only MIL H 5606 hydraulic fluid Air Pressure The correct air pressure is 250 psi 10 psi on a fully extended oleo no load or it can be inflated to approximately 3 4 inches on an unloaded
26. reactivate the circuits Troubleshoot hydraulic problem per section 3 1 1 3 3 LANDING GEAR OPERATION To retract or extend the landing gear pull out on the landing gear handle and move it to the desired position When the handle is positioned pressure on the hydraulic system reduces to where the hydraulic motors automatically turn on The motors power the hydraulic pumps and actuate the gear actuator for each gear During operation of the landing gear motors the PUMP ON 1 and 2 indicator lights are illuminated When the gear cycle is completed pressure builds up in the hydraulic system and automatically shuts off the hydraulic motors Each gear operates independently of the other and therefore the position lights illuminate at various times 1 3 4 EMERGENCY PUMP HANDLE An emergency hand pump is located on the floor to the left side of the seat for use in the event the normal hydraulic system fails This hand pump may be used to retract or extend the land gear Prior to utilizing the emergency hand pump pull the AMPHIB PUMP 1 and 2 circuit breakers to deactivate the electric hydraulic pumps Select UP and DOWN using the normal landing gear selector handle Pump the attached handle back and forth approximately 400 cycles When a gear reaches the selected position its indicator light will illuminate After all four 4 gears are in the selected position there is a noted increase in resistance of hand pump operation 1002545 Rev K Page 1
27. repair Wipline floats and each method depends on the degree and location of the damage The following figures are examples of some repairs For additional help contact Wipaire customer service at 651 306 0459 14 2 RIVET REPLACEMENT There are instances during float repair where replacement of solid rivets is not practical For these occasions Wipaire has composed a list of acceptable fastener substitutions Solid rivets may be replaced by the following 1 New solid rivet of the same or greater diameter 2 CherryMax blind rivets of equal or greater diameter 3 HuckLok blind rivets of equal or greater diameter 4 Hi Lok fasteners of equal or greater diameter NOTES 1 When installing any structural fasteners edge distance and rivet spacing guidelines per AC43 13 1B should be followed at all times 2 In areas where solid rivets are smoking or missing blind rivets are acceptable short term solution but should be replaced with solid rivets or Hi Lok fasteners or equivalent 3 Follow fastener manufacturer guidelines for installation 1002545 Rev K Page 71 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 52 30 iia 1 SPAC
28. the event of leakage of the float hull adjacent to the probe these pumps will automatically pump water overboard in that float compartment Also in that float compartment a water sensor indicator is located When this indicator senses water a light on the auxiliary instrument panel will light 6 2 ADJUSTMENT AND TEST No adjustment is necessary for this system When pumps are operating A light for the right float and left float will illuminate on the auxiliary instrument panel When water is present in the float compartment forward of the step the sensor will illuminate a light on the auxiliary instrument panel 6 3 REMOVAL OF THE SYSTEM To remove pumps from the float remove access covers on each float side just forward of the step and remove pumps Two pumps are located in each float 6 4 SERVICE BILGE SYSTEM The bilge pumps are not serviceable and cannot be overhauled Be sure pumps are not plugged and free of debris Check all hoses for obstructions and condition Check that the pump on lights are working Submerge water sensor in water to check for light operation 7 0 VENT AND OVERFILL PROTECTION SYSTEM 7 1 DESCRIPTION AND OPERATION On the top aircraft hopper door aft side is a domed shaped overfill relief door This door is hinged and spring loaded to blow open in the event of a tank overfill The spring tension is pre set by cable length To open the door by hand release the handle from its holder and pull forward to
29. to Annual Insp K 12 16 19 23 Added additional information regarding Spin On Filter 8 21 14 25 40 44 assembly including inspection intervals updated 54 55 83 85 numbering in Section 1 and added Means for Leveling 87 Section 1 10 Added green grease as approved grease corrected Hyd fluid level and air pressure Updated maintenance instructions 10 2 Modified finlet inspection requirements and added Visual Inspection L 83 89 Added Shear Torque Chart PR 1440 C Sealant and 5 26 2015 Tef Gel M 3 17 83 89 Added Dow Corning 4 Corrosion X and Mobil Aviation 12 4 2015 Grease 100 to approved product list Modified torque limit section 1002545 Rev M Page 3 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL THIS PAGE BLANK Page 4 of 91 1002545 Rev K FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL TABLE OF CONTENTS SECTION PAGE E GIOP REVISION a Sau er MEI Mn LATA d 3 9 GENE RAs siemens I MEME 9 9 10 1 2 1 FLOAT HULL 11 1 3 AMPHIBIAN LANDING GEAR 12 1 3 1 LANDING GEAR HANDLE LLL ttt ttt tas 12 TPS INDICATOR LIGHTS uu 13 1 3 3 LANDING GEAR OPERATION 13 1 3 4 EMERGENCY PUMP
30. 0 SERVICE MANUAL NOSE SPRING RETAINING STOP BEARING PLATE DETENT BALL BUSHING TOP THRUST BEARING SPRING COVER LOWER BEARING PIVOT PIN AND AXLE BLOCK ASS Y HEAT SHRINK FIT NOT REMOVABLE NOSE FORK LEGS SPACERS 6 00 X B 8 PLY TIRE FIGURE 2 10 ASSEMBLY NOSE GEAR LOWER END 1002545 Rev K Page 39 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 3 0 HYDRAULIC PUMP SYSTEM DISASSEMBLY AND SERVICE The hydraulic pump is factory preset to the following pressures Pressures switch operates below 525 psi and shuts off at 1250 psi The pump also has an internal relief valve that opens at 1450 psi and a thermal relief valve that opens at 2000 psi These pressures are set with factory test equipment and are recommended to be sent back for overhaul or repair The unit may be disassembled for cleaning 1 Relieve the pressure in the hydraulic system by placing the gear selector handle in the neutral position 2 forward lower side of the reservoir remove drain plug to drain most of the hydraulic fluid NOTE Due to the confines of the hydraulic power pack installation the power pack will need to be lifted up and supported with a ratchet strap or something like it while loosening up the clamps that will attach it to the aircraft tubing This will lift the assembly up far enough to remove the reservoir 3 Remove the 4 s
31. 1 1 1 T 33 26 END Le Sad B D SWITCH LL RS FIGURE 13 0 SCHEMATIC AUXILIARY INSTRUMENT PANEL Page 60 of 91 1002545 Rev FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL BUSS CONNECTOR 20 GA FILL SYST 20 GA 20 GA RR WARN 5A ANN 20 GA ITT 8 GA LH 2 RH 8 GA Te FOAM 8 GA P RH BLGE 8 GA LH BLGE _ LH 20 sh WATER 1A SENS RH a WATER SENS BUSS BAR CIRCUIT BREAKER PANEI FIGURE 13 1 SCHEMATIC CIRCUIT BREAKER PANEL 1002545 Rev K Page 61 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 1 3 AUDIO PANEL 24 GA LINMITED AUDIO VANE SENSOR 0 1 WHT 8 BLK 2 FLAP SENSOR RED 7 WHT 3 BLK 8 2 1 LOGIC MOUDULE ADA DISPLAY FLAP DISPLAY SET BOX FOR SET UP FIGURE 13 2 SCHEMATIC INSTALLATION ANGLE OF ATTACK 1002545 Rev 62 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL MODULE e C FLAP SENSO BOX C N 677 1429 FLAPS UP 1204 910 EAE D 2242 205 1 FLAPS 1110 1010 FLA A 375 T1590 28 4 19 13599 FIGURE 1
