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Wipaire Wipline 4000 Service Manual

Amphibious and seaplane floats on cessna a185e, a185f, and 206 series
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SERVICE MANUAL & ICA
WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES
WIPLINE FLOATS • SKIS • MODIFICATIONS • AIRCRAFT SALES
AVIONICS • INTERIOR • MAINTENANCE • PAINT REFINISHING
AMPHIBIOUS AND SEAPLANE FLOATS
ON CESSNA A185E, A185F, AND 206 SERIES
P/N 1002552
SERVICE MANUAL
FOR THE
WIPLINE MODEL 4000
Revision G
Revision G
Page 1

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  • Page 1 SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES WIPLINE FLOATS • SKIS • MODIFICATIONS • AIRCRAFT SALES AVIONICS • INTERIOR • MAINTENANCE • PAINT REFINISHING SERVICE MANUAL FOR THE WIPLINE MODEL 4000 AMPHIBIOUS AND SEAPLANE FLOATS...
  • Page 2 SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES THIS PAGE INTENTIONALLY LEFT BLANK Page 2 Revision G P/N 1002552...
  • Page 3 SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES LOG OF REVISIONS Pages Description Date 9, 22 Added an inspection time limit and tolerances for the Nose Block Track wear. 4/18/2006 Reformat of entire document, Add green grease as approved grease.
  • Page 4 SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES THIS PAGE INTENTIONALLY LEFT BLANK Page 4 Revision G P/N 1002552...

  • Page 5: Table Of Contents

    SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES CONTENTS INTRODUCTION ...............................7 CHAPTER 1 GENERAL INFORMATION ......................9 CHAPTER 2 FLOAT HULL MAINTENANCE ....................11 CHAPTER 3 CORROSION ..........................13 CHAPTER 4 FLOAT HANDLING AND JACKING ..................15 CHAPTER 5 RETRACT SYSTEM OPERATION AND MAINTENANCE ............21 CHAPTER 6 MAIN GEAR ..........................39...
  • Page 6 SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES LIST OF FIGURES FIGURE 4-1 JACK CRADLE RECOMMENDED MODIFICATION ............17 FIGURE 4-2 JACKING LOCATION ......................17 FIGURE 4-3 FLOAT SECURING LOCATIONS ..................18 FIGURE 4-4 FLOAT SECURING LOCATIONS OVERVIEW ..............19 FIGURE 5-1 SCHEMATIC HYDRAULIC SYSTEM ................23...

  • Page 7: Introduction

    This manual describes the general service and maintenance for the float hull, gear systems, installation, and control parts. For service and repair not covered by this manual contact Wipaire Customer Service. When performing standard repairs for Wipline Aluminum Floats, please refer to the “Structural Repair Manual For Wipline Aluminum Floats”...
  • Page 8 SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES THIS PAGE INTENTIONALLY LEFT BLANK Page 8 Revision G P/N 1002552...

  • Page 9: Chapter 1 General Information

    SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES CHAPTER 1 GENERAL INFORMATION CONTENTS 1.0 GENERAL ..............................10 P/N 1002552 Revision G Page 9...
  • Page 10 SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES 1.0 GENERAL The model 4000 seaplane or amphibious float is an all aluminum constructed float with watertight compartments. The actual displacement in fresh water for each float is 3802 pounds buoyancy for the seaplane and 3672 pounds buoyancy for the amphibian.

  • Page 11: Chapter 2 Float Hull Maintenance

    SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES CHAPTER 2 FLOAT HULL MAINTENANCE CONTENTS 2.1 GENERAL ..............................12 2.2 CLEANING ..............................12 P/N 1002552 Revision G Page 11...
  • Page 12 SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES 2.1 GENERAL The float structure is manufactured entirely of 2024-T3 or 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.

  • Page 13: Chapter 3 Corrosion

    SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES CHAPTER 3 CORROSION CONTENTS 3.0 CORROSION .............................14 P/N 1002552 Revision G Page 13...
  • Page 14 WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES 3.0 CORROSION Reference the Wipaire Structural Repair Manual (SRM) for allowable corrosion/material loss limits. Corrosion is a reaction that destroys metal by an electrochemical action that converts metal to oxide. Corrosion is accelerated when in contact with dissimilar metals such as aluminum and steel, or any material which absorbs moisture like wood, rubber, or dirt.

