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Wipaire Wipline 8000 Service Manual And Instructions

Amphibious and seaplane floats
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SERVICE MANUAL & ICA
WIPLINE 8000 FLOATS ON CESSNA 208
WIPLINE FLOATS • SKIS • MODIFICATIONS • AIRCRAFT SALES
AVIONICS • INTERIOR • MAINTENANCE • PAINT REFINISHING
AMPHIBIOUS AND SEAPLANE FLOATS
P/N 1002554
SERVICE MANUAL
AND
INSTRUCTIONS FOR
CONTINUED AIRWORTHINESS
FOR THE
WIPLINE MODEL 8000
Revision P
Revision P
Page 1

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  • Page 1 SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 WIPLINE FLOATS • SKIS • MODIFICATIONS • AIRCRAFT SALES AVIONICS • INTERIOR • MAINTENANCE • PAINT REFINISHING SERVICE MANUAL INSTRUCTIONS FOR CONTINUED AIRWORTHINESS FOR THE WIPLINE MODEL 8000 AMPHIBIOUS AND SEAPLANE FLOATS...
  • Page 2 SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 THIS PAGE INTENTIONALLY LEFT BLANK Page 2 Revision P P/N 1002554...
  • Page 3 11/7/2017 grease, corrected 6P-730A Teflon Spray to GP-730A. Removed new customer form. Removed repairing content found in Wipaire document 1008274. Edited retract and steering cable tensions. Added reference only note to metering pin. Added reference for Structural Repair Manual part number 1008274 in introduction.
  • Page 4 SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 THIS PAGE INTENTIONALLY LEFT BLANK Page 4 Revision P P/N 1002554...

  • Page 5: Table Of Contents

    SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 CONTENTS INTRODUCTION ...............................9 CHAPTER 1 GENERAL INFORMATION .......................11 CHAPTER 2 FLOAT HULL MAINTENANCE ....................13 CHAPTER 3 FLOAT HANDLING, JACKING, AND AIRCRAFT TOWING............17 CHAPTER 4 AMPHIBIAN LANDING GEAR SYSTEM OPERATION AND MAINTENANCE .....23 CHAPTER 5 MAIN AND NOSE GEAR OPERATION, REMOVAL AND SERVICE ........27...
  • Page 6 SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 LIST OF FIGURES FIGURE 3.1 JACK CRADLE RECOMMENDED MODIFICATION ............19 FIGURE 3.2 JACKING LOCATION ......................19 FIGURE 3.3 FLOAT SECURING LOCATIONS ..................20 FIGURE 3.4 FLOAT SECURING LOCATIONS OVERVIEW ..............21 FIGURE 5.1 SCHEMATIC HYDRAULIC SYSTEM ................53 FIGURE 5.2 SCHEMATIC ELECTRICAL SYSTEM ................54...
  • Page 7 SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 P/N 1002554 Revision P Page 7...
  • Page 8 SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 THIS PAGE INTENTIONALLY LEFT BLANK Page 8 Revision P P/N 1002554...

  • Page 9: Introduction

    When performing standard repairs for Wipline Aluminum Floats, please refer to the “Structural Repair Manual For Wipline Aluminum Floats” part number 1008274. It is available free of charge online at www.wipaire.com. The service products referred to throughout this manual are described by their trade name and may be purchased from the Wipaire Parts Department.
  • Page 10 SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 THIS PAGE INTENTIONALLY LEFT BLANK Page 10 Revision P P/N 1002554...

  • Page 11: Chapter 1 General Information

    SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 CHAPTER 1 GENERAL INFORMATION CONTENTS 1.0 GENERAL ..............................12 P/N 1002554 Revision P Page 11...
  • Page 12 SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 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 13: Chapter 2 Float Hull Maintenance

    SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 CHAPTER 2 FLOAT HULL MAINTENANCE CONTENTS 2.1 GENERAL ..............................14 P/N 1002554 Revision P Page 13...
  • Page 14 SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 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 15 WIPLINE 8000 FLOATS ON CESSNA 208 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 that absorbs moisture like wood, rubber, or dirt.
  • Page 16 SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 THIS PAGE INTENTIONALLY LEFT BLANK Page 16 Revision P P/N 1002554...

