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Wipaire Wipline 2100 Service Manual

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 2100/2350
AMPHIBIOUS AND SEAPLANE FLOATS
Wipaire Part Number: 1002549 Rev. J
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 2100/2350 AMPHIBIOUS AND SEAPLANE FLOATS Wipaire Part Number: 1002549 Rev. J 1700 Henry Ave – Fleming Field (KSGS), South St. Paul, MN 55075 Ph: 651.451.1205 Fax: 651.457.7858 www.wipaire.com...
  • Page 2 WIPLINE MODEL 2100/2350 SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Page 2 1002549 • Rev F...

  • Page 3: Table Of Contents

    WIPLINE MODEL 2100/2350 SERVICE MANUAL TABLE OF CONTENTS SECTION PAGE LOG OF REVISIONS ......................... 5 INTRODUCTION ........................8 1.0 GENERAL ..........................9 2.0 FLOAT HULL MAINTENANCE ....................10 2.1 GENERAL ........................10 2.2 CLEANING ........................10 3.0 CORROSION ........................11 4.0 FLOAT HANDLING, JACKING, AND AIRCRAFT TOWING ..........12 5.0 RETRACT SYSTEM OPERATION AND MAINTENANCE ...........13 5.1 DESCRIPTION AND OPERATION ..................13 5.2 ADJUSTMENT/TEST ......................14...
  • Page 4 WIPLINE MODEL 2100/2350 SERVICE MANUAL 8.4 REASSEMBLE NOSE TROLLEY TO NOSE BOX ............37 8.5 REMOVAL OF NOSE BOX FORK FROM PIVOT ASSEMBLY ........38 8.6 NOSE BOX REMOVAL FROM FLOAT ................38 8.7 NOSE BOX TRACK WEAR .....................38 FIGURE 7-3 FRONT VIEW NOSE BOX ................40 FIGURE 7-4 POSITION OF TROLLEY TO NOSE BOX ............41 9.0 WATER RUDDER RETRACTION AND STEERING SYSTEM ..........42 9.0 DESCRIPTION ........................42...

  • Page 5: Log Of Revisions

    11, 24, 25 Mobil Aviation Grease SHC 100 to approved 12/4/2015 product list. Modified torque limits section Cover, 4, Added Wipaire document number to cover, CC- 1/12/2017 5, 57 19 aircraft added to weighing procedures 1002549 • Rev J Page 5...
  • Page 6 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 1002549 • Rev F...
  • Page 7 WIPLINE MODEL 2100/2350 SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1002549 • Rev F Page 7...

  • Page 8: Introduction

    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 9: General

    WIPLINE MODEL 2100/2350 SERVICE MANUAL 1.0 GENERAL The model 2100/2350 seaplane or amphibious float is an all aluminum-constructed float with watertight compartments. The actual displacement in fresh water for each float is 2323 pounds (model 2100) and 2570 pounds (model 2350) buoyancy for the seaplane and 2185 pounds (model 2100) and 2432 pounds (model 2350) buoyancy for the amphibian.

  • Page 10: Float Hull Maintenance

    WIPLINE MODEL 2100/2350 SERVICE MANUAL 2.0 FLOAT HULL MAINTENANCE 2.1 GENERAL The float structure side and top skins are 6061-T6 and forward and aft bottom skins are 2024-T3 aluminum sheet and 6061-T6 extrusions. Skins are alodined and primed after being cleaned and acid-etched. Exterior is finished with an enamel color paint, or equivalent.

  • Page 11: Corrosion

    WIPLINE MODEL 2100/2350 SERVICE MANUAL 3.0 CORROSION Corrosion is a reaction that destroys metal by an electrochemical action that converts metal to oxide. Corrosion is accelerated when in contact with dissimilar metals such as aluminum and steel, or any material which absorbs moisture like wood, rubber, or dirt. The primary means of detection of corrosion is visual.

  • Page 12: Float Handling, Jacking, And Aircraft Towing

    Wipaire Parts has this tow bar available. A lifting apparatus that will pick the aircraft up by the lifting rings at wing attach points from a ceiling hoist, to be fabricated. Contact Wipaire Customer Service for details if necessary. Page 12...