  • Page 15: Chapter 4 Float Handling And Jacking

    SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES CHAPTER 4 FLOAT HANDLING AND JACKING CONTENTS 4.0 TOWING ..............................16 4.1 HOISTING ..............................16 4.2 LEVELING ..............................16 4.3 JACKING PROCEDURES ........................16 4.4 JACK REMOVAL ............................19 P/N 1002552...
  • Page 16 If the lifting rings are not installed, reference applicable aircraft maintenance/ service manual for additional hoisting specifications. Lake & Air Training and Pilot Shop has this hoisting rig available for purchase. Contact Wipaire Customer Service for additional guidance in removal or installation of floats.

  • Page 17: Figure 4-1 Jack Cradle Recommended Modification

    (X = WIDTH OF CRADLE) FIGURE 4-1 JACK CRADLE RECOMMENDED MODIFICATION NOTE: This is not required and Wipaire does not have the parts for modification. It is recommended a similar modification be performed to the jack saddle to prevent the slippage of the cradle.

  • Page 18: Figure 4-3 Float Securing Locations

    SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES FIGURE 4-3 FLOAT SECURING LOCATIONS ALTERNATE JACKING METHOD IF WIPAIRE JACKING FIXTURE IS NOT AVAILABLE (8000A model shown for reference only) Page 18 Revision G P/N 1002552...

  • Page 19: Figure 4-4 Float Securing Locations Overview

    SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES Fore Cradle Cradle Stand Aft Cradle Fore Stand Support Support (8000A MODEL SHOWN FOR REFERENCE ONLY) FIGURE 4-4 FLOAT SECURING LOCATIONS OVERVIEW 4.4 JACK REMOVAL Make sure nothing is under or above the airplane or floats when removing the jacks from the aircraft 1.
  • Page 20 SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES THIS PAGE INTENTIONALLY LEFT BLANK Page 20 Revision G P/N 1002552...

  • Page 21: Chapter 5 Retract System Operation And Maintenance

    SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES CHAPTER 5 RETRACT SYSTEM OPERATION AND MAINTENANCE CONTENTS 5.1 DESCRIPTION AND OPERATION ......................22 5.2 ADJUSTMENT / TEST ..........................28 5.3 SERVICE SCHEDULE ..........................28 5.4 INSPECTION CHECKLIST........................32 5.5 TROUBLE SHOOTING ..........................36...

  • Page 22: Description And Operation

    SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES 5.1 DESCRIPTION AND OPERATION Retraction and extension of the main and nose landing gear is effected by a hydraulic actuation system shown schematically in figure 5-1.

  • Page 23: Figure 5-1 Schematic Hydraulic System

    SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES FIGURE 5-1 SCHEMATIC HYDRAULIC SYSTEM P/N 1002552 Revision G Page 23...

  • Page 24: Figure 5-2 Schematic: Landing Gear Electrical System

    SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES FIGURE 5-2 SCHEMATIC: LANDING GEAR ELECTRICAL SYSTEM Page 24 Revision G P/N 1002552...

  • Page 25: Figure 5-3 Main Gear Actuation System

    SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES FIGURE 5-3 MAIN GEAR ACTUATION SYSTEM P/N 1002552 Revision G Page 25...

  • Page 26: Figure 5-4 Main Gear Locking System

    SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES FIGURE 5-4 MAIN GEAR LOCKING SYSTEM Page 26 Revision G P/N 1002552...

  • Page 27: Figure 5-5 Nose Gear Retraction System

    SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES FIGURE 5-5 NOSE GEAR RETRACTION SYSTEM P/N 1002552 Revision G Page 27...

  • Page 28: Adjustment / Test

    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 29 SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES General Lubricants LPS 1, LPS 2 and LPS 3 LPS Industries Wheel Bearings *HCF Grease, P/N 605 HCF Industries *Aeroshell 22 Shell Global Solutions *Green Grease, Multi-Purpose Green Grease Inc.
  • Page 30 SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES *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.
  • Page 31 SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES 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.

