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Wipaire WIPLINE 8000 Service Manual And Instructions

Amphibious and seaplane floats
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WIPLINE FLOATS • SKIS • MODIFICATIONS • AIRCRAFT SALES
AVIONICS • INTERIOR • MAINTENANCE • PAINT REFINISHING
SERVICE MANUAL
and
INSTRUCTIONS FOR
CONTINUED AIRWORTHINESS
for the
WIPLINE MODEL 8000
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

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  • Page 1 AVIONICS • INTERIOR • MAINTENANCE • PAINT REFINISHING SERVICE MANUAL INSTRUCTIONS FOR CONTINUED AIRWORTHINESS for the WIPLINE MODEL 8000 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...
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  • Page 3: Table Of Contents

    WIPLINE MODEL 8000 SERVICE MANUAL TABLE OF CONTENTS SECTION PAGE LOG OF REVISIONS ......................... 5 NEW CUSTOMER INFORMATION ................... 6 1.0 GENERAL ...........................11 2.0 FLOAT HULL MAINTENANCE ....................12 2.1 GENERAL ........................12 3.0 FLOAT HANDLING, JACKING, AND AIRCRAFT TOWING ..........15 4.0 AMPHIBIAN LANDING GEAR SYSTEM OPERATION & MAINTENANCE ......16 4.1 LANDING GEAR HANDLE ....................16 4.2 INDICATOR LIGHTS .......................16 4.3 LANDING GEAR OPERATION ..................17...
  • Page 4 WIPLINE MODEL 8000 SERVICE MANUAL FIGURE 5-1 SCHEMATIC HYDRAULIC SYSTEM ..............44 FIGURE 5-2 SCHEMATIC ELECTRICAL SYSTEM ...............45 FIGURE 5.3 ASSEMBLY MAIN GEAR RETRACTION SYSTEM ...........46 FIGURE 5.4 ASSEMBLY – MAIN GEAR SHOCK STRUT .............47 FIGURE 5-5 ASSEMBLY MAIN GEAR AND BRAKE ............48 FIGURE 5-6 ASSEMBLY NOSE GEAR SYSTEM ..............49 5.9 WEIGHT AND BALANCE ....................50 5.9.1 WEIGHING PROCEDURES FOR CESSNA 208 CARAVAN ........50...

  • Page 5: Log Of Revisions

    WIPLINE MODEL 8000 SERVICE MANUAL LOG OF REVISIONS PAGES DESCRIPTION DATE Revised Aircraft jacking position 3-16-05 Added greasing zerk to tasks and changed 12,18 9-28-05 drawing Added an inspection time limit and tolerances for the 7, 12 4-18-06 Nose Block Track wear. Made several additions to the inspection 19-22 1-18-07...

  • Page 6: New Customer Information

    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 62 1002554 • Rev H...
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  • Page 10 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. 1700 Henry Avenue – Fleming Field South St.

  • Page 11: General

    WIPLINE MODEL 8000 SERVICE MANUAL 1.0 GENERAL The model 8000 seaplane or amphibious float is an all aluminum constructed float with watertight compartments. The actual displacement in fresh water for each float is 8108 pounds buoyancy for the seaplane and 7922 pounds buoyancy for the amphibian.

  • Page 12: Float Hull Maintenance

    WIPLINE MODEL 8000 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.
  • Page 13 WIPLINE MODEL 8000 SERVICE MANUAL 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 wells, etc.
  • Page 14 WIPLINE MODEL 8000 SERVICE MANUAL 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. After removing the corroded area, restore area to original finish (prime and enamel).

  • Page 15: Float Handling, Jacking, And Aircraft Towing

    A rigid “V” frame can be fabricated to attach to these lugs and aircraft towed with a tractor. Wipaire Parts has this tow bar available. A lifting apparatus that will pick the aircraft up by the lifting rings at wing attach points from a ceiling hoist, to be fabricated.

  • Page 16: Amphibian Landing Gear System Operation & Maintenance

    WIPLINE MODEL 8000 SERVICE MANUAL 4.0 AMPHIBIAN LANDING GEAR SYSTEM OPERATION & MAINTENANCE 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.