  • Page 17: Chapter 3 Float Handling, Jacking, And Aircraft Towing

    SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 CHAPTER 3 FLOAT HANDLING, JACKING, AND AIRCRAFT TOWING CONTENTS 3.1 TOWING ..............................18 3.2 HOISTING ..............................18 3.3 LEVELING ..............................18 3.4 JACKING PROCEDURES ........................18 3.5 JACK REMOVAL ............................21 P/N 1002554 Revision P...
  • Page 18 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 19: Figure 3.1 Jack Cradle Recommended Modification

    (X = WIDTH OF CRADLE) FIGURE 3.1 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 20: Figure 3.3 Float Securing Locations

    SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 FIGURE 3.3 FLOAT SECURING LOCATIONS ALTERNATE JACKING METHOD IF WIPAIRE JACKING FIXTURE IS NOT AVAILABLE (8000A model shown for reference only) Page 20 Revision P P/N 1002554...

  • Page 21: Figure 3.4 Float Securing Locations Overview

    SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 Fore Cradle Cradle Stand Aft Cradle Fore Stand Support Support (8000A MODEL SHOWN FOR REFERENCE ONLY) FIGURE 3.4 FLOAT SECURING LOCATIONS OVERVIEW 3.5 JACK REMOVAL Make sure nothing is under or above the airplane or floats when removing the jacks from the aircraft 1.
  • Page 22 SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 THIS PAGE INTENTIONALLY LEFT BLANK Page 22 Revision P P/N 1002554...

  • Page 23: Chapter 4 Amphibian Landing Gear System Operation And Maintenance

    SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 CHAPTER 4 AMPHIBIAN LANDING GEAR SYSTEM OPERATION AND MAINTENANCE CONTENTS 4.0 GENERAL ..............................24 4.1 LANDING GEAR HANDLE ........................24 4.2 INDICATOR LIGHTS ..........................24 4.3 LANDING GEAR OPERATION ........................25 4.4 EMERGENCY PUMP HANDLE ........................25...
  • Page 24 SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 4.0 GENERAL 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 25 SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 4.3 LANDING GEAR OPERATION To retract or extend the landing gear, pull out on the landing gear handle and move it to the desired position. When the handle is positioned, pressure on the hydraulic system reduces to where the hydraulic motors automatically turn on.
  • Page 26 SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 THIS PAGE INTENTIONALLY LEFT BLANK Page 26 Revision P P/N 1002554...

  • Page 27: Chapter 5 Main And Nose Gear Operation, Removal And Service

    SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 CHAPTER 5 MAIN AND NOSE GEAR OPERATION, REMOVAL AND SERVICE CONTENTS 5.1 DESCRIPTION AND OPERATION ......................28 5.1.1 SERVICE – NOSE GEAR ........................28 5.1.2 SERVICE – MAIN WHEELS AND BRAKES ..................29 5.1.3 SERVICE –...

  • Page 28: Description And Operation

    SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 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 29: Service - Main Wheels And Brakes

    SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 The nose wheels contain grease nipples for the wheel bearings. They should be greased every 25 hours. Nose tires are standard 5:00 x 5, 10-ply, inflated to 60 +/- 5 psi.

  • Page 30: Nose Box Track Wear

    SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 Nose gear proximity switches are located on clips that are mounted on the outer cylinder body, one on each end. The most forward switch is for the gear down lights and most aft is for the gear up position lights. Set the proximity switch mounting clip along outer cylinder body to a position such that the light goes out when the over-center track is about ¼...

  • Page 31: Bleeding Hydraulic System After Service

    SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 5.2.4 BLEEDING HYDRAULIC SYSTEM AFTER SERVICE The system automatically bleeds, provided sufficient oil is maintained in the reservoir. To check the fluid level, fill the reservoir with hydraulic oil and cycle the gear. The fluid level should be maintained in the upper one third (1/3) of the sight glass.
  • Page 32 SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 2. Inspect all parts carefully after cleaning for wear and scoring, especially the piston, gland section, and the inside of the outer cylinder. Also make sure to check the bushings in the end-caps for wear and security.
  • Page 33 SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 7. To assemble the gland assembly, insert the inside T-seal and wiper, again using Vaseline on the T-seal. a. The gland must be installed from the end-cap side (this is the side without the holes).
  • Page 34 SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 12. Re-install the center bolts using Tef Gel. 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 35: Removal Of Main Gear Retraction Cylinder

    SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 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. Remove end cap from end of cylinder. Drain fluid. Remove forward end of cylinder from bulkhead flange.
  • Page 36 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 37 SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 1422 B2, B4 or B6 Pro Seal Company RTV Silicones General Electric SIKAFLEX 201 or 252 Sika Manufacturing Electrical Insulating Compound Dow Corning 4 (DC4) Dow Corning Corporation Brake Grease...

