Wipaire 8750 User manual

SERVICE MANUAL & ICA
8750 AMPHIBIAN/SEAPLANE FLOATS ON CESSNA 208/208B
Doc. No. W8750-24-01 P/N 1005723 Revision L Page 1
SERVICE MANUAL
AND
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
FOR THE
WIPLINE MODEL 8750
AMPHIBIOUS/SEAPLANE FLOAT
ON THE
CESSNA MODEL 208/208B CARAVAN
Revision L
WIPLINE FLOATS • SKIS • MODIFICATIONS • AIRCRAFT SALES
AVIONICS • INTERIOR • MAINTENANCE • PAINT REFINISHING
1700 Henry Ave. - Fleming Field (KSGS), South St. Paul, MN 55075
Ph: 651.451.1205 Fax: [phone]
www.wipaire.com

SERVICE MANUAL & ICA
8750 AMPHIBIAN/SEAPLANE FLOATS ON CESSNA 208/208B
Page 2 Revision L P/N 1005723 Doc. No. W8750-24-01
THIS PAGE INTENTIONALLY LEFT BLANK

SERVICE MANUAL & ICA
8750 AMPHIBIAN/SEAPLANE FLOATS ON CESSNA 208/208B
Doc. No. W8750-24-01 P/N 1005723 Revision L Page 3
Rev Pages Description Date
IR All Initial Release 7/3/2012
A All Add green grease as an approved grease. 4/18/2013
B All Added 208B eligibility, updated Hydraulic powerpack image. 6/28/2013
C All
Updated Fig 1-8 for new oleo, updated photo p. 25, changes to MLG rigging
procedure, update to inspection procedures, dened water rudder rigging
procedures, remaining pages repaginated, removed p. 107.
5/30/2014
D All
Added Shear Torque chart, PR 1440 C Sealant, Tef-Gel and full contact
info. Removed Warranty Claim Form. Corrected 1200 was 1000, 1400 was
1150 and 1900 was 1300.
5/26/2015
E All Added Dow Corning DC4 and Mobil Aviation Grease SHC 100 to approved
product list. 7/9/2015
F All Added instruction for main gear oil bath system. 9/22/2016
G11 Added reference for Structural Repair Manual part number 1008274 in
introduction. 5/21/2019
H82, 87-
89, 91
Added instructions to oat re-install checklist, changed pylon attachment
inspection intervals, updated oat removal checklist. 8/5/2019
J 84 Added note for Main Landing Gear Axle Shaft in Maintenance Inspection
Checklist. 9/5/2019
K All
Created manual in new software and changed formatting. Added
instructions for Oleo Strut and Tire Servicing. Removed instructions about
annual inspection under Main Gear Oleos in checklist. Added PR 1422 to
approved Float Sealant. Updated Corrosion Limits chart to add extrusions.
Removed Inspector sign o󰀨 column in maintenance checklist and oat
removal and re-install checklist.
1/9/2020
L
32-33,
35, 37,
67-68,
70, 73-
74
Added note about STA-Lube. Added information for Oil Bath Wheels.
Updated Figure 4-3. Updated title for Figure 4-2A. Added Figure 4-2B.
Added STA-Lube to Brake Caliper Grease. Added information about
corrosion limits. Removed Figure 9.1. Updated details in Maintenance
Checklist for spreader bars and y wires. Added Emergency Gear
Retractions/Extension steps to Maintenance Checklist due to previous
removal. Added Greased Wheel Only procedure in Maintenance Checklist.
Replaced inspector sign o󰀨 column in oat removal and re-install checklist.
8/3/2020
View most current revision of this ICA at www.wipaire.com.

SERVICE MANUAL & ICA
8750 AMPHIBIAN/SEAPLANE FLOATS ON CESSNA 208/208B
Page 4 Revision L P/N 1005723 Doc. No. W8750-24-01
CONTENTS
CHAPTER 1 INTRODUCTION AND GENERAL INFORMATION ........................................................................7
CHAPTER 2 AIRWORTHINESS LIMITATIONS ..................................................................................................23
CHAPTER 3 NOSE GEAR ....................................................................................................................................25
CHAPTER 4 MAIN LANDING GEAR BRAKES & GEAR RETRACTION ..........................................................31
CHAPTER 5 HYDRAULICS..................................................................................................................................49
CHAPTER 6 WATER RUDDER ............................................................................................................................55
CHAPTER 7 ELECTRICAL...................................................................................................................................59
CHAPTER 8 TKS SYSTEM EQUIPPED AIRCRAFT REQUIREMENTS...........................................................63
CHAPTER 9 RECOMMENDED PROCESSES, PRODUCTS, AND INSPECTION CHECKLISTS .................65
CHAPTER 10 TROUBLESHOOTING ..................................................................................................................81
CHAPTER 11 INSTALLATION PRINT INFORMATION ......................................................................................87
CHAPTER 12 AIRCRAFT INSTALLED PERFORMANCE ITEMS AND DESCRIPTIONS...............................89

