Model 3730 & 3900 Amphibious Float Wipline Service Manual
Contents
1. INSP General Placards Check the AFM POH and or drawings for correct placard X Hulls and Struts Float Installation Float exterior inspect for damage wrinkled metal corrosion paint loss etc Struts and attach fittings Spreader bars 4 Float structure interior Baggage compartment covers and seals inspect for condition security operation and excessive wear Water Water Rudder Boots inspect for cuts tears Rudder System Pumper Tube Installation inspect for condition security routing of hoses and condition Water Rudder Steering and retract systems 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 Check cable tensions Water Rudder blades and posts inspect for damage security of attachment corrosion paint rigging Electrical System Solenoids inspect wiring mounting and Pump and indicator light wiring inspect for chafing broken or loose terminals and general condition general condition Page 22 of 41 1002551 Rev E WIPLINE MODEL 3730 3900 SERVICE MANUAL INSPECTION TIME LIMITS amp MAINTENANCE CHECKLIST INSTRUCTIONS PROCEEDURES HOURLY LIMITS MECHANIC 25 50 100 200 Right Left INSP Pump motors inspect wir2. All extrusions in the float hull are formed 6061 T6 aluminum alloy Extrusions have channels on both sides which the hull skins are bonded to All extrusions may be repaired by splicing as shown in Figure 13 and 14 or capped as shown in Figure 15 Splicing is normally done when both inside and outside of extrusion is damaged Capping is done when outside of extrusion is damaged such as the keel on gear up landings on pavement Capping is also done when original skin is still bonded to the inside of the extrusion Sections of extrusion for splicing or capping may be purchased from Wipaire in full or desired lengths Stub skins can also be bonded on extrusion sections if desired to simplify installation There are many ways to repair Wipline floats and each method of course depends on degree and location of damage Qualified assistance is readily available by calling the factory on repairs which require special attention 8 4 SERVICE SCHEDULE As coded in the Inspection Time Limits chart in this section there are items to be checked each 25 50 100 and 200 hours Also there are notes on special items which may require servicing at more frequent intervals When conducting an inspection at 25 hours all items marked for 25 hours would be accomplished 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 accompl
3. certain joint in this manual or installation drawings Tension Application Shear Application Nut Torque Limits Nut Torque Limits Bolt Size Bolt Size oe Min Max Min Max 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 20 450 500 7 16 20 270 300 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 1 500 718 14 2 500 3 000 4 1 500 1 800 1 14 3 700 4 500 1 14 2 200 3 300 1 1 8 12 5 000 7 000 1 1 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 80 should be used when Tef Gel is applied to the bolt Some additional general maintenance areas are as follows Nose and Main Gear Tracks Clean and 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 1002551 Rev Page 21 of 41 WIPLINE MODEL 3730 3900 SERVICE MANUAL INSPECTION TIME LIMITS amp MAINTENANCE CHECKLIST INSTRUCTIONS PROCEEDURES HOURLY LIMITS MECHANIC 25 50 100 200 Right Left
4. empty aircraft 5 7 TIRE SIZE 1 5 00 5 2 165 1002551 Rev E Page 15 of 41 WIPLINE MODEL 3730 3900 SERVICE MANUAL 6 0 NOSE GEAR AND RETRACTOR 6 1 OPERATION The nose gear uses a spring leaf leg very similar to a Cessna style with a hydraulic driven truck track retracting mechanism A hydraulic ram is connected directly to the truck to which the spring leaf is mounted The rear two rollers on the truck assembly which make up the over center lock section follow a deeper groove in the track casting and for this reason do not go around the corner but straight ahead to make the over center down lock The upside has no mechanical lock and uses only friction and air pressure and the hydraulic lock to hold the gear in Magnetic proximity switches located on the right side of the actuating cylinder sense a magnet mounted in the hydraulic ram These can easily be adjusted from the front compartment access covers as per Figure 6 in the appendix On older floats Serial Numbers 37390 and under the magnetic proximity switches are located on top at the front and rear of the gear well housing and sense a magnet mounted on the hydraulic ram These can be easily adjusted from the front compartment access covers 6 2 WHEEL AND CASTOR The nose wheel and fork pivot 360 degrees around the fork shaft and use no shimmy damping devices A spring loaded cam rides in a groove in the fork shaft and serves the purpose of holding the shaft in the ho