  • Page 32: Inspection Checklist

    SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES 5.4 INSPECTION CHECKLIST Page 32 Revision G P/N 1002552...
  • Page 33 SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES P/N 1002552 Revision G Page 33...
  • Page 34 SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES Page 34 Revision G P/N 1002552...
  • Page 35 SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES P/N 1002552 Revision G Page 35...

  • Page 36: Trouble Shooting

    SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES 5.5 TROUBLE SHOOTING 1. PROBLEM - Power pack does not run after gear selection. PROBABLE CAUSE a. Circuit breaker has failed b. Pressure switch not pulling in at low cut in.
  • Page 37 SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES 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.
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  • Page 39: Chapter 6 Main Gear

    SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES CHAPTER 6 MAIN GEAR CONTENTS 6.1 MAIN OLEO ...............................40 6.1.1 DESCRIPTION ............................40 6.1.2 REMOVAL / INSTALLATION .........................41 6.1.3 SERVICE ..............................41 6.2 MAIN WHEELS AND BRAKES ........................41...

  • Page 40: Figure 6-1 Section Main Gear Oleo

    SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES 6.1 MAIN OLEO 6.1.1 DESCRIPTION Shock absorption for the main landing gear is provided by a hydraulically dampened air spring. Figure 6-1 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.
  • Page 41 SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES 6.1.2 REMOVAL / INSTALLATION Removal of the oleo assembly is accomplished by jacking the aircraft and removing the top oleo bolt and the bolt attaching the oleo to the landing gear yoke. The slide tube carriage must be moved forward approximately 1" to remove the top oleo bolt.

  • Page 42: Figure 6-2 Assembly Main Wheel And Brake

    SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES FIGURE 6-2 ASSEMBLY MAIN WHEEL AND BRAKE Page 42 Revision G P/N 1002552...

  • Page 43: Chapter 7 Nose Gear

    SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES CHAPTER 7 NOSE GEAR CONTENTS 7.1 DESCRIPTION ............................44 7.2 SERVICE SCHEDULE ..........................44 7.3 NOSE BOX TRACK WEAR ........................44 P/N 1002552 Revision G Page 43...
  • Page 44 SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES 7.1 DESCRIPTION The nose gear consists of scotchply fiberglass beams that are attached at the bottom to castoring blocks. Inside the block is a castoring pin that is set into the machined fork assembly. The castoring pin allows the nose wheel to pivot in a complete circle.

  • Page 45: Chapter 8 Water Rudder Retraction And Steering System

    SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES CHAPTER 8 WATER RUDDER RETRACTION AND STEERING SYSTEM CONTENTS 8.1 DESCRIPTION ............................46 8.2 ADJUSTMENT ............................46 8.3 SERVICE SCHEDULE ..........................46 P/N 1002552 Revision G Page 45...
  • Page 46 SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES 8.1 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.

  • Page 47: Chapter 9 Repairing Float Hull Skins

    SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES CHAPTER 9 REPAIRING FLOAT HULL SKINS CONTENTS 9.0 REPAIRING FLOAT HULL SKINS ......................48 P/N 1002552 Revision G Page 47...
  • Page 48 SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES 9.0 REPAIRING FLOAT HULL SKINS For all float skin structural repairs, refer to Wipaire's Structural Repair Manual (SRM) part number 1008274. Page 48 Revision G P/N 1002552...

  • Page 49: Chapter 10 Repairing Float Hull Extrusions

    SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES CHAPTER 10 REPAIRING FLOAT HULL EXTRUSIONS CONTENTS 10.0 REPAIRING FLOAT HULL EXTRUSIONS ....................50 P/N 1002552 Revision G Page 49...
  • Page 50 SERVICE MANUAL & ICA WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES 10.0 REPAIRING FLOAT HULL EXTRUSIONS For all float extrusion structural repairs, refer to Wipaire's Structural Repair Manual (SRM) part number 1008274. Page 50 Revision G P/N 1002552...

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