  • Page 17: Landing Gear Operation

    WIPLINE MODEL 8000 SERVICE MANUAL 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.

  • Page 18: Main And Nose Gear Operation, Removal And Service

    WIPLINE MODEL 8000 SERVICE MANUAL 5.0 MAIN AND NOSE GEAR OPERATION, REMOVAL AND SERVICE 5.1 DESCRIPTION AND OPERATION Retraction and extension of the main and nose landing gear is effected by a hydraulic actuation system shown schematically in figure 5.3. The gear system is hydraulically actuated and driven by two hydraulic pumps located in the Aft fuselage.

  • Page 19: Service - Nose Gear

    WIPLINE MODEL 8000 SERVICE MANUAL 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 castering pin that is set into the machined fork assembly.
  • Page 20 WIPLINE MODEL 8000 SERVICE MANUAL AIR PRESSURE – The correct air pressure is 210 psi (+/-10 psi) on a fully extended oleo (no load) or it can be inflated to approximately 5-6 inches on an unloaded aircraft while sitting static on level ground. SEALS –...

  • Page 21: Adjustment/Test

    WIPLINE MODEL 8000 SERVICE MANUAL 5.2 ADJUSTMENT/TEST 5.2.1 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.

  • Page 22: Bleeding Hydraulic System After Service

    WIPLINE MODEL 8000 SERVICE MANUAL the length of the slide tube shaft and locking ram in addition to using a grease gun for the zerk on the main carriage. Grease should be pumped several times past the point at which it comes out the front of the carriage so it can migrate all the way thru the system to the locking hooks.

  • Page 23: Main And Nose Gear Removal And Disassembly

    WIPLINE MODEL 8000 SERVICE MANUAL 5.3 MAIN AND NOSE GEAR REMOVAL AND DISASSEMBLY 5.3.1 REMOVAL OF MAIN GEAR OLEO Jack the aircraft by method described in section 3. With the main wheels off the ground (both sides), run the gear up so the main carriages are approximately 2 inches forward of down-lock position.
  • Page 24 WIPLINE MODEL 8000 SERVICE MANUAL b) The metering pin is threaded until the measurement from the floor 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. c) Tighten the associated jam nut at that end and stake it for added security.
  • Page 25 WIPLINE MODEL 8000 SERVICE MANUAL 6) Install the end-cap bolts with gasket sealer on the threads for added security. Tighten to 25-30 in/lbs. 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.
  • Page 26 WIPLINE MODEL 8000 SERVICE MANUAL 7) For piston install, place the piston onto the metering tube 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.
  • Page 27 WIPLINE MODEL 8000 SERVICE MANUAL 12) Re-install the center bolts using gasket sealer. 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 Schraider valve and install onto the outside of the end- cap.

  • Page 28: Removal Of Main Gear Retraction Cylinder

    WIPLINE MODEL 8000 SERVICE MANUAL 15) Fill the strut with nitrogen to 210 psi +/_ 10 psi and close the valve and cap. 5.3.2 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.

  • Page 29: Removal Of Nose Gear Box

    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.
  • Page 30 WIPLINE MODEL 8000 SERVICE MANUAL Protection of nuts, bolts, hydraulic lines or metal surfaces Zip D-5029NS Corrosion Inhibiting Compound Zip Chemical Company CRC – SP400 Soft Seal Tef-Gel CRC Industries Ultra Safety Systems, Inc. General Lubricants Float Sealant LPS 1, LPS 2 and LPS 3 890 B2 or B4 LPS Industries Pro Seal Company...
  • Page 31 WIPLINE MODEL 8000 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.

  • Page 32: Hydraulic Pump System, Disassembly And Service

    WIPLINE MODEL 8000 SERVICE MANUAL 5.5 HYDRAULIC PUMP SYSTEM, DISASSEMBLY AND SERVICE The hydraulic pump is factory preset to the following pressures: Pressures switch operates below 500 psi and shuts off at 1000 psi. The pump also has an internal relief valve that opens at 1200 psi and a thermal relief valve that opens at 1900 psi.