5. motor is bad 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 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 then disconnect and cap off 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 part of pump is bad and needs replacement b Visually inspect lines cylinders and hoses and replace as necessary 1002551 Rev E Page 25 of 41 WIPLINE MODEL 3730 3900 SERVICE MANUAL PROBLEM Powerpack cycles on and off during gear cycle Probable cause a Binding retraction unit b Pressure switch cut off limit too low Remedy a Investigate for free operation gear that retracts last b Replace pressure switch 6 PROBLEM Slow gear operation
6. of aircraft will provide a long service life Even in minimal usage it is recommended that the unit be cleaned and greased once at start of season mid season and end of season 1002551 Rev E Page 13 of 41 WIPLINE MODEL 3730 3900 SERVICE MANUAL 5 3 REMOVAL OF MAIN GEAR AND RETRACTOR The landing gear is simple to remove as there are only two pinion bolts a drag link bolt and two brake lines holding it in To remove the retracting mechanism disconnect the gear light wires in the inner gear well side compartment and the two hydraulic lines All that remains are twelve allen head cap screws which are easily accessible from the compartment behind the gear well Occasionally the RTV sealant around the cap screw holes holds the actuator solid but is easily loosened when pried from the top 5 4 ADJUSTMENT MAIN GEAR If for any reason the main gear retractor must be disassembled or need replacement of the hydraulic cylinder it may be accomplished as follows With entire unit assembled except for the bolt securing the lower end of the retracting cylinder put the drag brace in the retracted position against stops with up lock hooked We now set the travel of the cylinder by extending it until it is bottomed and observing through the anchor bolt hole on its base and retractor body The lock nut on the ram should be loosened and the ram turned thus adjusting total length until it is about 1 32 too long This will allow the drag brace t
7. 2 5 0 MAIN LANDING GEAR AND RETRACTOR ettet 13 Sanna 4 Aoc RAD MAD IE E OCA 13 52 FUBRICATION a a Eu e 13 5 3 REMOVAL OF MAIN GEAR AND 14 5 4 ADJUSTMENT MAIN 14 SS INSERTION Z lt lt saman aqa eu acc 15 5 6 SERVICING OLEO STRUT 15 EAS RUNE T E 15 6 0 NOSE GEAR AND RETRACTOR cete 16 EOP BEA LOIN ss a call tn 16 6 2 WHEEL AND CASTOR eM 16 63 LUBRICATION Om MOD a T EE A 16 GA REMOVAT tero teu 16 17 ME EUM ILI M M EE 17 6 KINSERTION est cule 17 6 8 NOSE BOX TRACK WEAR A desert edet ule v tote LAE Ar edi 17 1002551 Rev E Page 3 of 41 WIPLINE MODEL 3730 3900 SERVICE MANUAL ELEC PRICA Ds SYSTEM 18 8 0 REPAIRS 18 8 1 FLOAT HULL MAINTENANCE 18 8 2 REPAIRING FLOAT HULL SKINS n2 Baie 18 8 3 REPAIRING FLOAT 8 22 2 19 Si SER VICE SCHEDULE 19 INSPECTION TIME LIMITS amp MAINTENANCE CHECKLIST 22 9 0 TROUBLE S
8. 201 or 252 Sika Manufacturing Telflon Spray 6P 730A Comet Industries 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 Hydraulic Fluid Mil H 5606 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 Page 20 of 41 1002551 Rev WIPLINE MODEL 3730 3900 SERVICE MANUAL 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 Area For corrosion 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
9. 41 WIPLINE MODEL 3730 3900 SERVICE MANUAL 2 0 FLOAT HULL MAINTENANCE 2 1 GENERAL The float structure is manufactured entirely of 6061 T6 corrosion resistant aluminum sheet and extrusions Skins on the inside are primed with a 3M SCOTCHWELD primer after being cleaned and acid etched Exterior surfaces are cleaned and alodined Surfaces are then primed with an epoxy based primer and finished with enamel color paint 2 2 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 Inspect aircraft skins in area of float fitting attach for sign of bending or any other signs of damage 2 3 CLEANING The entire outside of the float should be kept clean by washing with soap and water Special care should be taken to remove engine exhaust trail water line marks and barnac