SERVICE MANUAL & ICA
8750 AMPHIBIAN/SEAPLANE FLOATS ON CESSNA 208/208B
Doc. No. W8750-24-01 P/N 1005723 Revision L Page 5
LIST OF FIGURES
FIGURE 1-1: FRONT VIEW CESSNA 208 CARAVAN .............................................................................9
FIGURE 1-2: TOP & SIDE VIEWS CESSNA 208 CARAVAN.................................................................10
FIGURE 1-3: FRONT VIEW CESSNA 208B CARAVAN.........................................................................11
FIGURE 1-4: TOP & SIDE VIEWS CESSNA 208B CARAVAN ..............................................................12
FIGURE 1-5: FLOAT TERMINOLOGY ....................................................................................................13
FIGURE 1-6: MAINTENANCE ACCESS POINTS..................................................................................14
FIGURE 1-7: HYDRAULIC FLUID LEVEL PLACARD ...........................................................................16
FIGURE 1-8: FLUID TYPES AND QUANTITIES ....................................................................................16
FIGURE 3-1: NOSE WHEEL BOX ...........................................................................................................27
FIGURE 3-2: NOSE WHEEL GREASING...............................................................................................28
FIGURE 3-3: NOSE GEAR & BOX ITEM ................................................................................................30
FIGURE 4-1: MINIMUM BRAKE LINING THICKNESS..........................................................................33
FIGURE 4-2A: MAIN GEAR, LOWER (OIL BATH WHEEL)...................................................................35
FIGURE 4-2B: MAIN GEAR, LOWER (GREASED WHEEL) .................................................................35
FIGURE 4-3: MAIN GEAR GREASING POINTS....................................................................................37
FIGURE 4-4A: MAIN GEAR ADJ. DOWN ...............................................................................................38
FIGURE 4-4B: MAIN GEAR ADJ. DOWN ...............................................................................................39
FIGURE 4-5: MAIN GEAR ADJ. UP.........................................................................................................40
FIGURE 4-6: MAIN GEAR DOWN STOP ADJ........................................................................................41
FIGURE 4-7: ROTARY ACTUATOR ........................................................................................................46
FIGURE 4-8: MAIN SHOCK STRUT........................................................................................................47
FIGURE 5-1: HYDRAULIC SCHEMATIC ................................................................................................52
FIGURE 6-2: WATER RUDDER/STEERING CABLE ROUTING, MODEL 208....................................57
FIGURE 6-3: WATER RUDDER/STEERING CABLE ROUTING, MODEL 208B .................................57

SERVICE MANUAL & ICA
8750 AMPHIBIAN/SEAPLANE FLOATS ON CESSNA 208/208B
Page 6 Revision L P/N 1005723 Doc. No. W8750-24-01
WIPLINE FLOATS • SKIS • MODIFICATIONS • AIRCRAFT SALES
AVIONICS • INTERIOR • MAINTENANCE • PAINT REFINISHING
NEW CUSTOMER INFORMATION
Customer Name
Billing Address
Shipping Address
Phone Number Fax Number
Purchasing Contract Phone Number
Email Fax Number
Accounts Payable Contact Phone Number
Email 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 [phone] Phone [phone] Email: CustomerService @wipaire.com

SERVICE MANUAL & ICA
8750 AMPHIBIAN/SEAPLANE FLOATS ON CESSNA 208/208B
Doc. No. W8750-24-01 P/N 1005723 Revision L Page 7
CHAPTER 1
INTRODUCTION AND GENERAL INFORMATION
CONTENTS
1.0 INTRODUCTION.........................................................................................................................................8
1.1 GENERAL FLOAT INFORMATION..........................................................................................................15
1.2 CLEANING.................................................................................................................................................18
1.3 CORROSION.............................................................................................................................................19
1.4 FLOAT HANDLING & JACKING...............................................................................................................20
1.5 MOORING..................................................................................................................................................21