  • Page 13: Retract System Operation And Maintenance

    WIPLINE MODEL 2100/2350 SERVICE MANUAL 5.0 RETRACT SYSTEM OPERATION AND MAINTENANCE 5.1 DESCRIPTION AND OPERATION Retraction and extension of the main and nose landing gear is effected by a hydraulic actuation system shown schematically in figure 5-1. The gear system is hydraulically actuated and driven by one reversible electric pump. A pressure of between 500 psi and 700 psi in the up and down position is maintained in the supply line.

  • Page 14: Adjustment/Test

    WIPLINE MODEL 2100/2350 SERVICE MANUAL 5.2 ADJUSTMENT/TEST Adjustment of the hydraulic actuator stroke is provided at the ends of the piston rods on the nose and main gear. Nose: The “gear down” position is set by adjusting the cylinder rod end so the over-center knuckle (brass) rollers bottom out in the Nose Fork Tracks without preload on the cylinder rod.
  • Page 15 WIPLINE MODEL 2100/2350 SERVICE MANUAL 5.3 Landing Gear Malfunction Procedures Landing Gear Fails to Retract or Extend: Battery Switch – ON Landing Gear Switch – RECHECK IN DESIRED POSITION Landing Gear Motor Circuit Breaker – CHECK IN Hand Pump Position Selector – CHECK in NEUTRAL POSITION Gear Lights –...

  • Page 16: Figure 5-1 Schematic Hydraulic System

    WIPLINE MODEL 2100/2350 SERVICE MANUAL FIGURE 5-1 SCHEMATIC HYDRAULIC SYSTEM Page 16 1002549 • Rev F...

  • Page 17: Figure 5-2 Schematic Electrical System

    WIPLINE MODEL 2100/2350 SERVICE MANUAL FIGURE 5-2 SCHEMATIC ELECTRICAL SYSTEM 1002549 • Rev F Page 17...

  • Page 18: Figure 5-3 Main Gear Actuation

    WIPLINE MODEL 2100/2350 SERVICE MANUAL FIGURE 5-3 MAIN GEAR ACTUATION Page 18 1002549 • Rev F...

  • Page 19: Figure 5-4 Nose Gear Retraction System

    WIPLINE MODEL 2100/2350 SERVICE MANUAL FIGURE 5-4 NOSE GEAR RETRACTION SYSTEM 1002549 • Rev F Page 19...

  • Page 20: Figure 5-5 Main Gear Wheel Assembly

    WIPLINE MODEL 2100/2350 SERVICE MANUAL FIGURE 5-5 MAIN GEAR WHEEL ASSEMBLY Page 20 1002549 • Rev F...

  • Page 21: Retract System Operation And Maintenance

    WIPLINE MODEL 2100/2350 SERVICE MANUAL 6.0 RETRACT SYSTEM OPERATION AND MAINTENANCE 6.1 DESCRIPTION AND OPERATION Retraction and extension of the main and nose landing gear is affected by a hydraulic actuation system shown schematically in Figures 5-1, 5-1B, 5-1C, or 5-1D. The gear system is hydraulically actuated and driven by one reversible electric pump.
  • Page 22 WIPLINE MODEL 2100/2350 SERVICE MANUAL The main gear has an over-center lock in both up and down positions. Retraction takes place when pressure is exerted on the actuator piston driving the actuating arm along the slide track (refer to Figure 6-1). A reverse process affects extension. Gear position light proximity switches are closed when the cylinder piston (containing the magnetic material) is adjacent to the switch.

  • Page 23: Service Schedule

    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 24 WIPLINE MODEL 2100/2350 SERVICE MANUAL Protection of nuts, bolts, hydraulic lines SIKAFLEX 201 or 252 or metal surfaces Sika Manufacturing Zip D-5029NS Corrosion Inhibiting Bolt Torque Compound Bolts in Critical Areas - For common, correct Zip Chemical Company torque when installed, or when visual CRC –...
  • Page 25 WIPLINE MODEL 2100/2350 SERVICE MANUAL Teflon Spray GP-730A Comet Industries Hydraulic Fluid Mil-H-5606 Electrical Insulating Compound Dow Corning 4 (DC4) Dow Corning Corporation 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, safe tying, proper operation, proper adjustment, correct travel, cracked fittings, security of hinges, defective...