10. HOOTING iere epa te ren rera t Pd akt venas bases 25 FIGURE 1 SCHEMATIC LANDING GEAR ELECTRICAL SYSTEM 27 FIGURE 2 SCHEMATIC LANDING GEAR ELECTRICAL SYSTEM 28 FIGURE HYDRAULIC SYSTEM 200 29 FIGURE 4 HYDRAULIC 30 FIGURE 5 LUBRICATION CHART MAIN GEAR eee 31 FIGURE 6 TYPICAL SKIN REPAIR ette prar ede ERIS FOROR aed 32 FIGURE 7 TXPICAL SKIN 33 FIGURE 3 TYPICAL SKIN REPAIR vious Seca eti h au a 34 FIGURE 9 TYPICAL REPAIR BOTTOM SKIN TO KEEL INSTRUCTIONS 35 FIGURE 10 TYPICAL REPAIR BOTTOM SKIN TO KEEL INSTRUCTIONS 36 FIGURE 10 TYPICAL REPAIR BOTTOM SKIN KEEL INSTRUCTIONS 37 FIGURE 11 TYPICAL REPAIR BOTTOM SKIN TO KEEL ALT INSTRUCTIONS 38 FIGURE 12 TYPICAL REPAIR SPLICE OF KEEL recto 39 FIGURE 13 TYPICAL REPAIR SPLICE OF 22222 40 EIGURE EETYPICAL CAP SPLICE TO KEE tbe poesie 41 Page 4 of 41 1002551 Rev E WIPLINE MODEL 3730 3900 SERVICE MANUAL LOG OF REVISIONS PAGES DESCRIPTION DATE Added an inspection time limit and tolerances for the Nose Block Track wear 4 14 16 Updated TOC added new inspection 22307 checklist TOC 6 Table of contents updates expanded 7 8 16 corrosion prevention added steps to insp 10 31 08 17 18 checklist Es
11. NV 100386 71333 319934 Q3A0434 099990 133 319934 3413238 01 13334 9NIISIX3 NMOHS SV 6 1333 30 3015100 3038 FIGURE 2 TYPICAL REPAIR SPLICE OF KEEL Page 39 of 41 1002551 Rev WIPLINE MODEL 3730 3900 SERVICE MANUAL AU012V3 WOYS Q3NIHOVW ONY 102344 INIHI 14934 INfIS 9 001 4710 6417 24 13 14 XNnS 9 90790087 350 FIGURE 13 TYPICAL REPAIR SPLICE OF CHINE 414434 3A13939 01 NMOHS SY 3NIH 30 3015110 3A0W3U 03A0434 39VWVO HLIM 2 9NIISIX3 1002551 Rev E Page 40 of 41 WIPLINE MODEL 3730 3900 SERVICE MANUAL NEW CAP PRECUT FROM FACTORY i gt nu a o w gt uw D gt a e gt lt ul en ti e lal 3 CO oO ei 1 4 WN x O ri PE m s 21 159 DIA 100 C SUNK USE AN426AD5 C SUNK RIVETS SHAPE TO RECEIVE NEM OUTSIDE CAP REMOVE BY aude AND FILING OUTSIDE OF EXTRUSION TO TH FIGURE 14 TYPICAL CAP SPLICE TO KEEL LAYOUT NEW REPAIR CAP ON DAMAGED EXTRUSION REMOVE OUTSIDE OF DAMAGED EXTRUSION BY FILING OR GRINDING TO INSIDE SHAPE OF REPAIR CAP MATCH DRILL OR LAYOUT AND DRILL HOLE PATTERN AS SHOWN RIVET OUTSIDE CAP TO EXISTING INSIDE EXTRUSION APPLY KEEL WEAR STRIP WITH ANY GOOD 2 PART APOXY 1002551 Rev E Page 41 of 41
12. PAIRE INC WIPLINE FLOATS SKIS MODIFICATIONS AIRCRAFT SALES AVIONICS INTERIOR MAINTENANCE PAINT REFINISHING 2 SERVICE MANUAL and INSTRUCTIONS FOR CONTINUED AIRWORTHINESS for the WIPLINE MODEL 3730 3900 AMPHIBIOUS AND SEAPLANE FLOATS Revised December 2015 1700 Henry Ave Fleming Field KSGS South St Paul MN 55075 Ph 651 451 1205 Fax 651 457 7858 WWW Wipaire com WIPLINE MODEL 3730 3900 SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Page 2 of 41 1002551 Rev E WIPLINE MODEL 3730 3900 SERVICE MANUAL TABLE OF CONTENTS SECTION PAGE LOG OP REVISION Sea 5 dicc ste ene 5 NEW CUSTOMER 6 INTRODUCTIONS aym hah Ae Sai ELS Aloe Reh a 8 A a 9 2 0 FLOAT HULL MAINTENANCE cte 10 2 2 foe sss ALMUS 10 22 HARD LANDING AND DAMAGE INVESTIGATION eene 10 E DIM EE 10 DASA ING E era ict tet Lane 1 BO CORRBOSION LIS LEM EU Rupe manuna qasa 11 4 0 THETHYDRAULICSYSTENIS ete cre ran RR Ea d Rp d mas 12 AT OPERATION natn Saee dd ana U 12 42 MAINTENANCE de ya a Li aan Sala 12 4 3 BLEEDING THE SYSTEM 0 ccccccscsssssssescsssssssscssuscssesssseccsssesssscesusessevessusessecssseessusestevesses 1
13. PP SIDE PROXIMITY SWITCHES NO p DIODE m PRESSURE M 2 AWG SOLENOID SWITCH GEAR TO t NO MOTOR SPLICE use 12 NENNEN S N 37390 amp DOWN FIGURE 2 SCHEMATIC LANDING GEAR ELECTRICAL SYSTEM Page 28 of 41 1002551 Rev E WIPLINE MODEL 3730 3900 SERVICE MANUAL KINO 9079193 13494 OL 93334 NMOHS SYIIWNN 23108 2 a H lt Pe ei t 5 E TO 62 69 8 19 0 16 mb TE UL d 4 E aga Lr FIGURE 3 HYDRAULIC SYSTEM 206 Page 29 of 41 1002551 Rev WIPLINE MODEL 3730 3900 SERVICE MANUAL KINO SOTVLVD 51848 OL 83439 NMOHS Su38W N 310N C9 12 6 EM 60 Dr comede Om 2 12 69 FIGURE 4 HYDRAULIC SYSTEM 185 1002551 Rev E Page 30 of 41 WIPLINE MODEL 3730 3900 SERVICE MANUAL FIGURE 5 LUBRICATION CHART MAIN GEAR 3730 1 STANDARD GREASE ZERK 2 NEEDLE POINT GREASE HOLE 3 APPLY GREASE THESE SURFACES 1002551 Rev E Page 31 of 41 WIPLINE MODEL 3730 3900 SERVICE MANUAL OO Dia Use AN470 456 AD4 Rivers 2 20 Use AN470 45 AD4 Rivets FIGURE 6 TYPICAL SKIN REPAIR Page 32 of 41 1002551 Rev E WIPLINE MODEL 3730 3900 SERVICE MANUAL 3 20 Use AN470 oe AN456 AD4 Rivets FIGURE 7 TYPICAL SKIN REPAIR 1002551 Rev E Page 33 of 41 WIPLINE MODEL 3730 3900