32. 3 3 A AOA FLAP CALIBRATION READINGS 1002545 Rev K Page 63 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 2 279707 1 1 1 1 1 l 9 1 1 1581 DI 5394 OL l 1 1 1 Ca E AQ ae E 4 t aaa 1 Wid d30V3H INTH 14905 45 1 kl v 1 1 Fed 1 815 LHOTA EXE 50 I mys H 1 ays AS 734357 12 1 l 1 8 1 5 1 1 B LT T AS D B 81 I 8 9 1181 1397 1 4 Ea yo ve TW CERIN 344 Id 1 41 FIGURE 13 4 SCHEMATIC INSTALLATION FOAM TANKS PUMPS 1002545 Rev K Page 64 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL L H FLHAT 22 22 PRESS TEST LIGHT
33. 3 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 1 4 SCOOP SYSTEM The Wipaire 802 Fire Boss has two water scoops one in each float The scoops are three inches in diameter and are hydraulically operated by the 1000 psi float hydraulic system The hydraulic system has an accumulator to enhance the speed of scoop deployment and retraction The scoops complete down or up cycle in approximately one second A trigger switch located on the front of the control stick grip controls the scoops Pulling in the top of the trigger switch puts the scoops down Releasing the trigger switch puts the scoops back up pulling on the bottom of the trigger switch operates the smoke system see Air Tractor Flight Manual The scoop system master switch is located on the glare shield panel and has three positions auto off and manual When manual is selected the scoops move to the down position and remain there as long as the trigger switch is depressed when the trigger switch is released the probes move back to the up stowed position CAUTION In the manual position it is possible to overflow the hopper When auto is selected the pilot may select how many gallons he wants to scoop by rotating the fill level selector knob located to the right side of the hopper quantity and fill level readout window hopper quantity is on the top reading and the selected fill level is on the bottom When the quantity reads approximately 255 gallons the hopper empty t
34. AIN GEAR ASSEMBLY Page 35 of 91 1002545 Rev FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL WHEEL GREASE INNERT BEARINGS WHEEL GREASE INSERT AXLE DRAG LINK ASS Y AXLE HEAT SHRINK FIT NOT REMOVABLE FIGURE 2 7 ASSEMBLY MAIN GEAR DRAG LINK Page 36 of 91 1002545 RevK FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL BAHA 9110 WAS eain hw SOS aJNIVIdB8 ISYA 13357 SONIBV38 AINNI JanL WAS AINNI JIL Ald 01 058 JH AINNI Vd 2510 548 vd 3lV d 8 Dad 36 FIGURE 2 8 ASSEMBLY MAIN GEAR WHEEL AND BRAKE Page 37 of 91 1002545 Rev K FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL BULKHEAD MOLNTING FLANGE ORIENT SLIDE BLOCKS RING AN6227 30 AS SHOWN FLANGE CYLTNDER BIDY RING 528775 314 RING ANE227 30 0 WIPER FELT l RING 207 23 MOUNTING FLANGE CYLINGER PLATE FLANGE NISE BOX a RAM NISE GEAR RING PISTON 6227 24 JAMB NUT SPACER LP STOP ROD ROO END RAM RUD RETAINING ROLLER 2 DOW SNAP RINK 2 TROLLEY AXLE AXLE LINK NOSE GEAR TROLLEY NOSE GEAR TRACK LINK RAM SLIDE BLOCK 4 FIGURE 2 9 ASSEMBLY NOSE GEAR BOX AND RETRACTION 1002545 Rev Page 38 of 91 FIRE BOSS CONVERSION ON 1000
35. ATION Retraction and extension of the main and nose landing gear is effected by a hydraulic actuation system shown schematically in figure 2 1 The gear system is hydraulically actuated and driven by two hydraulic pumps located in the fuselage station 159 5 A pressure of between 525 and 1250 psi is maintained in the supply line When the pressure falls below 525 psi the pressure switch activates the pump solenoid providing power to the pump When the pressure reaches 1150 1250 psi the pressure switch deactivates the solenoid and the pump motor stops Figure 2 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 internal relief valve which directs oil back to the pump reservoir when the line pressure exceeds 1450 psi The system also has an internal relief valve to protect against thermal expansion when line pressure exceeds 2000 psi A cockpit mounted control valve accomplishes the selection of gear up or gear down Each float gear has individual indicator lights on the control valve allowing the pilot to confirm that each gear has fully retracted or extended 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 is mechanically locked in both up and down positions Locking and unlocking is done using
36. DRAULIC SYSTEM AFTER SERVICE 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 You should notice that the reservoir level drops significantly when the system pressure builds as the accumulator is filling with fluid You will have to add more fluid at this time Conversely when opening a connection in the system a discharge of fluid under pressure will occur as the accumulator empties itself Once the accumulator is full the fluid level should be maintained in the upper one third 1 3 of the sight glass 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 cycles check for external leaks Generally the fluid level in the site glass should be about 34 full when the gear is down 2 7 4 HYDRAULIC ACCUMULATOR SERVICE The accumulator is pre charged with nitrogen to a pressure of 225 psi If recharging becomes necessary slower than normal probe retraction time of 1 second Recharge with dry nitrogen gas to a pressure of 225 psi 1002545 Rev K Page 27 of 91 BOSS CONVERSION ON 10000 SERVICE MANUAL 2 8 MAIN AND NOSE
37. LHES 1 28 PIN ah De Mo p 1 TOL FLOAT WATER SENSER GRN PIN 2 m gt 5 TU PLUG P 3 PIN 14 E e 2 FLOAT VATER SENSOR CRN 7 PIN 2 3 TO PRO BO CH AUDIO 9 4 TEST RELAY R 2 P 15 PIN 4 E L FLOAT BILGE 2 PLMP KBRNAWHT2 PIN 5 7 R FLOAT BILGE 1 PLMP CBRNAWHTO 5 PIN 5 TEST RELAY R 2 15 PIN 3 ET g TH SCOOP POSITION PRESS SWITCH P 1 PIN H SV a 10 SCOOP DN POSITION PRESS SWITCH P 1 PIN 14 ON 4 11 12 C B PLUG P 3 PIN 12 K Y EXCESS POVER 14 POR 0 AUDIO 10 D 15 PRESS SWITCH TO ITT TN 16 L FLOAT FOAM PUMP P 4 PIN 95 10 w 17 TU FLOAT FOAM PUMP P S PIN 3 P D 1 1 20 18 OGA m 16 P 3 1 OFF 20 GA 1 20 G 1361 SCOOP SWITCH 1 Anm 1 22 20 20 G m c PIN 1 NANLAL 22 G 27 22GA m scm RELAY 8 3 d NANLIAL 1 22 G 2B 22 G scm RELAY R 3 22 GA 21 22 GA p SV RELAY R 3 RED 43 WIRE FILL SYSTEM DISPLAYS PTT 24 0 22 END 23 RELAY P 15 PIN 1 pO eras 1 25 22 TH PLUG P 3 PIN 11 IE 1 1 TO BILEE LITES 1 1 I I I FOAM RIVP LITES I I I I
38. NDING GEAR HANDLE The landing gear handle controls a hydraulic selector valve within the control unit on the left hand side of cockpit by fuel shut off handle and has two 2 positions UP and DOWN LAND which give a mechanical indication of the gear position selected From either position the handle must be pulled out to clear a detent before it can be repositioned Page 12 of 91 1002545 Rev K FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 1 3 2 INDICATOR LIGHTS Ten 10 indicator lights are mounted on the landing gear control unit adjacent to the landing gear handle Four 4 blue indicator lights labeled NOSE and MAIN left hand lights for the left float and right hand lights for the right float show by their illumination that the landing gear is up and locked The four 4 green indicator lights labeled NOSE and MAIN left hand lights for the let float and right hand lights for the right float are illuminated when the landing gear is down and locked Neither set of lights is illuminated when the landing gear is in transit Two 2 red indicator lights labeled PUMP ON 1 and 2 illuminate when current is supplied to the landing gear motors If the motors continue running during flight or on and off repeatedly the motors should be shut off by pulling AMPHIBIAN PUMP 1 AND AMPHIBIAN PUMP 2 circuit breakers Continual running of the motors can result in premature motor failure Prior to landing the circuit breakers should be pushed in to