  • Page 33: Inspection Time Limits And Checklist

    WIPLINE MODEL 8000 SERVICE MANUAL 5.6 INSPECTION TIME LIMITS AND CHECKLIST INSTRUCTIONS/PROCEEDURES HOURLY LIMITS MECHANIC INSP. General Details 100 200 Annual Right Left General Wash aircraft and floats with fresh water If the airplane is exposed to salt- or and inspect surfaces, hardware and strut polluted water, the chances for connections for corrosion.
  • Page 34 WIPLINE MODEL 8000 SERVICE MANUAL INSTRUCTIONS/PROCEEDURES HOURLY LIMITS MECHANIC INSP. Annual General Details 100 200 Right Left Water Water rudder boots - inspect for cuts, Water rudder blades and posts - Rudder tears, and condition inspect for damage, security of System attachment, corrosion, paint, &...
  • Page 35 WIPLINE MODEL 8000 SERVICE MANUAL INSTRUCTIONS/PROCEEDURES HOURLY LIMITS MECHANIC INSP. Annual General Details 100 200 Right Left Nose gear pivot blocks and forks - inspect Clean and Inspect for condition, lubrication, corrosion, paint. Nose & main wheel bearing - grease Zerks Clean and Inspect Main gear slide tube, ram Grease with HCF p/n 605.
  • Page 36 WIPLINE MODEL 8000 SERVICE MANUAL INSTRUCTIONS/PROCEEDURES HOURLY LIMITS MECHANIC INSP. Annual 100 200 Right Left Clean the wheel wells to facilitate general condition inspection. Main gear oleos - inspect for evidence of leakage, proper extension, check cylinder for corrosion, pitting, cleanliness and security Hydraulic lines and fittings - inspect for leaks, Refer to section 5.2 condition and security.

  • Page 37: Cessna Float Removal Instructions / Procedures

    WIPLINE MODEL 8000 SERVICE MANUAL 5.7 CESSNA FLOAT REMOVAL INSTRUCTIONS / PROCEDURES MECHANIC INSP. THIS IS INTENDED AS A GENERAL GUIDE. EACH INSTALLATION MAY HAVE Right Left SUBTLE DIFFERENCES. ALWAYS USE THE INSTALLATION DRAWINGS AS THE FINAL REFERENCE. ALL WORK SHOULD BE DONE BY CERTIFIED AIRCRAFT TECHNICIONS.
  • Page 38 WIPLINE MODEL 8000 SERVICE MANUAL MECHANIC INSP. (CONT.) CESSNA 208 FLOAT REMOVAL INSTRUCTIONS/PROCEEDURES THIS IS INTENDED AS A GENERAL GUIDE. EACH INSTALLATION MAY HAVE Right Left SUBTLE DIFFERENCES. ALWAYS USE THE INSTALLATION DRAWINGS AS THE FINAL REFERENCE. ALL WORK SHOULD BE DONE BY CERTIFIED AIRCRAFT TECHNICIONS.
  • Page 39 WIPLINE MODEL 8000 SERVICE MANUAL (CONT.) CESSNA 208 FLOAT REMOVAL INSTRUCTIONS/PROCEEDURES MECHANIC INSP. THIS IS INTENDED AS A GENERAL GUIDE. EACH INSTALLATION MAY HAVE Right Left SUBTLE DIFFERENCES. ALWAYS USE THE INSTALLATION DRAWINGS AS THE FINAL REFERENCE. ALL WORK SHOULD BE DONE BY CERTIFIED AIRCRAFT TECHNICIONS.

