Wipaire Wipline 2100 User manual

SERVICE MANUAL & ICA
WIPLINE 2100 & 2350 FLOATS
P/N 1002549 Revision N Page 1
SERVICE MANUAL
AND
INSTRUCTIONS FOR
CONTINUED AIRWORTHINESS
FOR THE
WIPLINE MODEL 2100/2350
AMPHIBIOUS AND SEAPLANE FLOATS
Revision N
WIPLINE FLOATS • SKIS • MODIFICATIONS • AIRCRAFT SALES
AVIONICS • INTERIOR • MAINTENANCE • PAINT REFINISHING

SERVICE MANUAL & ICA
WIPLINE 2100 & 2350 FLOATS
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SERVICE MANUAL & ICA
WIPLINE 2100 & 2350 FLOATS
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LOG OF REVISIONS
Rev Pages Description Date
A 12, 23 Added an inspection time limit and tolerances for the Nose Block Track wear. 4/18/2006
B 5-7, 38-40 Added table of contents and renumbered all pages. Added keel splice repair and gures. 6/30/20/06
C 17-19 New instructions to checklist and changed format to include mechanic signature and right and
left oat. 10/5/2006
D28-30, 23,
46-53
Altered Checklist format with INSP. Sign-o󰀨. Added hydraulic actuator rebuild instructions to pg
23. Added weighing info. 5/1/2008
E12, 13, 20,
27, 28 Sections 5.2 instructions, 6.1 instructions, 7.4 instructions. 6/25/2008
F All Reformat of entire document. Add green grease as approved grease. 4/12/2013
G 24, 25 Added Shear Torque chart, PR 1440 C Sealant and Tef-Gel. Removed Warranty Claim Form. 5/26/2015
H 11, 24, 25 Added Dow Corning DC4, Corrosion X, and Mobil Aviation Grease SHC 100 to approved
product list. Modied torque limits section. 12/4/2015
J 1, 4, 5, 57 Added Wipaire document number to cover, CC-19 aircraft added to weighing procedures. 1/12/2017
K 8 Added reference for Structural Repair Manual part number 1008274 in introduction. 5/1/2019
L 51 Added part numbers 21A01321-001 and 21S01321-004 for amphib and seaplane main keels
in Keel Splice Repair section. 11/4/2019
M11, 25, 35,
42-44
Added information about corrosion limits. Added note about STA-Lube. Added STA-Lube to
Brake Caliper Grease. Removed inspection column on Maintenance Checklist. 8/3/2020
N All
Reformatted manual in new software. Added sections 4.0 through 4.4. Removed Comet
Industries GP-730A. Removed content in Chapter 10 and replaced with note about SRM.
Created Chapter 12 for Inspection Checklist and Troubleshooting.
2/3/2021
View most current revision of this ICA at www.wipaire.com.

SERVICE MANUAL & ICA
WIPLINE 2100 & 2350 FLOATS
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SERVICE MANUAL & ICA
WIPLINE 2100 & 2350 FLOATS
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CONTENTS
INTRODUCTION...............................................................................................................................................7
CHAPTER 1 GENERAL INFORMATION .........................................................................................................9
CHAPTER 2 FLOAT HULL MAINTENANCE .................................................................................................11
CHAPTER 3 CORROSION .............................................................................................................................13
CHAPTER 4 FLOAT HANDLING, JACKING, AND AIRCRAFT TOWING....................................................15
CHAPTER 5 GEAR RETRACT SYSTEM OPERATION AND MAINTENANCE..........................................21
CHAPTER 6 GEAR OPERATION AND MAINTENANCE .............................................................................31
CHAPTER 7 MAIN GEAR REMOVAL AND OPERATION ............................................................................37
CHAPTER 8 NOSE GEAR ..............................................................................................................................43
CHAPTER 9 WATER RUDDER RETRACTION AND STEERING SYSTEM...............................................49
CHAPTER 10 REPAIRING FLOAT HULL SKINS & EXTRUSIONS.............................................................51
CHAPTER 11 WEIGHT AND BALANCE ........................................................................................................53
CHAPTER 12 INSPECTION CHECKLIST & TROUBLESHOOTING ..........................................................63

SERVICE MANUAL & ICA
WIPLINE 2100 & 2350 FLOATS
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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 ................................................................................25
FIGURE 5-2 SCHEMATIC ELECTRICAL SYSTEM ..............................................................................26
FIGURE 5-3 MAIN GEAR ACTUATION ..................................................................................................27
FIGURE 5-4 NOSE GEAR RETRACTION SYSTEM .............................................................................28
FIGURE 5-5 MAIN GEAR WHEEL ASSEMBLY......................................................................................29
FIGURE 8-1 NOSE BOX ACCESS LOCATION......................................................................................46
FIGURE 8-2 FRONT VIEW NOSE BOX..................................................................................................47
FIGURE 8-3 POSITION OF TROLLEY TO NOSE BOX.........................................................................48