39. Relieve the pressure in system place gear selector handle in neutral position lever between up and down and remove rear hydraulic line Remove 4 bolts on forward end of cylinder Drain fluid Pull aft to expose internal piston rod Loosen jamb nut on forward side of cylinder ram at rod end Turn piston from aft side of nose box out of rod end Push on trolley assembly to unlock and remove the bottom thru bolts Slide out of nose box Note On installation adjust piston so it bottoms out on aft flange at the same time as the bearings when nose gear is in locked position Also note orientation of trolley blocks The side with the most edge distance from hole is to go toward each other on inside of trolley See figure 2 9 for details 2 8 5 REMOVAL OF NOSE GEAR BOX Remove bolts securing forward box from nose bulkhead Remove bolts securing aft box from bulkhead 2 Slide box out from front of float Note Sealant will have to be cut for removal and replaced when installing 2 8 6 REMOVAL OF LOWER NOSE GEAR FROM PIVOT BLOCK On top of pivot block remove cotter pin from retaining nut Remove nut On aft side of pivot block remove the 2 cap bolts on 25 thick cover Remove spring This will loosen retaining ball and lower fork will slide out Refer to figure 2 10 for assembly Page 28 of 91 1002545 Rev K FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 2 8 7 TO REMOVE THE NOSE GEAR Remove the nose gear from the nose box by unbolti
40. TIONS AND ENVIRONMENT ARE STRONGLY LINKED TO CORROSION AND MUST BE ADDRESSED PROACTIVELY Page 16 of 91 1002545 Rev K FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 1 9 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 that 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 sanding or chromic acid Moderate and severe corrosion blistering flaking and pitting may be removed by heavy sanding or grinding and applying chromic acid If significant loss of skin material thickness will result in corrosion treatment reinforcement or replacement of the affected area may be necessary After removing the corroded area restore area to original finish prime and enamel BOESHIELD T9 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 gre
41. aint loss etc Struts 8 attach fittings X Spreader bars X Float Structure interior X Foam Compartment Covers and Seals Inspect for condition security operation and excessive wear X Pumper Tube Installation Inspect for condition security routing of hoses X Water Water Rudder Hinges Inspect Rudder freedom of rotation System Water Rudder Steering and Inspect cable pulleys for freedom of Systems Inspect the following rotation cable guard pins for presence cables for broken wire cable fittings for rigging Retract for operations check cable slippage cracks and distortion X Water Rudder Blades and Posts Inspect water rudder bulkhead boots for Inspect for damage security of cracks and wear attachment corrosion paint rigging X Electrical Pump and Indicator Light Wiring System Inspect for chafing broken or loose Gear and terminals and general condition Probe X Solenoids Inspect wiring mounting and general condition X Pressure Switches Inspect wiring mounting and general condition X All Pump Motors Inspect wiring mounting and general condition X X Page 84 of 91 1002545 Rev K FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL HOURS MECHANIC INSP INSPECTION TIME INTERVALS 15 2 25 50 100 ANN RT LT Float Float Landing Lubricate Nose Gear Tracks Systems Nose Gear Box Block Tracks measured slide route for wear 070 inches
42. aircraft while sitting static on level ground Seals Seals should be replaced whenever the oleo is disassembled or leaking CAUTION Release air pressure and remove air valve before attempting to disassemble oleo The seals are standard O rings whose part numbers are depicted in figure 2 5 NOTE When reinstalling the main gear oleo bolts tighten so oleo is free to rotate Shock Strut Servicing NOTE RELEASE PRESSURE IN STRUT BEFORE DISASSEMBLY 1 Disassemble the strut removing both end caps Take apart the gland section and metering pin so the parts can be easily inspected for wear and replacement parts can installed as needed Page 20 of 91 1002545 RevK FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 2 4 Onthe other end install the metering pin with Loctite onto the end cap Inspect all parts carefully after cleaning for wear and scoring especially the piston gland section and the inside of the outer cylinder Also make sure to check the bushings in the end caps for wear and security The metering tube does not need to be taken apart form the end cap of the inside cylinder unless extensive cleaning is desired If it is disassembled a the metering tube height and condition to factory preset first apply blue Loctite to the threads of the inner end cap threads that hold the metering pin for added security until next removal b The metering pin is threaded until the measurement from the floor
43. ase or Paralketone Under saltwater conditions bolts should be removed at least once a year and grease reapplied to the shafts heads and nuts THE ABOVE CLEANING TECHNIQUES ARE VITAL FOR KEEPING CORROSION TO A MINIMUM SALTWATER OPERATIONS AND ENVIRONMENT ARE STRONGLY LINKED TO CORROSION AND MUST BE ADDRESSED PROACTIVELY 1002545 Rev M Page 17 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 1 10 MEANS FOR LEVELING The airplane is leveled to level flight attitude See Float Handling Jacking and Aircraft Towing section of this manual The airplane should be in this level position for aircraft weighing and other maintenance installation items that require the aircraft to be in level flight attitude The airplane is in level flight attitude when the top right next to the side of the fuselage of the L H Main Gear Float Attach Fitting on airplane is at an angle of 5 degrees tail down from level To measure this angle use an electronic level placed atop the Main Gear Float Attach Fitting on airplane On aircraft equipped with the aluminum engine air scoop on the bottom of the cowling non ram air induction system there are two small screws provided on the left hand side of the engine air scoop that provide a level reference When a bubble level is aligned with the heads of these screws the bubble level will indicate level when the aircraft is level 2 0 MAIN AND NOSE GEAR OPERATION REMOVAL AND SERVICE 2 1 DESCRIPTION AND OPER