  • Page 26: Main Gear Removal And Operation

    25. To remove shaft from upper shock strut, remove the two (2) outside grease zerk fittings. 26. For shock strut service, shock strut must be compressed before disassembly. NOTE Shock strut maybe returned to Wipaire for service. 27. Clean and inspect all parts. Page 26 1002549 • Rev F...
  • Page 27 WIPLINE MODEL 2100/2350 SERVICE MANUAL 7.2 Installation and Assembly of Main Gear Assemble track assembly before installing in float. Lay shock strut on bench with grease zerk facing up. Install retract yoke to shock strut upper end with roller shaft. NOTE Holes in shaft to match holes in shock strut bushing.
  • Page 28 WIPLINE MODEL 2100/2350 SERVICE MANUAL 15. Untie shock strut and attach to drag link 5/8-inch bolt NOTE Do not over tighten, lugs will bend. 16. Position by hand gear to the “Up” lock. 17. Install coupling nut NOTE Nut must be installed in same position as removed or cotter keyholes will not line up.
  • Page 29 WIPLINE MODEL 2100/2350 SERVICE MANUAL 30. Set gear position switch by sliding bracket on outside of hydraulic cylinder body by running gear to down position, slide switch bracket up so lights (green) are illuminated on selector head (refer to Figure (6-12). 31.

  • Page 30: Dissassembly Of Shock Strut

    WIPLINE MODEL 2100/2350 SERVICE MANUAL 7.3 DISSASSEMBLY OF SHOCK STRUT Shock strut requires no maintenance except if urethane blocks seem sloppy or spin around easily. To dissemble, remove cotter pin in top retaining pin and remove pin. If replacing urethane blocks, pressure must be applied by arbor press or vice to compress strut and install retaining pin.

  • Page 31: Servicing Hydraulic Actuator Cylinders (Nose Or Main Actuators)

    7.4 SERVICING HYDRAULIC ACTUATOR CYLINDERS (NOSE OR MAIN ACTUATORS) Wipaire, Inc. has created a new design to replace the previous, unserviceable main and nose gear actuators for the 2100, 2350, 3000 and 3450 amphibious floats and is detailed in Service Letter 97 available on our website or from our customer service department. The actuators are fully serviceable.
  • Page 32 WIPLINE MODEL 2100/2350 SERVICE MANUAL 3. Following that, slide the piston down into the cylinder being careful of the quad rings Check the top of the cylinder when this is done for flakes of rubber to indicate any damage from installation. Page 32 1002549 •...
  • Page 33 WIPLINE MODEL 2100/2350 SERVICE MANUAL 4. Clean the threads and install the quad rings into the rod end cap. NOTE Make sure that quad rings are not twisted and are Seated in the grooves. If they are compromised in Any way, they will not seal or hold pressure properly. 5.

  • Page 34: Hand Pump Operation

    WIPLINE MODEL 2100/2350 SERVICE MANUAL 7.5 HAND PUMP OPERATION For normal operation (electrical power pack) the handle is in the neutral position (handle pointed to the neutral position.) If electrical pump should not operate, select to gear up (handle pointed forward) or gear down (handle pointed aft). Insert stowable handle in pump and pump gear to desired position.

  • Page 35: Gear Selector

    WIPLINE MODEL 2100/2350 SERVICE MANUAL 7.6 GEAR SELECTOR The gear selector is an electrical switch which changes pump direction of the electro power pack for gear up or down. The red light on panel indicates the pump is running. The four (4) green lights indicate the landing gear is down.

  • Page 36: Main Wheels And Brakes

    WIPLINE MODEL 2100/2350 SERVICE MANUAL 7.7 MAIN WHEELS AND BRAKES Grease zerks are provided on all wheels and bearings and should be greased every 25 hours or after an extended period of time in the water. Water/heat resistant grease is recommended. The brakes need no special care other than to maintain the brake disc free of rust, which causes premature brake lining wear.

  • Page 37: Nose Gear

    WIPLINE MODEL 2100/2350 SERVICE MANUAL 8.0 NOSE GEAR 8.1 DESCRIPTION The nose gear consists of scotchply fiberglass beams that are attached at the bottom to castoring blocks. A nylon thrust washer is located on top of the castoring pin. To disassemble, remove ¼...