  • Page 40: Cessna Float Re-Installation Instructions / Procedures

    WIPLINE MODEL 8000 SERVICE MANUAL 5.8 CESSNA FLOAT RE-INSTALLATION INSTRUCTIONS / PROCEDURES MECHANIC INSP. CESSNA 208 FLOAT RE-INSTALLATION INSTRUCTIONS/PROCEEDURES THIS IS INTENDED AS A GENERAL GUIDE. EACH INSTALLATION MAY HAVE Right Left SUBTLE DIFFERENCES. ALWAYS USE THE INSTALLATION DRAWINGS AS THE FINAL REFERENCE.
  • Page 41 WIPLINE MODEL 8000 SERVICE MANUAL MECHANIC INSP. (CONT.) CESSNA 208 FLOAT RE-INSTALL INSTRUCTIONS/PROCEEDURES THIS IS INTENDED AS A GENERAL GUIDE. EACH INSTALLATION MAY HAVE Right Left SUBTLE DIFFERENCES. ALWAYS USE THE INSTALLATION DRAWINGS AS THE FINAL REFERENCE. ALL WORK SHOULD BE DONE BY CERTIFIED AIRCRAFT TECHNICIONS.
  • Page 42 WIPLINE MODEL 8000 SERVICE MANUAL DESCRIPTION AND OPERATION 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.
  • Page 43 WIPLINE MODEL 8000 SERVICE MANUAL 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.

  • Page 44: Figure 5-1 Schematic Hydraulic System

    WIPLINE MODEL 8000 SERVICE MANUAL FIGURE 5-1 SCHEMATIC HYDRAULIC SYSTEM Page 44 of 62 1002554 • Rev H...

  • Page 45: Figure 5-2 Schematic Electrical System

    WIPLINE MODEL 8000 SERVICE MANUAL FIGURE 5-2 SCHEMATIC ELECTRICAL SYSTEM 1002554 • Rev H Page 45 of 62...

  • Page 46: Figure 5.3 Assembly Main Gear Retraction System

    WIPLINE MODEL 8000 SERVICE MANUAL FIGURE 5.3 ASSEMBLY MAIN GEAR RETRACTION SYSTEM Page 46 of 62 1002554 • Rev H...

  • Page 47: Figure 5.4 Assembly – Main Gear Shock Strut

    WIPLINE MODEL 8000 SERVICE MANUAL FIGURE 5.4 ASSEMBLY – MAIN GEAR SHOCK STRUT 1002554 • Rev H Page 47 of 62...

  • Page 48: Figure 5-5 Assembly Main Gear And Brake

    WIPLINE MODEL 8000 SERVICE MANUAL FIGURE 5-5 ASSEMBLY MAIN GEAR AND BRAKE (Refer to Parts Manual for complete parts list) Page 48 of 62 1002554 • Rev H...

  • Page 49: Figure 5-6 Assembly Nose Gear System

    WIPLINE MODEL 8000 SERVICE MANUAL FIGURE 5-6 ASSEMBLY NOSE GEAR SYSTEM 1002554 • Rev H Page 49 of 62...

  • Page 50: Weight And Balance

    WIPLINE MODEL 8000 SERVICE MANUAL 5.9 WEIGHT AND BALANCE 5.9.1 WEIGHING PROCEDURES FOR CESSNA 208 CARAVAN Level aircraft per manufacturer’s instructions or use the cabin door lower sill. Place scales under the right and left main and nose gears. Place blocking under the right and left main gears to level aircraft. Draw lines on the floor from the centerline main wheels and centerline nose wheel left to right.

  • Page 51: Water Rudder Retraction And Steering System

    WIPLINE MODEL 8000 SERVICE MANUAL 6.0 WATER RUDDER RETRACTION AND STEERING SYSTEM 6.1 DESCRIPTION The water rudder-retract system is manually operated by a lever through a system of cables and pulleys. Steering is directed from the aircraft rudder steering system. 6.2 ADJUSTMENT Rigging of the water rudder steering cables is accomplished by centering the airplane rudder and adjusting the turnbuckles such that both rudders trail with the float center line.

  • Page 52: Repairing Float Hull Skins, Bulkheads And Sheet Metal

    7-2, 7-3, or any acceptable repair method listed in FAA Advisory Circular 43.13.1A. Any float hull skin or bulkhead or part thereof can be purchased from Wipaire to aid in repair. To simplify repairs, the skins can be ordered precut to shape.