44. ble to remove small portions of the finlet side skins or sealant adjacent to the attach fittings to enable visual inspection of the fitting up to the weld fillet REMOVE AND INSPECT 100hrs Remove the lower finlet and strut if installed to expose access panel Either remove panel and inspect forward and aft attach points as well as spar corner radius for cracks and corrosion or remove hole plug and use borescope for same Remove upper finlet and strut if installed Inspect all finlets struts and attach fittings for cracks corrosion loose rivets or other un airworthy conditions MISC Inspect elevator servo tab extension for condition and security 1002545 Rev K Page 55 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 11 0 AUXILIARY INSTRUMENT PANEL 11 1 DESCRIPTION AND OPERATION An auxiliary instrument is mounted on top of the landplane instrument panel This panel houses all the switches lights and displays for the water scooping portion of this installation This panel also houses the ITT and Torque gauges for easier viewing Figure 11 1 shows the panel layout along with the circuit breaker panel layout Page 56 of 91 1002545 Rev K FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL LITE GREEN AOA DIM POA PUN FILL SYSTEM DISPLAY ANGLE OF ATTACK DISPLAY SWITCH SCOOP POS SCOOPS UP um TORQUE GAUGE SCOOPS DOWN LITE SWITCH AOA LT BILGE PUMP 2 ITT GAUGE RT BILGE PUMP MOM SWITCH PRESS TO
45. ck 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 Shear Application Torque Limits Tension Application Nut Torque Limits Nut Bolt Size Size 8 36 12 15 8 36 7 9 10 32 20 25 10 32 12 15 1 4 28 50 70 1 4 28 30 40 5 16 24 100 140 5 16 24 60 85 3 8 24 160 190 3 8 24 95 110 7 16 20 270 300 7 16 20 450 500 1 2 20 480 690 1 2 20 290 410 9 16 18 800 1 000 9 16 18 480 600 5 8 18 1 100 1 300 5 8 18 600 780 3 4 16 2 300 2 500 3 4 16 1 300 1 500 7 8 14 2 500 3 000 7 8 14 1 500 1 800 1 14 3 700 4 500 1 14 2 200 3 300 11 8 12 5 000 7 000 11 8 12 3 000 4 200 1 1 4 12 9 000 11 000 1 1 4 12 5 400 6 600 A Torque of 8096 should be used when Tef Gel is applied to the bolt 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 Page 89 of 91 1002545 Rev M BOSS CONVERSION ON 10000 SERVICE MANUAL 16 0 WEIGHING PROCEDURES FOR THE AT 802 FIRE BOSS AMPHIBIAN Level aircraft per manufacturer s instructions Place scales under the right and left nose and main gear wheels Place b
46. crews on each tank 2 on upper side of the reservoir 4 Dump out remaining oil and clean reservoir 5 Unscrew stand pipe with the filter screen attached 6 Clean filter screens 7 If filter screen is removed from stand pipe a new filter screens should be used 8 Reinstall tank and install seals to top of reservoir before installing on pump 9 Install drain plug and fill with clean MIL H 5606 hydraulic fluid through the breather pipe 10 Fluid level should be in the upper 2 3 of the sight gauge 11 Remove and clean all in line 10 micron filters located above and adjacent to the accumulator aft of the hydraulic pumps on the pressure line 12 If the fluid is not a clean red color it should be replaced with new fluid 3 1 OPERATION TROUBLESHOOTING 1 PROBLEM Powerpack does not run after gear selection PROBABLE CAUSE a Circuit breaker has failed b Pressure switch not pulling in at low cut in c Solenoid switch not pulling in d Faulty pump motor e Motor not properly grounded 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 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
47. e Check motor ground Page 40 of 91 1002545 Rev K FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 2 PROBLEM Powerpack does not shut off after gear reaches position PROBABLE CAUSE 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 3 PROBLEM Powerpack shuts off before gear reaches position PROBABLE CAUSE a Binding or jammed gear retractor which causes pressure to build up and stay up and pressure switch shuts off powerpack b Faulty or dirty pressure relief valve allowing insufficient pressure buildup REMEDY a Repair retractor 4 PROBLEM Powerpack cycles on and off after gear is in position PROBABLE CAUSE a Internal hydraulic leak b External hydraulic leak REMEDY a Verify leak is not external by checking fluid level in reservoir and looking at couplings for oil leaks If no external leaks are found disconnect and cap off the hydraulic actuators one at a time and find the leaky one by process of elimination If isolating entire system still indicates internal leak powerpack check valve located in pressure port of pump is bad and needs replacement or reseating b Visually inspect lines cylinders and hoses and replace as necessary 5 PROBLEM Powerpack cycles on and off during gear cycle PROBABLE CAUSE a Binding in retraction unit b Pressure switch cut off lim
48. e factory to ensure that the main gear is locked at the end of each stroke and that correct indication is given on the cockpit console The up and down lock may be adjusted so the lock is fully engaged by adjusting the set screws shown in figure 2 4 Loosen the jamb nut adjust and tighten jamb nut The service intervals on the Main Gear Actuators should be every 25 hours if the aircraft is regularly taxiing on sand and gravel Otherwise they should be cleaned and serviced according to the checklists from the back of this manual Clean the slide tube with clean solvent remove any build up of dry or dirty lubricants Inspect the slide tube for erosion and or nicks and protrusions caused by gravel or debris being thrown by the Main Landing Gear tires Grease the actuator mechanism with HCF grease p n 605 or equivalent and wipe the slide tube down with a clean rag soaked in lubricant The main gear proximity switches are located on each end of the gear stroke The forward switch is located on the forward side of the gear tunnel It is accessible through the top deck access cover The aft proximity switch is located on the float bulkhead just aft of the wheel well accessible though the float top deck cover The main gear proximity switches are adjusted loosening the mounting screws and positioning them as such that the light goes out when the lock hook is raised about 1 8 inch off its nested position and comes on again upon nesting 2 7 3 BLEEDING HY
49. e using hydraulic fluid for lube to prevent damage to the threads a Using a spanner wrench tighten the piston to the inner cylinder b Install the jam nut onto the piston end of the metering tube and stake for security c Install the 2 T seals onto the exterior of the piston and gland and lube with Vaseline 9 Gently clamp the outer tube end in a vise and add 1900 ml of hyd fluid 5606 or equivalent 10 Lube the inside of the outer cylinder where the gland and the piston will rest 11 Install the inner cylinder into the outer assembly making sure that the gland is seated against the piston 1002545 Rev K Page 23 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 12 Re install the center bolts using gasket sealer Page 24 of 91 1002545 Rev FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 13 Install the O ring onto the fill drain plug before installing the plug onto the end cap and tighten 14 Install the O ring onto the Schrader valve and install onto the outside of the end cap NOTE Align Schrader valve 180 degrees from the Placard NOTE Double check the plugs and bolts for proper Installation and security before adding gas charge 15 Fill the strut with nitrogen to 250 psi 10 psi and close the valve and 1002545 Rev K Page 25 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL TN 2 6 SERVICE NOSE AND MAIN GEAR RAMS Lubricate the nose and main gear cylinder mounting