SERVICE MANUAL & ICA
8750 AMPHIBIAN/SEAPLANE FLOATS ON CESSNA 208/208B
Page 8 Revision L P/N 1005723 Doc. No. W8750-24-01
CHAPTER 1 INTRODUCTION AND GENERAL INFORMATION
This manual is provided for the owners of Wipaire model 8750 Floats as installed on the Cessna 208 Caravan and
208B Grand Caravan. It has two main priorities:
To inform owners of the level and amount of servicing required to properly maintain their oatplane, and to provide
technical data and servicing as specied to maintenance professionals charged with servicing the oats.
The service products referred to throughout this manual are described by their trade names and may be
purchased from the Wipaire Parts Department.
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.
We, at Wipaire, welcome your purchase and look forward to years of satisfying exchanges with you. Your oats
are built with pride and attention to detail, but we want that care to extend beyond your purchase. Our customer
service department is available for your questions 24 hours a day, 7 days a week, where ever you are in the
world.
Parts Sales and Technical Support Dept:
Wipaire, Inc.
1700 Henry Avenue – Fleming Field
South St. Paul, MN 55075
Telephone: [phone]
Fax: [phone]
Website: www.wipaire.com
Email: [email protected]
In this service manual we have worked hard to include many repair scenarios in addition to the recommended
products, practices, and routine maintenance required to keep your oats in working order.
When a oat part is signicantly changed, or an additional inspection is recommended or required, often a service
letter and/or kit is issued. If a warranty is issued, most commonly it is for an 18-month time period, so it is crucial
to check for service letters specic to your oat model at each periodic inspection to be eligible.
Service Manuals and the installation prints included are also revised periodically and kept updated. Service
letters, Service Kits and Service Manuals are available on our web site at no charge, www.wipaire.com.
NOTE: IT IS CRITICAL TO CHECK FOR MANUAL UPDATES EACH TIME AN INSPECTION IS EXECUTED.
1.0 INTRODUCTION

SERVICE MANUAL & ICA
8750 AMPHIBIAN/SEAPLANE FLOATS ON CESSNA 208/208B
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FIGURE 1-1: FRONT VIEW CESSNA 208 CARAVAN

SERVICE MANUAL & ICA
8750 AMPHIBIAN/SEAPLANE FLOATS ON CESSNA 208/208B
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FIGURE 1-2: TOP & SIDE VIEWS CESSNA 208 CARAVAN

SERVICE MANUAL & ICA
8750 AMPHIBIAN/SEAPLANE FLOATS ON CESSNA 208/208B
Doc. No. W8750-24-01 P/N 1005723 Revision L Page 11
FIGURE 1-3: FRONT VIEW CESSNA 208B CARAVAN

SERVICE MANUAL & ICA
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FIGURE 1-4: TOP & SIDE VIEWS CESSNA 208B CARAVAN

SERVICE MANUAL & ICA
8750 AMPHIBIAN/SEAPLANE FLOATS ON CESSNA 208/208B
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FIGURE 1-5: FLOAT TERMINOLOGY