14. RUSION APPLY SEALANT IN GROOVE Be sure to use plenty of Sealant INSERT REPAIR SKIN INTO EXTRUSION INSTALL SPACER BETWEEN REPAIR SKIN AND EXTRUSION DRILL AND COUNTERSINK HOLES AND RIVET INTO PLACE AMP YE NE Page 36 of 41 1002551 Rev E AMERY WIPLINE MODEL 3730 3900 SERVICE MANUAL SPACER 040 REPAIR SKIN 21 159 DIA 1009 C SUNK USE AN426AD5 C SUNK RIVETS EXISTING SKIN FIGURE 10 TYPICAL REPAIR BOTTOM SKIN TO KEEL INSTRUCTIONS REMOVE ORIGINAL DAMAGED SKIN FROM EXTRUSION REMOVE CAULKING FROM GROOVE OF EXTRUSION APPLY SEALANT IN GROOVE Be sure to use plenty of Sealant INSERT REPAIR SKIN INTO EXTRUSION INSTALL SPACER BETWEEN REPAIR SKIN AND EXTRUSION DRILL AND COUNTERSINK HOLES AND RIVET INTO PLACE 1002551 Rev Page 37 of 41 WIPLINE MODEL 3730 3900 SERVICE MANUAL USE AN470AD4 RIVETS 30 1285 DIA FIGURE 11 TYPICAL REPAIR BOTTOM SKIN TO KEEL ALT INSTRUCTIONS 0 REMOVE ORIGINAL DAMAGED SKIN LEAVING APPROXIMATELY 1 OF SKIN PROTRUDING FROM EXTRUSION REMOVE CAULKING FROM GROOVE IN EXTRUSION INSTALL SEALANT IN GROOVE BE SURE TO USE PLENTY OF SEALANT INSERT REPAIR SKIN IN GROOVE APPROXIMATELY 4 LAYOUT HOLE PATTERN DRILL DE CHIP SEAL AND RIVET wi tS be Page 38 of 41 1002551 Rev E WIPLINE MODEL 3730 3900 SERVICE MANUAL 2 0001 VIG 661 2 SLIATY ANAS S0V92hNV ISN o St 44 Au012V3 043 Q3NIHOVW
15. SERVICE MANUAL 5 20 ed 5 gt HOLE IN SKIN bey 4 0 Max m Q UN QUO 5 20 IM M TRIM HOLE TO THESE P o 4 DIMENSIONS 5 Use 42470 AN4SG AD4 Rivets FIGURE 8 TYPICAL SKIN REPAIR TRIM HOLE AS SHOWN BY DOTTED LINE PATCH MATERIAL TO BE AT LEAST SAME THICKNESS AS ORIGINAL SKIN PRIME ALL BARE SURFACES SEAL BETWEEN PATCH AND SKIN RIVET IN PLACE Q ps Page 34 of 41 1002551 Rev E EXTRUSION ORIGINAL SKIN CUT FLUSH WITH REPAIR SKIN WEES SCAN WIPLINE MODEL 3730 3900 SERVICE MANUAL 21 159 DIA 1000 C SUNK USE AN426AD5 C SUNK RIVETS FIGURE 9 TYPICAL REPAIR BOTTOM SKIN TO KEEL INSTRUCTIONS PREFERRED METHOD REMOVE ORIGINAL DAMAGED SKIN CUT FLUSHE WITH EXTRUSION REMOVE CAULKING FROM GROOVE OF EXTRUSION APPLY SEALANT IN GROOVE BE SURE TO USE PLENTY OF SEALANT INSERT REPAIR SKIN INTO EXTRUSION DRILL AND COUNTERSINK HOLES AND RIVET INTO PLACE 1002551 Rev Page 35 of 41 WIPLINE MODEL 3730 3900 SERVICE MANUAL So mx SPACER 040 N REPAIR SKIN 21 159 DIA 1009 C SUNK USE AN426AD5 C SUNK RIVETS TATRA EXISTING SKIN FIGURE 10 TYPICAL REPAIR BOTTOM SKIN TO KEEL INSTRUCTIONS REMOVE ORIGINAL DAMAGED SKIN FROM EXTRUSION REMOVE CAULKING FROM GROOVE OF EXT
16. ag brace through an air oil oleo strut The main wheels and brakes and standard Cleveland parts Aluminum brakes are used for saltwater resistance Interchangeable stainless steel brake discs are also available 5 2 LUBRICATION see figure 5 A periodic cleaning and lubrication schedule is the best service there is for smooth and trouble free operation Lubrication is also a must for saltwater operation or where steel hardware and aluminum come in contact with each other A lubrication chart is provided to show places of grease access and type of zerk to use Use only waterproof grease recommended in Products Chart On Lubrication Chart note 1 is a standard grease zerk One is located on lower hook where actuating cylinder is attached and one on end of each wheel axle The grease zerks on axle ends allow grease to be forced into wheels Use these to periodically add grease as it is lost and not as an alternate for repacking wheel bearings If on some older models lower hook does not have grease zerk apply grease to all mating and hinged areas and also to end of hook Note 2 is a needle point grease hole where grease may be forced in with a needle point zerk end Note 3 is where grease is applied by hand to lubricate other moving or hinged surfaces These areas should include gear up hook tip push rod to up hook down lock hook tip uplock hook push rod and any other moving surface not mentioned above Greasing intervals matched to the usage