50. flanges with MIL H 5606 Hydraulic Fluid thru the oilers The nose has a flip lip type oiler and the mains have a ball needle type oiler The purpose is to wet the felt wiper so it pre lubes the penetration rams and enables the seals inside to work and not become damaged over time 2 7 ADJUSTMENT TEST 2 7 1 NOSE GEAR 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 at the same time The up stops nests in the up stop bolt See figure 2 9 and 2 10 for locations and assembly Nose gear proximity switches are located on clips that are mounted on the outer cylinder body one on each end The most forward switch is for the gear down lights and most aft is for the gear up 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 Page 26 of 91 1002545 Rev FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 2 7 2 MAIN GEAR The main gear actuator cylinder is not adjustable These are pre set at th
51. g cleanliness and security Check lower attach bolt for wear and lubrication X Hydraulic Lines and Fittings Inspect for leaks condition and security x Hydraulic Manifolds Inspect for condition security and leaks X 1002545 Rev K Page 85 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL Fuselage Frame Inspect fuselage frame tubing Inspect in the areas of front float strut and and float attaching parts for any signs of bending or the main float pylon attach weld cracking X Hydraulic Pump Inspect hydraulic pump Check Hydraulic selector head and hand accumulator assembly and Vickers valve for leaks pump for leaks condition and security condition and security Instrument Panel press 2 test bulbs X Page 86 of 91 1002545 Rev FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL INSPECTION TIME INTERVALS 15 2 HOURS MECHANIC 25 50 100 ANN LT Float Float Brake System Plumbing Inspect for leaks condition and security X Main Gear Oleos Service X Perform Retraction Test Main Gear Inspect up and down for proper engagement X Nose Gear Trolley Inspect for proper travel X Nose Gear Inspect for excessive side play in the down position X Perform emergency gear Extension hand pump X Nose and Main Wheel Bearings Disassemble and inspect
52. gure 4 1 for view of the entire scooping system 4 2 ADJUSTMENT AND TEST The lower probe assembly is set at the factory for full open and close positions Any adjustment necessary to the probe is accomplished by adjusting the probe jack cylinder Figure 4 2 shows a cross section of the cylinder Remove hydraulic lines before adjusting The adjustment for probe full open is the large bushing on the cylinder shaft Loosen the jamb nut and adjust so lower probe seats firmly on upper scoop jamb and not loose Bushing to bottom out on cylinder body at same time probe seats firmly on jamb The cylinder shaft rod end adjusts the up stop Loosen the jamb nut and turn rod end The piston to be bottomed out inside the cylinder is when the scoop is above the lower most part of the main keel by approximately 1 8 After adjustment reconnect hydraulic lines and cycle probe for proper operation Check if probe up and down position lights are operating properly 4 3 REMOVAL OF SCOOP AND FILL SYSTEM Lower Scoop Assembly and Scoop Cylinder Remove attaching bolt for scoop assembly accessible from outside of the float Drop down and disconnect the rod end from the probe jack cylinder For removal of the cylinder remove attaching bolt accessible from outside of the float From inside of the float remove forward top tunnel access cover Remove hydraulic lines and remove cylinder Scoop Tube Assembly Internal Remove access covers on left and right side skins just f
53. h float To use fluid stored in the float tanks it is necessary to pump fluid from the float tank to the fuselage firewall tank This transfer can be accomplished manually or automatically by selecting the appropriate position with the left and right foam control switches located on the glare shield panel When manual on is selected fluid will be pumped via the electric pump located on the top of the tank to the firewall tank Page 14 of 91 1002545 Rev K FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL The pump does not shut off when the tank is full In the event of an over flow fluid would come out of the firewall tank vent fitting located just aft of the front left float strut When auto is selected the float tank transfer pump will come on at approximately 7 gallons of fluid remaining in the fuselage tank It will shut off automatically when the fuselage tank is approximately 2 3 full or whenever the selected float tank has about 2 gallons remaining The left and right transfer systems can be used individually or simultaneously as desired Whenever a foam transfer pump is operating the appropriate green Pump On light will illuminate manual or auto The Pump On lights can be tested utilizing the test switch on the left side of the glare shield panel 1 6 VENT AND OVERFLOW PROTECTION The original 802 hopper vent door has been modified to allow for a greater venting volume during scooping operations The original 3 inch Air Tract
54. he scale starts at that number with auto selected the scoops will go down when the rocker switch is depressed and move back up automatically when the quantity selected is reached with the rocker switch still depressed If the rocker switch is released before the quantity is reached the scoops will move back up Thusly if the pilot wants to abort the scoop operation once it is initiated simply releasing the rocker switch will put the scoops back up such as in an emergency or other unplanned occurrence Scoop up and scoop down lights are provided that indicate scoop position via a pressure switch that illuminates the lights The scoop lights 2 can be tested utilizing the test switch on the left side of the glare shield panel 1 5 FOAM SYSTEM The Wipaire 802 Fire Boss foam system consists of three individual tanks The original 18 gallon firewall tank is supplemented by an additional 30 U S gallon tank in each float at sta 1 of which approximately 28 U S gallons is usable in the automatic mode In the manual mode all 30 gallons are usable A total of approximately 74 U S gallons can be delivered to the hopper in the automatic mode utilizing the foam control panel located on the left side of the cockpit just below the fire gate computer In the manual mode a total of 78 gallons can be delivered to the hopper The float tanks are optional and one or both can be removed depending on the type of operation Tank and floor 50 16 at 1 0 eac
55. ipaire com Email CustomerService wipaire com 1 0 GENERAL 1 1 AIRPLANE The airframe of the Fire Boss is adapted from the Air Tractor AT 802A agricultural airplane It is an all metal low cantilever wing design It is powered by a Pratt and Whitney PT6A 67AG turboprop engine of 1350 SHP or PT6A 67F of 1600 SHP The airframe is detailed in Air Tractor publications To create this fire suppression version of the airplane a number of changes to the landplane were incorporated Amphibious floats with hydraulically actuated water scoops are installed The Air Tractor Fire Retardant Delivery System FRDS is utilized The Air Tractor foam system and controls are utilized Additional foam tanks in the floats supplement the standard firewall tank Changes to the hopper venting system are incorporated A new upper instrument panel is added to contain some of the scoop related and system controls and indicators A bilge pumping system and a water in floats warning system are incorporated These changes will be briefly discussed in the following paragraphs 1002545 Rev K Page 9 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 1 2 FLOATS The model 10000 amphibious float is an all aluminum constructed float with 12 watertight compartments of approximately 10 000 pounds buoyancy As a part of the float installation the following additional changes are made to the landplane 1 The hydraulic landing gea