SERVICE MANUAL & ICA
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FIGURE 1-6: MAINTENANCE ACCESS POINTS

SERVICE MANUAL & ICA
8750 AMPHIBIAN/SEAPLANE FLOATS ON CESSNA 208/208B
Doc. No. W8750-24-01 P/N 1005723 Revision L Page 15
1.1 GENERAL FLOAT INFORMATION
The model 8750 amphibious oat is an all aluminum structure. The alloy used throughout is mostly corrosion
resistant 6061-T6, with 2024-T3 and 7075-T651 used in strength critical ttings and panels. Interior parts are
cleaned, acid-etched and then primed prior to being riveted for enhanced corrosion resistance. Exterior surfaces
are cleaned, alodine is applied as a corrosion resistant barrier, and then primed and custom painted.
Model 8750 oats contain sixteen (16) water tight compartments per hull. Access to the inside of the oats for
cleaning, inspection and repairs is through the access covers on the oat deck and the access covers inside the
wheel well.
Figures 1-1 and 1-2 show three view drawings of the Cessna 208 as installed on Wipline model 8750 amphibious
oats.
Figures 1-3 and 1-4 show three view drawings of the Cessna 208B as installed on Wipline model 8750
amphibious oats.
As a part of the oat installation, the following additional changes are made to the landplane:
1. The hydraulic landing gear retraction system components and cockpit controls are added
2. The landing gear emergency gear operation hand pump and system are added
3. A water rudder steering system is installed
4. Auxiliary Vertical Fins (Finlets) are added
5. A seaplane extended chord rudder is installed
6. TKS pod & reservoir (if equipped) is removed
Operational information is detailed in the Cessna 208 Airplane Flight Manual Supplement or Cessna 208B
Airplane Flight Manual Supplement.
Actual displacement for each oat in fresh water is:
Amphibian:
at 100% Buoyancy = 8240 pounds
at 80% Reserve = 9155 pounds
Seaplane:
at 100% Buoyancy = 8741 pounds
at 80% Reserve = 9712 pounds
LANDING GEAR
The landing gear incorporated within the amphibious oats is a retractable quadricycle type with two swiveling
nose (or bow) wheels and four (4) (two (2) dual sets) of main wheels. Shock absorption is provided by air-oil
shock struts on the two main landing gear assemblies and composite at springs on the nose gear assemblies.
Each main wheel is equipped with a hydraulically-actuated disc brake.
Landing gear extension and retraction is accomplished by two (2) electrically-driven hydraulic pumps and four (4)
hydraulic actuators (one (1) for each gear).
The hydraulic pumps are located in the aircraft empennage and can be accessed by removing the aft cabin
bulkhead. The hydraulic actuators are located adjacent to each gear.
Hydraulic system uid level should be checked at 25-hour intervals and should be serviced to levels in

SERVICE MANUAL & ICA
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The nose wheels are fully castoring for maneuverability while the airplane is under engine power or being towed.
The main landing gear has dual 6:00x6 8-ply tires and the nose gear has a single 5:00x5 10-ply tire. All tires must
be approved to TSO C62, type III. Di󰀨erential use of the main-wheel brakes steers the aircraft on land.
Grease zerks are provided in many locations that have pivoting joints. Greasing is recommended at 25-hour
intervals, or more often depending on operating environment, with HCF Grease or equivalent. See Figure 3-2 for
nose gear grease zerk locations. See Figure 4-3 for main gear grease zerk locations.
OLEO STRUT & TIRE SERVICING
Full service of the oleo strut is accomplished by releasing the nitrogen pressure, draining the hydraulic uid,
relling the hydraulic uid to level in Figure 1-8, and servicing with nitrogen to pressure specied in Figure 1-8.
FIGURE 1-7: HYDRAULIC FLUID LEVEL PLACARD
FIGURE 1-8: FLUID TYPES AND QUANTITIES
accordance with the installed placard using MIL-H-5606 (red) hydraulic uid. The uid level placard (Figure 1-7) is
installed on the forward hydraulic Reservoir.

SERVICE MANUAL & ICA
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STRUT PACKAGE
The strut package attaches the oats to the aircraft. The strut package is comprised of the forward struts, main
pylons, rear cross-wires, and front cross wires (or ying wires).
The streamlined struts are made from extruded aluminum alloys. The main pylon is built from machined aluminum
trusses, internal ribs, and skinned with aluminum sheet.
WATER RUDDERS
The oats are equipped with water rudders attached at the rear of the oat structure. These rudders steer when
the oats are in the water.
Rudder controls are integrated into the existing aircraft rudder system and should move in the same direction as
the air rudder.
Water rudders are extended and retracted with a handle installed to the right of the pilot seat.
Water Rudder & Springs

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The outside of the oat should be kept clean by washing with fresh water and soap. Special care should be taken
to remove engine exhaust trails, water-line marks, and barnacle deposits. After salt water operations, washing
with fresh water should be done daily with special attention paid to hard to reach places like:
- skin seams
- wheel well areas
- oat attach points
- hardware
Alternatively, water taxiing in fresh water at step-speed can help ush the oats themselves, but additional rinsing
should be conducted on struts and ttings. The oat interior should be ushed out, especially if salt water or
polluted water gets inside the compartments. If the oats are being stored inside a building either installed on the
aircraft or not, it is strongly recommended to remove the inspection covers so the interior of the oats can dry out.
1.2 CLEANING
OPERATORS IN SALT WATER ARE STRONGLY CAUTIONED
RINSING THE AIRCRAFT AND FLOATS WITH FRESH WATER AT THE END OF EACH DAY IS CRITICAL.
ADHERING TO THESE CLEANING RECOMMENDATIONS IS VITAL FOR KEEPING CORROSION TO A
MINIMUM. FAILURE TO CLEAN THOROUGHLY CAN SEVERLY SHORTEN THE LIFE OF THE FLOATS.
SALT WATER, POLLUTED WATER AND THEIR ENVIROMENTS, ARE STRONGLY AND DIRECTLY LINKED
TO CORROSION AND MUST BE HANDLED PRO ACTIVELY.
EVEN WITHOUT DIRECT CONTACT WITH SALTWATER, THIS HYDRAULIC PUMP IN THE AIRCRAFT
FUSELAGE HAS SEVERELY CORRODED DUE TO BEING IN A SALTWATER ENVIRONMENT WITHOUT
BEING KEPT CLEAN.