  • Page 53: Figure 7-1 Typical Skin Repair

    WIPLINE MODEL 8000 SERVICE MANUAL FIGURE 7-1 TYPICAL SKIN REPAIR 1. TRIM HOLE AS SHOWN BY DOTTED LINE. 2. PATCH MATERIAL TO BE AT LEAST SAME THICKNESS AS ORIGINAL SKIN. 3. PRIME ALL BARE SURFACES. 4. SEAL BETWEEN PATCH AND SKIN. 5.

  • Page 54: Figure 7-2 Typical Skin Repair

    WIPLINE MODEL 8000 SERVICE MANUAL FIGURE 7-2 TYPICAL SKIN REPAIR Page 54 of 62 1002554 • Rev H...

  • Page 55: Figure 7-3 Typical Skin Repair

    WIPLINE MODEL 8000 SERVICE MANUAL FIGURE 7-3 TYPICAL SKIN REPAIR 1002554 • Rev H Page 55 of 62...
  • Page 56 WIPLINE MODEL 8000 SERVICE MANUAL FIGURE 7-4 TYPICAL REPAIR BOTTOM SKIN TO KEEL INSTRUCTIONS (Preferred method) 1. REMOVE ORIGINAL DAMAGED SKIN CUT FLUSH WITH EXTRUSION. 2. REMOVE CAULKING FROM GROOVE OF EXTRUSION. 3. APPLY SEALANT IN GROOVE. (BE SURE TO USE PLENTY OF SEALANT!) 4.

  • Page 57: Figure 7-5 Typical Repair Bottom Skin To Keel Instructions

    WIPLINE MODEL 8000 SERVICE MANUAL FIGURE 7-5 TYPICAL REPAIR BOTTOM SKIN TO KEEL INSTRUCTIONS. 1. REMOVE ORIGINAL DAMAGED SKIN FROM EXTRUSION. 2. REMOVE CAULKING FROM GROOVE OF EXTRUSION. 3. APPLY SEALANT IN GROOVE. (BE SURE TO USE PLENTY OF SEALANT!) 4.
  • Page 58 WIPLINE MODEL 8000 SERVICE MANUAL FIGURE 7-6 TYPICAL REPAIR BOTTOM SKIN TO KEEL (ALT) INSTRUCTIONS (ALTERNATE METHOD) 1. REMOVE ORIGINAL DAMAGED SKIN LEAVING APPROXIMATELY 1 ½” OF SKIN PROTRUDING FROM EXTRUSION. 2. REMOVE CAULKING FROM GROOVE IN EXTRUSION. 3. INSTALL SEALANT IN GROOVE. (BE SURE TO USE PLENTY OF SEALANT!) 4.

  • Page 59: Repairing Float Hull Extrusions

    Capping also is done when the original skin is still bonded to the inside of the extrusion. Sections of extrusion for splicing or capping may be purchased from Wipaire in any length needed. Stub skins can also be bonded on extrusion sections if desired, to simplify the repair.

  • Page 60: Figure 8-1 Typical Repair Splice Of Keel

    WIPLINE MODEL 8000 SERVICE MANUAL FIGURE 8-1 TYPICAL REPAIR SPLICE OF KEEL Page 60 of 62 1002554 • Rev H...

  • Page 61: Figure 8-2 Typical Repair Splice Of Chine

    WIPLINE MODEL 8000 SERVICE MANUAL FIGURE 8-2 TYPICAL REPAIR SPLICE OF CHINE 1002554 • Rev H Page 61 of 62...

  • Page 62: Figure 8-3 Typical Cap Splice To Keel

    WIPLINE MODEL 8000 SERVICE MANUAL FIGURE 8-3 TYPICAL CAP SPLICE TO KEEL 1. LAYOUT NEW REPAIR CAP ON DAMAGED EXTRUSION. 2. REMOVE OUTSIDE OF DAMAGED EXTRUSION BY FILING OR GRINDING TO INSIDE SHAPE OF REPAIR CAP. 3. MATCH DRILL OR LAYOUT AND DRILL HOLE PATTERN AS SHOWN. 4.

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