56. ir Tractor installation with a Wipaire liquid level sensor added and line routed to the float tank 5 4 SERVICE FOAM SYSTEM The foam pump on each float tank is not serviceable and cannot be overhauled The float sensor in the 18 gallon tank also is not serviceable Check lines for leaks and condition Refer to Air Tractor manual for tank to hopper pump information Page 48 of 91 1002545 Rev K FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL r EXISIING HOPPER LINE AIRCRAFT FIREWALL FOAM TANK x FUSELAGE p 4 N N _ FILLER EXISTING A C o BREATHER LEVEL 9 EXISTING A C SETARDANT TANK PUMP LOAT 1 N 2 Z FOAM PUMP FLDAT TANK _ TO FIREWALL TANK EXISTING A C 2 LINES RETARDANT TANK FLDAT R FOAM PUMP FLOAT TANK FIREWALL FIGURE 5 SCHEMATIC PLUMBING FOAM SYSTEM Page 49 of 91 1002545 Rev K BOSS CONVERSION ON 10000 SERVICE MANUAL 6 0 FLOAT BILGE SYSTEM OPERATION REMOVAL AND SERVICE 6 1 DESCRIPTION AND OPERATION Each float is equipped with 2 bilge pumps These pumps are located in float compartments just forward of the step These pumps are accessible through the inspection covers on each float side just forward of the step In
57. it too low REMEDY a Investigate for free operation Check gear that retracts last b Replace pressure switch 1002545 Rev K Page 41 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 6 PROBLEM Slow gear operation cycle considerably longer than 30 seconds PROBABLE CAUSE a Plugged oil screen b Poor electrical connection to motor c Poor motor d Worn pump gears e Low ship voltage REMEDY a Clean intake screen located inside reservoir tank b Connect motor direct to 24 volt source and note its operation if good wire connection is bad if operation poor motor needs overhaul Covered in b above d Replace pump 7 PROBLEM Circuit breaker pops during cycle PROBABLE CAUSE a Wire connections bad or corroded b Bad motor brushes c Badcircuit breaker REMEDY a Clean and protect terminal with grease b Overhaul motor c Replace circuit breaker Page 42 of 91 1002545 Rev K FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 4 0 SCOOP SYSTEM OPERATION REMOVAL AND SERVICE 4 1 DESCRIPTION AND OPERATION Full operating information of scooping system is described in Introduction Section 1 4 The scoops one in each float are hydraulically operated Hydraulic Schematic Figure 2 1 shows how the scooping system is integrated with the landing gear hydraulic system The only moving part in the scooping system is the lower probe assembly which is actuated hydraulically by the probe jack cylinder See Fi
58. locking under right and left main gear wheels to level aircraft Drop plumb bob from wing leading edge on either side of the plane to the floor and mark This is the datum line station 0 0 Draw another line between the nose wheel centers and 39 line between the main wheel centers Measure the distance from 0 0 to the nose wheel line This is X Measure the distance from 0 0 to the main wheel line This is Y Use this table for the calculations Scale Reading Distance from 0 0 Weight x Arm Weight Arm Moment Left Front X Right Front T i X LeftRear 7 Y Right Y Rear Totals Notes 1 Zero out deduct tare weights at the Y arm 1002545 Rev K Page 90 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL m Page 91 of 91 1002545 Rev K
59. n covers in the top deck 8 4 SERVICE OF STEERING AND RETRACT SYSTEM The pulley bearing on both systems are sealed and not serviceable Inspect condition of all pulleys and cables for wear every 100 hours and replace as necessary 1002545 Rev K Page 51 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL SPRING RUDDER HORN STEERING CABLE WATER RUDDER BLADES BALANCE CABLE RETRACT CABLE RETRACT HANDLE FIGURE 8 WATER RUDDER STEERING AND RETRACTION SYSTEM Page 52 of 91 1002545 RevK FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL THIS PAGE BLANK 1002545 Rev K Page 53 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 9 0 ANGLE OF ATTACK SYSTEM 9 1 GENERAL The Rite Angle 111b AOA system is installed in this aircraft A separate manual is provided for installation and operation of this system This system is not a primary aircraft instrument and is for advisory only 9 2 MAINTENANCE The AOA system is pre programmed for the 802 aircraft on 10000 floats The wiring schematic is on figure 9 4 The manual for all other instructions is in the manufacturer s manual The vane setting should be 7 8 nose up from aircraft leveling point when 1 green light just comes on Measurements were taken from flat section of vane Figure 9 4A shows resistances in ohms across the P 12 connection on J6 module box These readings are approximates only and vary from installation to installation
60. ng the spring 4 bolts 1002545 Rev K Page 29 of 91 55 CONVERSION ON 10000 SERVICE MANUAL CONTROL VALVE SELECTOR HEAD FLOAT TOP DECK FLOAT TOP DECK TO OPERATE M L G TO OPERATE M L G RIGHT SIDE OF LEFT SIDE OF AIRCRAFT AIRCRAFT FILTER ACUMULATOR FILTER ACUMULATOR L SCOOP UP RIGHT SCOOP DWN ACCUMULATOR LEFT SCOOP DWN PROBE CYLINDER PROBE CYLINDER FIGURE 2 1 HYDRAULIC SYSTEM SCHEMATIC Page 30 of 91 1002545 Rev K FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL SEE FIGURE 22 amp 23 NOTES 1 GE WIRES ARE 20 GA GA WIRES ARE 12 ALL WIRES GA EXCEPT AS NOTED ALL WIRES TO MEET MIL W 5086 SPECIFICATION 2 ALL GROUND WIRES GE9 3 PUMP WIRING SCHEMATIC RELAYS SHOWN IN RELAXED CONDITION R DOWN SV NOSE GEAR UP SV TO AUDIO 2 0 500 HEADPHONE LEVEL D 1 444 EN DC BUSS DC BUSS NOSE GEAR L UP SV L L DOWN SV cE 2 GE L UP SV m 29 MAIN GEAR L DOWN SV Page 31 of 91 1002545 Rev K FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL FIGURE 2 2 SCHEMATIC ELECTRICAL SYSTEM SEE FIGURE 2 4 SEE FIGURE 2 6 SEE FIGURE 2 8 SEE FIGURE 2 7 FIGURE 2 3 LAYOUT MAIN GEAR 1002545 Rev Page 32 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL HOVLIV 0570 dll 1108 10
61. ocated on the outboard edge of each float topskin Page 10 of 91 1002545 RevK FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 1 2 1 FLOAT HULL MAINTENANCE 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 Float Handling Jacking and Aircraft Towing 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 Example is shown on the picture proceeding this text The jack should contact the keel squarely and if room permits slip a board between the jack and keel 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 landing wheels chocked Position a sawhorse under main and after body keel to keep aircraft from tipping fore and aft When towing the amphibian aircraft tow lugs 2 are provided on underside of the front spreader bar outboard ends A rigid frame can be fabricated to attach to these lugs and aircraft towed with a tractor Wipaire Pa