  • Page 38: Hydraulic Pump System, Disassembly And Service

    SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 **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.
  • Page 39 SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 Relieve the pressure in the hydraulic system by placing the gear selector handle in the neutral position. 1. On the forward lower side of the reservoir, remove drain plug to drain most of the hydraulic fluid.

  • Page 40: Inspection Time Limits And Checklist

    SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 5.6 INSPECTION TIME LIMITS AND CHECKLIST Page 40 Revision P P/N 1002554...
  • Page 41 SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 P/N 1002554 Revision P Page 41...
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  • Page 46: Float Removal Instructions/Procedures

    SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 5.7 FLOAT REMOVAL INSTRUCTIONS/PROCEDURES Page 46 Revision P P/N 1002554...
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  • Page 48 SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 Page 48 Revision P P/N 1002554...

  • Page 49: Float Reinstallation Instructions/Procedures

    SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 5.8 FLOAT REINSTALLATION INSTRUCTIONS/PROCEDURES P/N 1002554 Revision P Page 49...
  • Page 50 SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 Page 50 Revision P P/N 1002554...
  • Page 51 SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 DESCRIPTION AND OPERATION PROBLEM – Powerpack does not run after gear selection. PROBABLE CAUSE • Circuit breaker has failed • Pressure switch not pulling in at low cut in. • Solenoid switch not pulling in.
  • Page 52 SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 PROBLEM – Powerpack cycles on and off during gear cycle. PROBABLE CAUSE • Binding in retraction unit. • Pressure switch cut off limit too low. REMEDY • Investigate for free operation. Check gear that retracts last.

  • Page 53: Figure 5.1 Schematic Hydraulic System

    SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 FIGURE 5.1 SCHEMATIC HYDRAULIC SYSTEM P/N 1002554 Revision P Page 53...

  • Page 54: Figure 5.2 Schematic Electrical System

    SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 FIGURE 5.2 SCHEMATIC ELECTRICAL SYSTEM Page 54 Revision P P/N 1002554...

  • Page 55: Figure 5.3 Assembly Main Gear Retraction System

    SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 FIGURE 5.3 ASSEMBLY MAIN GEAR RETRACTION SYSTEM P/N 1002554 Revision P Page 55...

  • Page 56: Figure 5.4 Assembly - Main Gear Shock Strut

    SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 FIGURE 5.4 ASSEMBLY – MAIN GEAR SHOCK STRUT Page 56 Revision P P/N 1002554...

  • Page 57: Figure 5.5 Assembly Main Gear And Brake

    SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 FIGURE 5.5 ASSEMBLY MAIN GEAR AND BRAKE (Refer to Parts Manual for complete parts list) P/N 1002554 Revision P Page 57...

  • Page 58: Figure 5.6 Assembly Nose Gear System

    SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 FIGURE 5.6 ASSEMBLY NOSE GEAR SYSTEM Page 58 Revision P P/N 1002554...

  • Page 59: Weight And Balance

    SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 5.9 WEIGHT AND BALANCE 5.9.1 WEIGHING PROCEDURES FOR CESSNA 208 CARAVAN 1. Level aircraft per manufacturer’s instructions or use the cabin door lower sill. 2. Place scales under the right and left main and nose gears.
  • Page 60 SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 THIS PAGE INTENTIONALLY LEFT BLANK Page 60 Revision P P/N 1002554...

  • Page 61: Chapter 6 Water Rudder Retraction And Steering System

    SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 CHAPTER 6 WATER RUDDER RETRACTION AND STEERING SYSTEM CONTENTS 6.1 DESCRIPTION ............................62 6.2 ADJUSTMENT ............................62 6.3 SERVICE SCHEDULE ..........................62 P/N 1002554 Revision P Page 61...
  • Page 62 SERVICE MANUAL & ICA WIPLINE 8000 FLOATS ON CESSNA 208 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.

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