  • Page 38: Removal Of Nose Box Fork From Pivot Assembly

    WIPLINE MODEL 2100/2350 SERVICE MANUAL 8.5 REMOVAL OF NOSE BOX FORK FROM PIVOT ASSEMBLY Remove ¼ inch bolt. NOTE This is a heat-treated bolt. Entire pivot shaft on nose fork will drop down for service. Assemble per Figure 7-1. Axle bolt is modified for grease service. A special anti-rotation washer is under bolt head to keep axle from turning.
  • Page 39 WIPLINE MODEL 2100/2350 SERVICE MANUAL FIGURE 7-2 NOSE BOX ACCESS LOCATION 1002549 • Rev F Page 39...

  • Page 40: Figure 7-3 Front View Nose Box

    WIPLINE MODEL 2100/2350 SERVICE MANUAL FIGURE 7-3 FRONT VIEW NOSE BOX Page 40 1002549 • Rev F...

  • Page 41: Figure 7-4 Position Of Trolley To Nose Box

    WIPLINE MODEL 2100/2350 SERVICE MANUAL FIGURE 7-4 POSITION OF TROLLEY TO NOSE BOX 1002549 • Rev F Page 41...

  • Page 42: Water Rudder Retraction And Steering System

    WIPLINE MODEL 2100/2350 SERVICE MANUAL 9.0 WATER RUDDER RETRACTION AND STEERING SYSTEM 9.0 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. 9.1 ADJUSTMENT Rigging of the water rudder steering cables is accomplished by centering the airplane rudder and adjusting the turnbuckles such that both rudders trail with the float centerline.
  • Page 43 WIPLINE MODEL 2100/2350 SERVICE MANUAL INSPECTION TIME LIMITS HOURS Mech Initial INSP. General Placards Hulls & Float Installation. Float exterior – inspect for damage, Struts wrinkled metal, corrosion, paint loss, etc. Struts & attach fittings Spreader bars Float Structure (interior) Baggage Compartment Covers and Seals Remove inspection plates &...
  • Page 44 WIPLINE MODEL 2100/2350 SERVICE MANUAL HOURS MECH. INITIAL INSP. INSPECTION TIME LIMITS Landing Main and Nose Gear Tracks – lubricate. Gear Nose Gear Box/Block Tracks measured at slide Systems route for wear, .020 inches or less wear tolerance. Nose Gear Pivot Blocks and Forks – inspect for Inspect Pivot Bolt condition, lubrication, corrosion, paint.
  • Page 45 WIPLINE MODEL 2100/2350 SERVICE MANUAL INSP. Perform Retraction Test Main Gear – inspect up and down for proper engagement. Nose Gear Trolley – inspect for proper travel Nose Gear – inspect for excessive side play in the down position. Perform emergency gear extension (if equipped).
  • Page 46 WIPLINE MODEL 2100/2350 SERVICE MANUAL 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. c. Solenoid switch not pulling in. d.
  • Page 47 WIPLINE MODEL 2100/2350 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. If isolating entire system still indicates internal leak, power pack check valve (located in pressure port of pump) is bad and needs replacement or reseating.

  • Page 48: Repairing Float Hull Skins

    Damage to the skins may be repaired per Figures 9-1, 9-2, 9-3, or any acceptable repair method listed in FAA Advisory Circular 43.13.1A. Any float hull skin or part thereof can be purchased from Wipaire to aid in repair. To simplify repairs, the skins are precut and drilled.

  • Page 49: Figure 9-1 Typical Skin Repair

    WIPLINE MODEL 2100/2350 SERVICE MANUAL FIGURE 9-1 TYPICAL SKIN REPAIR 1002549 • Rev F Page 49...

  • Page 50: Figure 9-2 Typical Skin Repair

    WIPLINE MODEL 2100/2350 SERVICE MANUAL FIGURE 9-2 TYPICAL SKIN REPAIR Page 50 1002549 • Rev F...

  • Page 51: Figure 9-3 Typical Skin Repair

    WIPLINE MODEL 2100/2350 SERVICE MANUAL FIGURE 9-3 TYPICAL SKIN REPAIR 1002549 • Rev F Page 51...

  • Page 52: Keel Splice Repair

    WIPLINE MODEL 2100/2350 SERVICE MANUAL KEEL SPLICE REPAIR 1. Remove rivets about 6-8” on either end of the area to be repaired. 2. Mark damaged area to be removed. Note: Be sure to start and end spliced area in the centers of the floats bays to prevent interference with the bulkheads or bottom stiffeners.