62. ockpit and the hydraulic actuators are located adjacent to each gear Hydraulic system fluid level should be checked periodically by viewing the sight glass for fluid level in the upper one third of the range If fluid is low fill with MIL H 5606 or equivalent Filter screens are installed on each pickup tube inside of hydraulic reservoirs and there are also 3 external 10 micron filters as well Clean filter screens and elements every 100 hours Per Service Letter 103 a Spin on Type filter assembly with a Baldwin Filter has been incorporated to facilitate additional filtering of the hydraulic system Replace Baldwin filter if pop out gage has been released indicating bypass has been activated due to clogged filter or at time of annual inspection Landing gear operation is initiated by movement of the landing gear handle When the handle is repositioned hydraulic pressure in the system will drop and pressure switches will automatically turn on the hydraulic pump motors to maintain operating pressure in the system When the gear cycle is completed the pump will automatically shut off If the pressure in the system drops to a preset value the pressure switches turn the pump motors back on and build up the pressure to the limit again Eight 8 position indicator lights four 4 gear UP and four 4 gear DOWN are provided to show landing gear position Two 2 additional indicator lights show when the landing gear pump motors are operating 1 3 1 LA
63. of the inside of the end cap to the end of the inserted metering tube is 12 037 inches if the new T seals are being used and 11 937 inches if the old style O rings are used Tighten the associated jam nut at that end and stake it for added security Set this metering tube assembly aside and move on to next steps and tighten to approx 30 ft Ibs 5 Install outer T seal to end cap with Vaseline Also lube the inside of the outer cylinder where the end cap seats for ease of assembly NOTE Use Vaseline or equivalent as it dissolves in hydraulic fluid 1002545 Rev K Page 21 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 6 Install the end cap bolts with gasket sealer on the threads for added security Tighten to 25 30 in Ibs making sure not to over tighten damaging the T seal Set this part of the unit aside and move on to next steps 7 To assemble the gland assembly insert the inside T seal and wiper again using Vaseline on the T seal a The gland must be installed from the end cap side this is the side without the holes b Lube the outside of the inner cylinder with hydraulic fluid for ease of assembly c Install the T seal into the end cap again using Vaseline for lube d Install the inner cylinder into the end cap the end of the tube without holes Page 22 of 91 1002545 Rev FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 8 For piston install place the piston onto the metering tub
64. or less wear tolerance Nose Gear Pivot Blocks and Forks Inspect for condition lubrication corrosion and paint Nose and Main Wheel Bearing Grease zerk fittings M Hydraulic Fluid Level X Wheels and Tires Inspect for wear pressure condition X Brake Assemblies Inspect for wear corrosion leakage X Hydraulic Fluid Screen Clean and inspect Hydraulic fluid in reservoir should be Note If floats sit for extended periods of time i e checked for moisture or other contaminates if removed during winter months screen should be and changed if necessary cleaned before putting floats back into service X 3 External Hydraulic 10 micron filter elements Hydraulic fluid in reservoir should be Clean and inspect checked for moisture or other contaminates Note If floats sit for extended periods of time i e and changed if necessary if removed during winter months screen should be cleaned before putting floats back into service X Main and Nose Gear Actuator Assemblies NOTE Follow revised directions in Inspect for condition lubrication leakage corrosion Service Letter 80 for operations from and cleanliness sand and gravel X Nose Gear Springs Scotchply springs inspect for cracks delamination and paint X Main Gear Drag Link Inspect for condition Grease the pivot points lubrication corrosion check attach bolts for wear X Main Gear Shock Strut Inspect for evidence of corrosion pittin
65. or vent located on the aft right side of the fire gate is supplemented with the addition of a 5 inch vent that exits at the right aft side of the rear fire gate fairing In the event of an overflow during scoop operations a spring loaded relief valve door is located directly aft of the main drop vent door Water will exit the hopper to the right and forward of the cockpit windshield The pilot can see ahead out of the left side of the windshield during an overflow condition The door spring needs approximately 40 pounds of pressure to open To check this use a hand held spring type scale Locate scale to the center of door on outside edge NOTE Before opening the main vent door for access the door bracing turnbuckles located inside the hopper just below the vent door need to be disconnected They are accessible with the drop vent door open 1 on each side 1002545 Rev K Page 15 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 1 7 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 st
66. orward of step From these holes unsafety clamp connecting the 2 scoop tubes Remove forward leading edge fairings from the main gear pylon Unclamp and remove the connecting hose to upper filler pipe Remove the bolts attaching upper attach flange to the float top deck Slide out scoop tube from the top When reinstalling check condition or replace gasket in connecting clamp Upper Probe Scoop Assembly With the lower scoop and internal scoop tube removed unbolt scoop from float tunnel Break sealant and remove from the top Reseal cover on reinstallation Filler Tube Main Gear Pylon Remove fairings unbolt attaching clamps and disconnect connecting hose Remove hose Before reinstalling check condition or replace clamp chafing strips Fill Tube at Aircraft Tank From inside and outside of tank remove attaching bolts Break sealant on inside and outside flanges Remove from inside tank On reinstallation seal completely and reattach 1002545 Rev K Page 43 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 4 4 SERVICE SCOOP SYSTEM Figure 4 2 shows a cross section of the hydraulic probe cylinder Replace O rings if cylinder shows signs of leaking A gasket is between upper probe and internal tube at connecting clamp Replace if necessary Check condition of connecting hose and clamps above float deck 2 each side Inside of aircraft tank on each inlet tube there is a rubber flapper valve or a platypus type valve Check if