SERVICE MANUAL & ICA
WIPLINE 2100 & 2350 FLOATS
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This manual describes the general service and maintenance for the oat, 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” 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.
To contact Wipaire for technical support or parts sales, call, write or email:
Wipaire, Inc.
Customer Service
1700 Henry Avenue – Fleming Field
South St. Paul, MN 55075
Phone: [phone]
Fax: [phone]
Website: www.wipaire.com
Email: [email protected]
INTRODUCTION

SERVICE MANUAL & ICA
WIPLINE 2100 & 2350 FLOATS
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CHAPTER 1 GENERAL INFORMATION
CONTENTS
1.0 GENERAL..................................................................................................................................................10

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1.0 GENERAL
The model 2100/2350 seaplane or amphibious oat is an all aluminum-constructed oat with watertight
compartments. The actual displacement in fresh water for each oat 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. The amphibian oat is geometrically the same as the seaplane except for the
addition of landing gear and internal structure for the gear.
The water rudder system is cable operated with ball bearing pulleys. Water rudder cables tie into the existing
aircraft rudder system.
The main landing gear has a 5.00 x 5 6-ply tire and the nose landing gear has a 2.50 x 4 4-ply tire. The gear
system is hydraulically actuated and driven by one reversible electric pump. Brakes are hydraulic and have a
caliper on each main wheel.
Steering on land is accomplished by di󰀨erential braking. The nose wheels are full castering.
Access to the oat interior is accomplished by removing covers on the top deck, side skins and two covers inside
the wheel well. When necessary, water inside the oat hulls may be removed through pumpout cups located on
the outboard edge of each oat top skin.

SERVICE MANUAL & ICA
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CHAPTER 2 FLOAT HULL MAINTENANCE
CONTENTS
2.1 GENERAL..................................................................................................................................................12
2.2 CLEANING.................................................................................................................................................12
2.3 HARD LANDING AND DAMAGE INVESTIGATION ...............................................................................12

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2.1 GENERAL
The oat 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 nished
with an enamel color paint, or equivalent.
2.2 CLEANING
The outside of the oat should be kept clean by washing with soap and water, with special care taken to remove
engine exhaust trails, water line marks, and barnacle deposits as these are all linked to corrosion. After saltwater
operation, washing with fresh water should be done daily with special attention to hard-to-reach places, such as
seams, wheel well, etc. The oat interior should be ushed if salt water enters the compartments; it’s easy to tell
by the smell inside the oat lockers. At night or when the oatplane is in storage, the inspection and/or baggage
covers should be opened so the interior has a chance to dry out.
THE ABOVE CLEANING TECHNIQUES ARE VITAL
FOR KEEPING CORROSION TO A MINIMUM. SALTWATER
OPERATIONS ARE STRONGLY LINKED TO
CORROSION AND MUST BE ADDRESSED PROACTIVELY.
2.3 HARD LANDING AND DAMAGE INVESTIGATION
After a thorough cleaning of the damaged area, all structural parts should be carefully examined to determine
the extent of damage. Frequently, the force causing the initial damage is transmitted from one member to the
next, causing strains and distortions. Abnormal stresses incurred by shock or impact forces on a rib, bulkhead, or
similar structure, may be transmitted to the extremity of the structural member, resulting in secondary damage,
such as sheared or stretched rivets, elongated bolt holes, or canned skins or bulkheads. Points of attachment
should be examined carefully for distortion and security of fastenings in the primary and secondary damaged
areas at locations beyond the local damage.

SERVICE MANUAL & ICA
WIPLINE 2100 & 2350 FLOATS
P/N 1002549 Revision N Page 13
CHAPTER 3 CORROSION
CONTENTS
3.0 CORROSION.............................................................................................................................................14

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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.
The primary means of detection of corrosion is visual. The most obvious sign is a corrosive deposit of white
powder. Other signs are discoloration of the metal surface or bubbles and blisters under the painted surface. Light
corrosion may be removed by light hand sanding or chromic acid. Moderate and severe corrosion (blistering,
aking, and pitting) may be removed by heavy sanding or grinding, and applying chromic acid. No more than
1/3rd the thickness of skin material should be removed before complete replacement or reinforcement of an area
is necessary.
After removing the corroded area, restore area to original nish (prime and enamel). BOESHIELD T9, Corrosion
X, or ACF-50 may also be applied to stop corrosion. Refer to manufacturer’s instructions for application
instructions.
Maintaining the oat inside and outside nishes by washing after saltwater operations will help protect the oat
from corrosion. Periodically, all hardware should be covered with a waterproof grease, or paralketone. Under
saltwater conditions, bolts should be removed at least once a year and grease reapplied to the shafts, heads and
nuts.