  • Page 53: Figure 9.5 Doubler Sections

    WIPLINE MODEL 2100/2350 SERVICE MANUAL 7. Fabricate keel splice doubler sections from 6061-T6 .060” aluminum and using figure 9.5 as recommended dimensions. FIGURE 9.5 DOUBLER SECTIONS 8. Back drill the splice parts from existing holes. Be sure to center the splice on the split of the repair area.

  • Page 54: Figure 9.7 Finished Keel With Stiffeners

    WIPLINE MODEL 2100/2350 SERVICE MANUAL 10. Wet the skin under the repair with the required sealant. Sikaflex polyurethane sealant or PRC sealant (PR890 or PR1422). 11. Rivet together with appropriate diameter and length rivets depending on splice location with structural rivets. Clean excess sealant from the repair areas with MEK or equivalent solvent. 12.

  • Page 55: Weight And Balance

    WIPLINE MODEL 2100/2350 SERVICE MANUAL 11.0 WEIGHT AND BALANCE WEIGHING PROCEDURES FOR PIPER PA-18 FLOATPLANE Level aircraft per manufacturer’s instructions. Place scales under the right and left nose and main gear wheels. Place blocking under the right and left main gears to level aircraft. Drop plumb bob from the wing leading edge to the floor and mark a line to establish station 0.0, the datum.

  • Page 56: Weighing Procedures For Piper Pa-12 Floatplane

    WIPLINE MODEL 2100/2350 SERVICE MANUAL WEIGHING PROCEDURES FOR PIPER PA-12 FLOATPLANE Level aircraft per manufacturer’s instructions or drop a plumb bob from the machine screw at the door frame channels at rear upper corner of the door to a hole in the plate near the rear seat. When these meet the plane is level.

  • Page 57: Weighing Procedures For Cub Crafters Cc-18 And Cc-19 Floatplane

    WIPLINE MODEL 2100/2350 SERVICE MANUAL WEIGHING PROCEDURES FOR CUB CRAFTERS CC-18 AND CC-19 FLOATPLANE Level aircraft per manufacturer’s instructions in Maintenance Manual TC10000AMM for CC-18 or XC10000AMM for CC-19. Place scales under the right and left main and nose gears. Place blocking under the right and left main gears to level aircraft.

  • Page 58: Weighing Procedures For The Husky A-1, A-1A, A-1B Or A-1C Floatplane

    WIPLINE MODEL 2100/2350 SERVICE MANUAL WEIGHING PROCEDURES FOR THE HUSKY A-1, A-1A, A-1B OR A-1C FLOATPLANE 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. Drop plumb bob from the wing leading edge and mark the floor parallel to the aircraft leading edge.

  • Page 59: Weighing Procedure For Cessna 172 Floatplane

    WIPLINE MODEL 2100/2350 SERVICE MANUAL WEIGHING PROCEDURE FOR CESSNA 172 FLOATPLANE Level the aircraft as per the weight and balance section of the landplane handbook. Place the scales under all 4 wheels. Place whatever blocking is required under the mail gears to level the aircraft.

  • Page 60: Weighing Procedure For Cessna 170 Floatplane

    WIPLINE MODEL 2100/2350 SERVICE MANUAL WEIGHING PROCEDURE FOR CESSNA 170 FLOATPLANE Level the aircraft as per the weight and balance section of the landplane handbook or use the upper pilot’s door sill. Place the scales under all 4 wheels. Place whatever blocking is required under the mail gears to level the aircraft.

  • Page 61: Weighing Procedure For Cessna 175 Floatplane

    WIPLINE MODEL 2100/2350 SERVICE MANUAL WEIGHING PROCEDURE FOR CESSNA 175 FLOATPLANE Level the aircraft as per the weight and balance section of the landplane handbook or use the upper pilot’s door sill. Place the scales under all 4 wheels. Place whatever blocking is required under the mail gears to level the aircraft.
  • Page 62 WIPLINE MODEL 2100/2350 SERVICE MANUAL WEIGHING PROCEDURE FOR 8GCBC SCOUT FLOATPLANE Level the aircraft as per the weight and balance section of the landplane handbook or draw a pencil mark on the top of the stub gear, 10 3/16” from the front face of the front lift strut attach lug. Drop a plumb bob from the wing leading edge and lift the tail until the plumb reaches this mark.

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Wipline 2350

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