67. r retraction system components and cockpit controls are added The cockpit landing gear controls and emergency hand pump and system are added The float water rudder retraction system and cockpit controls are added The water rudders are locked center when retracted for improved directional stability 4 A ventral fin is added for improved directional stability 5 Two auxiliary finlets are added to each side of the horizontal stabilizer for 10 11 12 improved directional stability Four total per aircraft The vertical fin is sealed to the fuselage stabilizer top for improved directional stability The open fuselage structure near the landplane tail wheel mount is faired over for improved directional stability Pump out cups on float top deck are placed between each float watertight compartment to pump out any water in floats before flight Vortex generators are added to the wing upper surface leading edges for improved longitudinal controllability Vortex generators are added to the horizontal stabilizer upper surface leading edges for improved longitudinal controllability and stall soeed reduction The elevator trim servo tabs incorporate a 1 inch chord extension for improved longitudinal controllability Access to the float interior is accomplished by removing covers on the top deck and six covers inside the wheel well When necessary water inside the float hulls may be removed through pump out cups l
68. release the stop from its holder and let the cable go slack The door is now free to hinge To reattach pull cable forward so cable ball is in its holder and stow handle 7 2 ADJUSTMENT AND TEST No adjustment is necessary for this system The cable lengths determine the pressure on the spring It should unseat at approximately 40 pounds of force 7 3 SERVICE OVERFILL VENT SYSTEM No service is necessary except to examine the condition of the cables canvas defector and all other parts Page 50 of 91 1002545 Rev K FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 8 0 FLOAT STEERING AND RETRACT SYSTEM 8 1 DESCRIPTION AND OPERATION The water rudder retract system is manually operated by a lever in the cockpit The water rudder is then operated by a system of cables and pulleys Steering is directed from the aircraft steering system See Figure 8 for retract and steering schematic 8 2 ADJUSTMENT Rigging of the water rudder steering cables is accomplished by centering the aircraft rudder and adjusting the turnbuckles such that both rudders trail with the float centerline Cables should be tensioned to 10 pounds 5 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 and lightly resting on the stops 8 3 REMOVAL AND ACCESS Cables can be accessed through the fuselage side panels aft of the trailing edge of the pylon and through float inspectio
69. retched 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 Inspect aircraft tubes in area of float fitting attach for sign of bending cracked welds or any other signs of damage 1 8 CLEANING The outside of the float should be kept clean by washing with soap and water Special care should be taken to remove engine exhaust trails waterline marks and barnacle deposits 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 Alternatively water taxiing in FRESH WATER at step speed with the water scoops in the DOWN position and the fire gates OPEN can help to flush the entire system This method is especially recommended as a daily cleaning for operators scooping in salt water OPERATORS SCOOPING SALTWATER ARE STRONGLY CAUTIONED RINSING THE ENTIRE AIRCRAFT amp FLOATS WITH FRESH WATER INSIDE AND OUTSIDE AT THE END OF EACH DAY IS CRITICAL FAILING IN THIS CLEANING WILL SEVERLY SHORTEN THE LIFE OF THE FLOATS The float interior should be flushed if salt water enters the compartments If the floats are being stored inside remove inspection covers so the interior will dry out THE ABOVE CLEANING TECHNIQUES ARE VITAL FOR KEEPING CORROSION TO A MINIMUM SALTWATER OPERA
70. rts has this tow bar available On water the aircraft may be towed with a rope bridle arrangement from these lugs A lifting apparatus that will pick the aircraft up by 4 points will facilitate lifting of the entire aircraft on floats from a ceiling hoist Two points are provided on aft cockpit sides Two points are the engine mount at the firewall on each side A lifting beam that will pick up all four points is available at Wipaire Parts Dept or a drawing of one can be provided 1002545 Rev K Page 11 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 1 3 AMPHIBIAN LANDING GEAR SYSTEM The landing gear incorporated within the amphibious floats on this airplane is retractable quadricycle type with two swiveling nose or bow wheels and four 4 two 2 sets of dual main wheels Air oil shock struts on the two main landing gear assemblies provide shock absorption The main landing gear has dual 8 50 x 10 8 ply tires and the nose landing gear has one 6 00 x 6 8 ply tire The gear system is hydraulically actuated and driven by two hydraulic pumps Brakes are hydraulic and have a caliper on each main wheel for a total of four brakes Steering on land is accomplished by differential braking The nose wheels are full castering 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 fuselage aft of c
71. the flat on the opposite end Remove the filter elements and note the placement of the internal springs Clean the filter elements by washing in clean solvent and blowing compressed air through the inside Check the condition of the O rings before reassembly and carefully retighten the fittings Page 44 of 91 1002545 Rev K FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL COUPLING AND CLAYP ASS Y INLET TUBE COUPLING CLAMP TUBE STRUT TO TANK BOLT ATTACH TO GUNWALL TOPSKIN CENTER SKIN ATTACH BLLKHEAD 415 SEE FIGURE 4 IA FIR LOWER AREA FIGURE 4 1 ASSEMBLY SCOOPING SYSTEM COMPLETE 1002545 Rev K Page 45 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL ASY Y 3 CLAMP WITH SEAL ATTACH LPPER LOMER FLANGES SAFETY WIRE WORM DRIVE BLLKHEAD 16 BOLT CYL TO PROBE ATTACH ASS CYLINDER PROHE CYLINDER ROD END TU BOTH UP AND POSITION SCOOP TUBE UPPER PROBE UPPER AND LOWER PROBE ATTACH ASS Y SCOOP TUBE LOWER PROBE LOWER PROBE TU SEAT IN LIPPER HILT CYL FIGURE 4 1A ASSEMBLY SCOOPING SYSTEM 1002545 Rev Page 46 of 91 FIRE BOSS CONVERSION ON 10000 SERVICE MANUAL 65 25 53 9 oo w 25 s DN 2s 5 gt 7 a lt 2
72. valve is closing tight and condition of valve Replace if necessary 4 5 SERVICE OF SELONOID VALVE SCOOP RETRACTION If scoop probes stick it may be necessary to clean the Vickers solenoid valve This valve is located aft of the hydraulic pump and above the accumulator Remove the pressure in the hydraulic system by placing the gear selector in the neutral position between up and down Remove the large 94 inch Hex nut located on the left side of the valve Remove nut and spring and gently remove the valve spring Remove the electrical box cover the one with the amber light by loosening the two center round knobs Pull off electrical box Remove solenoid block from the manifold by removing the four Allen hex head bolts Remove the solenoid valve from the manifold and clean by carefully blowing air through the ports Reinstall the block with the four Allen hex head bolts and their accompanying O rings Reinstall the electrical box cover Clean the valve solenoid stem and gently reinstall it Reinstall spring and nut NOTE This above procedure should be in conjunction with cleaning of the entire hydraulic system in line filter elements and removing the hydraulic pump tank and cleaning the filters in Section 3 4 6 SERVICE OF IN LINE FILTERS SCOOP RETRACTION Adjacent to the solenoid valve referred to in 4 5 are in line filter elements To service and clean these filter elements unscrew them by turning the hex and nut and holding

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