SERVICE MANUAL & ICA
8750 AMPHIBIAN/SEAPLANE FLOATS ON CESSNA 208/208B
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CORROSION HOT SPOTS
- DISSIMILAR METAL CONTACT LIKE LANDING GEAR, FLOAT ATTACH POINTS AND OTHERS.
- ENCLOSED SPACES THAT STAY MOIST LIKE LANDING GEAR FLOAT INTERIORS, SKIN
LAP-JOINTS, AND OTHERS.
- CONTAMINATES ON THE METAL LIKE DIRT, SALT, ENGINE EXHAUST, AND OLD OR OTHERWISE
COMPRISED GREASE.
Corrosion is the process by which metals are turned into oxides. It is a natural and ultimately unavoidable
chemical reaction that is accelerated by dissimilar metals in contact with each other, and enclosed spaces and
contaminants like dirt and exhaust deposits that hold moisture against the metal. If that moisture is salt water or
fresh water that is polluted, it conducts the electrolytes better and the process of corroding is faster.
Most aircraft and most oats are made out of aluminum due to its strength to weight ratio, and its ability to
withstand fatigue and remain eld repairable.
Steel is used for strength in hardware and landing gear parts, and these are often areas where these dissimilar
metals cause corrosion.
Areas where moisture and dirt mix and stay wet against metal are common sites of oxidation. Float strut attach
points, water rudders, and skin joints are examples of areas where this occurs.
Cladding, plating, anodizing, painting, greasing and waxing are all processes used to help protect metal from
corrosion; Wipaire uses all these techniques during manufacture. But due to the rugged way our oats are used
and the environment, these surface sealers become abraded or wear away, leaving the metal exposed.
Removal of corrosion is detailed more fully in Chapter 9, but there are a few things an owner can do to stop
the spread of corrosion and minimize the damage. Aside from the already detailed cleaning and inspection
procedures, an anti-corrosion spray like Corrosion X, or its equivalent, should be used liberally. Because it has the
ability to displace moisture and contaminants, it can be used when the oats are still wet or when they are dry.
1.3 CORROSION

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Periodically, hardware should be covered with waterproof grease. Especially in a salt water environment, bolts
should be removed at least once a year and grease applied to the shafts, bolt/screw heads, and nuts.
1.4 FLOAT HANDLING & JACKING
To jack the oats for servicing tires, brakes, or doing retraction tests, it is recommended that a oor type jack
(three ton minimum). be used if lifting apparatus is not available. These jacks are commonly used for truck repair.
The jack should be positioned on the keel centerline on the rst bulkhead forward of the step. The jack should
contact the keel squarely and if room permits, slip a board between the jack and keel.
CAUTION!
Due to critical angle of aircraft when single oat jacking; check that wing fuel tank valves are conrmed
closed, if possible use wing tie rope from oat side to be jacked and tie o󰀨 to tug.
Raise the oat slowly; making sure the aircraft stays balanced. After raising, block up the keel in several places
and lower the jack. Raise only one oat at a time with the opposite oat wheels chocked. Position a sawhorse
under main and after body keel to keep aircraft from tipping fore and aft.
TOWING
When towing the amphibian aircraft, two lugs are provided on the lower forward side of the nose spring. A rigid “V”
frame can be fabricated to attach to these lugs for towing the aircraft with a tractor. Wipaire parts has this tow bar
available for purchase.
HOISTING
Hoisting the aircraft can be performed using a lifting apparatus that attaches to the aircraft with lifting rings which
are installed at the wing spar joints. Contact Wipaire Parts for details if necessary to remove or install oats.
LEVEL
The level reference for the Caravan is two jig located nut plates and screws installed on left side of fuselage below
side windows and forward of cargo door. Weight and balance information should be taken with aircraft in a level
attitude. The oat deck is at a 4-degree nose-down incidence from the aircraft level reference.