17. brication corrosion Main gear oleos inspect for evidence of leakage proper extension check cylinder X for corrosion pitting cleanliness and security Hydraulic lines and fittings inspect for leaks condition and security X Hydraulic manifolds if equipped inspect for condition security and leaks X Brake system plumbing inspect for leaks condition and security X Main gear oleos service fluid pressure X Landing Perform retraction test Inspect main gear up and down Gear hooks for proper engagement X Systems Inspect nose gear trolley for X proper travel Inspect nose gear for excessive X side play in the down position Perform emergency gear extension if equipped X Nose and main wheel bearings disassemble and inspect X Page 24 of 41 1002551 Rev E WIPLINE MODEL 3730 3900 SERVICE MANUAL 9 0 TROUBLE SHOOTING 1 PROBLEM Powerpack does not run after gear selection Probable cause a Circuit breaker out b Pressure switch not pulling in at low cut in c Solenoid switch not pulling in d Faulty pump motor or motor ground Verification and Remedy a Reset Circuit Breaker b Short across pressure switch leads and see if motor runs c Short across main solenoid leads and see if motor operates If it operates replace pressure switch d If c above does not produce results and it is verified that voltage was actually applied to the motor it can be assumed that the
18. cycle considerably longer than 23 seconds Probable cause b Plugged oil screen c Poor electrical connection to motor d Poor motor e Worn pump gears 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 7 PROBLEM Circuit breaker pops during cycle Probable cause b Wire connections bad or corroded c Motor brushes are bad Remedy a Clean and protect terminals with insulating grease b Overhaul motor Page 26 of 41 1002551 Rev E WIPLINE MODEL 3730 3900 SERVICE MANUAL INDICATOR LIGHTS es ES NOSE GEAR PROXIMITY SWITCHES B UP 12 AWG 25 AMP AWG ALL WIRE SIZES ARE tol d mp 22 AWG OR LARGER O Ol EXCEPT AS NOTED 2 2 ALL GROUND WIRES EE 2l GE9 GE8 THIS SIDE cea SYM WITH 4 aces OPP SIDE NE UP PRESSURE MAIN DIODE SWITCH GEAR 12 AWG SOLENOID o ITEMS AMP pump M MOTORS en 4 12 MEME S N 37392 amp UP FIGURE 1 SCHEMATIC LANDING GEAR ELECTRICAL SYSTEM 1002551 Rev E Page 27 of 41 WIPLINE MODEL 3730 3900 SERVICE MANUAL INDICATOR LIGHTS ALL WIRE SIZES ARE 22 AWG OR LARGER EXCEPT AS NOTED 12 AWG 20 AMP t2 AWG THIS SIDE SYMMETRICAL o o WITH THE O
19. e Reformat of entire document Add green 162008 6 2013 grease as approved grease Added Shear Torque Chart PR 1440 C 20 21 Sealant and Tef Gel Removed Warranty Claim Form Added Dow Corning DC4 Corrosion X and Mobil Aviation Grease SHC 100 to approved product list Modified torque limits section 1002551 Rev Page 5 of 41 WIPLINE MODEL 3730 3900 SERVICE MANUAL 27 SANIPAIRE INC lt 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 Page 6 of 41 1002551 Rev E WIPLINE MODEL 3730 3900 SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1002551 Rev E Page 7 of 41 WIPLINE MODEL 3730 3900 SERVICE MANUAL INTRODUCTION This manual describes the general servicing and maintenance for the Model 3730 3900 float including hull and landing gear 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 Wipaire Par
20. hes are the magnetic proximity type and their adjustment is self explanatory and can be done with the unit installed in the float 6 6 TIRE SIZE 1 4 10 NHS 4ply 2 PSI 38 lbs 6 7 INSERTION Insertion of the nose gear retractor is simply the reverse of the removal When reinstalling the nose box be sure to remove all old deposits of Apply new sealant between bulkheads and nose box Note Be sure access hole on top of nose box is covered and sealed before installation 6 8 NOSE BOX TRACK WEAR Due the wear over time 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 050 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 is to be done every 200 hours On the 3730 Series Floats Gear Track P N 3407349 001 LT 002 RT 1002551 Rev E Page 17 of 41 WIPLINE MODEL 3730 3900 SERVICE MANUAL 7 0 THE ELECTRICAL SYSTEM The electrical system consists of the following components Pump motor pressure switch solenoid contractor 20 amp circuit breaker and the separate system of indicating lights and switches as per the electrical schematic of Figure 1 and 2 8 0 REPAIRS AND MAINTENANCE 8 1 FLOAT HULL MAINTENANCE GENERAL The float structure is manufactured entirely of corrosion resistant aluminum sheet and ex