SERVICE MANUAL & ICA
WIPLINE 2100 & 2350 FLOATS
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CHAPTER 4 FLOAT HANDLING, JACKING, AND AIRCRAFT
TOWING
CONTENTS
4.0 TOWING.....................................................................................................................................................16
4.1 HOISTING..................................................................................................................................................16
4.2 LEVELING .................................................................................................................................................16
4.3 JACKING PROCEDURES........................................................................................................................16
4.4 JACK REMOVAL .......................................................................................................................................19

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4.0 TOWING
When towing the amphibian aircraft, 2 lugs are provided on the lower forward side of the nose spring.
On land, a rigid “V” frame can be fabricated to attach to these lugs for towing the aircraft with a tractor. Lake & Air
Training and Pilot Shop has this tow bar available for purchase.
On water, a rope bridle arrangement can used to tow the aircraft from the lugs described above.
4.1 HOISTING
Hoisting the aircraft can be performed using a lifting rig that attaches to the aircraft with lifting rings that are
installed at the wing attach points. If the lifting rings are not installed, reference applicable aircraft maintenance/
service manual for additional hoisting specications. 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
oats.
CAUTION!
Make sure nothing is under or above the airplane or oats when hoisting the aircraft
1. Raise aircraft high enough to place oat cradle under oats as shown in Figure 4-4.
2. Lower aircraft onto oat cradle as shown in Figure 4-4.
3. Place fore and aft supports as shown in Figure 4-3 and Figure 4-4.
4.2 LEVELING
See applicable aircraft maintenance/service manual.
4.3 JACKING PROCEDURES
CAUTION!
Make sure nothing is under or above the airplane or oats when jacking the aircraft.
1. Turn o󰀨 fuel.
2. Place weighted bags above the nose gear (approximately 100 lbs. on each oat to start, more may be
added as needed).
3. Position 1 person at each fore and aft of each oat, and 3 people at the jacking location of one oat.
4. Modify jack saddle of a 3 ton minimum jack by welding as shown in Figure 4-1.

SERVICE MANUAL & ICA
WIPLINE 2100 & 2350 FLOATS
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(X = WIDTH OF CRADLE)
FIGURE 4-1 JACK CRADLE RECOMMENDED MODIFICATION
NOTE: This is not required and Wipaire does not have the parts for modication. It is recommended a similar
modication be performed to the jack saddle to prevent the slippage of the cradle.
1. Center cradle on saddle and position so cradle is as far aft on the main keel as possible without interfering
with main gear as it decompresses as shown in Figure 4-2.
NOTE: If desired to prevent possible cosmetic damage to oat, use material to separate cradle and oat.
FIGURE 4-2 JACKING LOCATION
1. Jack one side at a time, taking care to check the balance of the aircraft and adding more weight to the front
if needed.
2. Two people, both outboard, lift the fore and aft cradle stands up to the cradle as a 3rd person release the
pressure slowly, allowing the cradle and stands to gently contact the ground.
3. Repeat previous procedure to the other oat.
NOTE: A smaller jack may be needed to slightly lift the oat into a high enough position for the main jack.
4. Secure oats with fore and aft supports as shown in Figure 4-3 and Figure 4-4.

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FIGURE 4-3 FLOAT SECURING LOCATIONS
ALTERNATE JACKING METHOD IF WIPAIRE
JACKING FIXTURE IS NOT AVAILABLE
(8000A model shown for reference only)

SERVICE MANUAL & ICA
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P/N 1002549 Revision N Page 19
Aft Cradle
Stand
Fore Cradle
Stand Cradle
Fore
Support
Aft
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 oats when removing the jacks from the aircraft
1. Turn o󰀨 fuel.
2. Verify landing gear is in the down and locked position.
3. Verify weighted bags are still located above the nose gear.
4. Position 1 person at each fore and aft of each oat, and 1 person at the jacking location of one oat.
5. Remove all fore and aft supports as shown in Figure 4-3 and Figure 4-4.
6. Using modied jack saddle as shown in Figure 4-1, center jack saddle in center of cradle on 1 of the oats,
7. Lift aircraft to clear fore and aft cradle stands and remove fore and aft cradle stands of lifted oat.
8. Slowly lower oat to the ground, remove jack from under oat, and remove cradle from jack saddle.
9. Repeat previous procedure to the other oat.
10. Remove weighted bags from oats.

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