21. ing mounting and general condition X Landing Gear Systems Pressure switches inspect wiring mounting and general condition Lubricate nose gear tracks and pivot Nose Gear Box Block Tracks measured at slide route for wear 050 inches or less wear tolerance Nose gear pivot blocks and forks inspect for condition lubrication corrosion paint X Nose and main wheel bearing grease Zerk fittings Hydraulic Fluid Level Wheels and tire 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 Le 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 Main and nose gear actuator assemblies inspect for condition lubrication leakage corrosion and cleanliness 1002551 Rev E Page 23 of 41 WIPLINE MODEL 3730 3900 SERVICE MANUAL INSPECTION TIME LIMITS amp MAINTENANCE CHECKLIST INSTRUCTIONS PROCEEDURES HOURLY LIMITS MECHANIC INSP 25 50 100 200 Right Left Nose gear springs scotch ply springs X inspect for cracks delamination and paint Main gear drag link garlock bushings X inspect for condition lu
22. ing 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 1002551 Rev Page 11 of 41 WIPLINE MODEL 3730 3900 SERVICE MANUAL 4 0 THE HYDRAULIC SYSTEM 4 1 OPERATION The hydraulic system consists of an electro hydraulic power pack with a non reversing type pump and a hand pump backup tied in between the return and pressure lines see hydraulic schematic in figures 3 amp 4 The pump and reservoir assembly is mounted in the left float A pressure of between 500 psi and 1000 psi is maintained in the supply line When the pressure falls below 500 psi a pressure switch will activate the pump solenoid providing power to the pump When the pressure reaches 1000 psi the pressure switch deactivates the solenoid and the pump motor is stopped Figures 1 amp 2 show 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 1200 psi The system also has an external relief valve to protect against thermal expansion when line pressure exceeds 1900 psi The selection of gear up or gear down is accomplished by a cockpit mounted control valve Each float gear has individual indicator lights on the control valve allowing the pilot to co
23. ished When conducting an inspection at 200 hours the 25 50 100 and 200 hour items would be accomplished Acomplete inspection Annual Inspection would include all 25 50 100 and 200 hour items When servicing float hull and amphibian components below is list of recommended lubricants and protection products This lists products used by Wipaire during assembly of the floats There may be equivalent products that are just as satisfactory for protection It is recommended if trying different products to inspect them frequently so as to determine their effectiveness 1002551 Rev E Page 19 of 41 WIPLINE MODEL 3730 3900 SERVICE MANUAL Protection of nuts bolts hydraulic lines or metal surfaces Zip D 5029NS Corrosion Inhibiting Compound Zip Chemical Company CRC SP400 Soft Seal CRC Industries General Lubricants LPS 1 LPS 2 and LPS 3 LPS Industries Wheel Bearings HCE Grease P N 605 HCF Industries Aeroshell 22 Shell Global Solutions Green Grease Multi Purpose Green Grease Inc Rust Protection Boeshield T9 Rut Protection Boeing Company ACF 50 Rust Protection Corrosion X Corrosion Technologies Corporation Tef Gel Ultra Safety Systems Inc Electrical Insulating Compound Dow Corning 4 DC4 Dow Corning Corporation 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
24. le type deposits After saltwater operation washing with fresh water should be done daily with special attention to hard to reach places such as seams wheel wells areas underneath strut covers etc Float interior should be flushed if evidence of saltwater in compartments is noted 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 SALTWATER OPERATIONS ARE STRONGLY LINKED TO CORROSION AND MUST BE ADDRESSED PROACTIVELY Page 10 of 41 1002551 Rev E WIPLINE MODEL 3730 3900 SERVICE MANUAL 2 4 SEALING The float hull has eight sealed compartments Each compartment is equipped with a pump out cup and inspection cover These compartments must be pumped out before flight and after prolonged periods of sitting in water Each compartment is individually sealed as is wheel well halves and nose box Water from one should not contaminate the other If leaks are found check by filling only one compartment at a time water will appear on outside of hull in adjacent compartment nose box or wheel well Float hull must also be inspected for leaks from damage and sealed around nose box nose box access cover spreader bar fairings water rudder boot baggage a
25. nd inspection covers Refer to Products List for recommended sealants and caulk 3 0 CORROSION Corrosion is a reaction that destroys metal by an electro chemical action and 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 etc 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 grease 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 TECHNIQUES ARE VITAL FOR KEEPING CORROSION TO A MINIMUM SALTWATER OPERATIONS ARE STRONGLY LINKED TO CORROSION AND MUST BE ADDRESSED PROACTIVELY 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 sand
26. nfirm that each gear has fully retracted or extended 4 2 MAINTENANCE Maintenance of the hydraulic system is very easy keep the proper amount of oil in the reservoir A sight glass is provided for this and the level should be kept in the upper 1 3 of the range A screen is located in the reservoir tank around the fluid pick up pipe and can be cleaned or checked at annual inspection or every 100 hour Check and replace if oil is dirty or if moisture is found MIL H 5601 Hydraulic Fluid RED 4 3 BLEEDING THE SYSTEM Simply fill the reservoir with hydraulic oil and start a gear cycle If the reservoir empties i e fluid goes out of sight in the sight glass stop the cycle and add oil and complete the cycle Continue with approximately four more gear cycles after the fluid level in the reservoir normalizes it will vary in level between up and down positions and check for leaks Page 12 of 41 1002551 Rev E WIPLINE MODEL 3730 3900 SERVICE MANUAL 5 0 MAIN LANDING GEAR AND RETRACTOR 5 1 OPERATION The main landing gear retractor is merely a hydraulic cylinder which pushes and pulls a drag brace The locking is accomplished using a small amount of lost motion of the hydraulic cylinder to pivot a hook on the drag brace The first part of travel of the cylinder unlocks the lock and the last part locks it There is a proximity switch that activates the gear panel indicator lights The main truss is an aluminum alloy and is connected to the dr
27. o bottom on its up stops before the hydraulic ram bottoms out when gear is retracted Re tighten lock nut and install the cylinder bolt There should be enough travel left on the other end to amply hook the down lock this can now be checked The next item to be adjusted is the up lock release rod When the gear is in the up position and starts down the pivot should push against the release rod to raise the hook just high enough to let it snap over the bar in the drag brace and need not be adjusted to raise so high as to miss the rod completely as this can cause the pivot to hit the rod while the gear is being retracted Usually if a gear has been retracted while the aircraft was on the ground this rod will be bent because the pivot is in the wrong position pull instead of push when the drag brace comes up With this done the only thing left is to adjust the down micro switch the up can be adjusted in the float and this is accomplished by bending the probe On newer models this switch is a magnetic proximity type and is located in the compartment behind the wheel well and can be adjusted after actuator installation It can be noted that the down lock hook contacts an aluminum spring containing the magnet and positions it near the bulkhead where the proximity switch senses it through the bulkhead It is a good idea to attach an ohmmeter to the switch to see that it functions and use a hand hydraulic system to operate the unit as they have been kno
28. trusion material Skins on the inside are primed with a 3M Scotchweld primer after being cleaned and acid etched Exterior surfaces are cleaned and alodined then primed with an epoxy based primer and painted with enamel 8 2 REPAIRING FLOAT HULL SKINS The float hull skins are manufactured from the following aluminum alloys Side top and afterbody skins 032 2024 T3 Bottoms 040 6061 T6 Bulkheads nose 100 6061 T6 Aft wheel well 050 2024 3 Afterbody 040 2024 T3 All remaining bulkheads 032 2024 T3 Damage to the skins may be repaired per Figures 7 8 amp 9 or any acceptable repair method listed in FAA Advisory Circular 43 13 1 Any portion of skins or complete skins may be purchased from Wipaire to aid in repair These skins are pre cut to shape from proper material and all holes are drilled to match the float All outside hull skins are bonded to corner extrusions chines keel etc with a special heat pressure 3M adhesive This bond adheres skins to inside of all extrusions Skins may be reattached to extrusions by method shown in Figures 10 11 amp 12 If skin bond must be broken from extrusion for a large distance heating extrusion with a propane torch until bond starts to loosen and slide apart is the simplest method CAUTION must be taken not to heat and loosen bonds not needing replacement Page 18 of 41 1002551 Rev E WIPLINE MODEL 3730 3900 SERVICE MANUAL 8 3 REPAIRING FLOAT HULL EXTRUSIONS
29. ts Department To contact Wipaire for technical support or parts sales call or email 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 Page 8 of 41 1002551 Rev E WIPLINE MODEL 3730 3900 SERVICE MANUAL 1 0 GENERAL The model 3730 3900 seaplane or amphibious float is an all aluminum constructed float with watertight compartments The actual displacement in fresh water for each float is 3453 pounds buoyancy for the amphibian The amphibian float is geometrically the same as the seaplane except for the addition of landing gear and internal structure for the gear The water rudder system is cable operated with ball bearing pulleys Water rudder cables tie into the existing aircraft rudder system The main landing gear has a 5 00 x 5 6 ply tires and the nose landing gear has a 3 50 x 10 4 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 Steering on 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 and covers inside the wheel well When necessary water inside the float hulls may be removed through pump out cups located on the outboard edge of each float top skin 1002551 Rev E Page 9 of
30. using and centering the wheel during flight by means of a flat in the circumference of the groove A nylon thrust washer is located on top of the castoring pin 6 3 LUBRICATION Needle type grease fittings are also used in the nose gear and retracting mechanism There are two needle style and two normal styles in each nose gear The needle styles are on the truck pivots and the standard fittings are on the nose wheel pivot shaft housing and wheel axle The nose wheel main bearings should be greased using the same procedure as the main gear A long greasing stick or brush should be made and used to spread grease along each track in addition to the gun greasing 6 4 REMOVAL The whole nose gear and retracting assembly is removed by removing the nose bumper and both hydraulic lines There are then six inch bolts through the nose bulkhead and two 4 inch allen head cap screws through the 2 bulkhead into the track castings that must be removed and the end unit should slide out Sealant must be cut between nose box and bulkheads Page 16 of 41 1002551 Rev E WIPLINE MODEL 3730 3900 SERVICE MANUAL 6 5 ADJUSTMENT The nose gear retractor travel is preset and does not require adjustment Side play in the gear leg can be taken up by slightly tightening the side play take up bolt Caution be careful not to over tighten It is recommended that a gear check on the ground be accomplished afterwards to make sure gear operates smoothly The switc
31. wn to click without an actual contact or to click and get a contact and to lose it again when the hydraulic pressure is built up against the lock Before installing the unit a dab of waterproof grease should be put on all contacting surfaces such as lock hooks pivot etc Page 14 of 41 1002551 Rev E WIPLINE MODEL 3730 3900 SERVICE MANUAL 5 5 INSERTION Installing the actuator is almost as simple as removing it Before installing a small dab of sealant such as RTV silicone rubber or chromate paste should be applied around each hole on the mounting flange The unit is then inserted and held in place while a second person starts a couple of the allen head cap screws The procedure is then just the opposite of the removal Be careful to draw up the pivot bolts on the main gear casting only lightly as the tab can be easily broken or cracked This also applies to oleo and drag link bolts 5 6 SERVICING OLEO STRUT The oleo is easy to service if the following steps are followed 1 If the oleo is removed from the float hold in an upright position similar to when mounted in float 2 Release air pressure and extend oleo 3 Remove entire plug from top of air chamber and fill with Mil H 5606 red hydraulic oil using pump can Get air to come out as you pump in oil 4 Completely compress oleo and let excess oil run out 5 Reinstall plug and let aircraft weight down on gear 6 Inflate cylinder 1 7 8 inches of exposed piston with
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