Wipaire Wipline 4000 User manual

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

SERVICE MANUAL & ICA
WIPLINE 4000 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
P/N 1002552 Revision G Page 3
LOG OF REVISIONS
Rev Pages Description Date
A 9, 22 Added an inspection time limit and tolerances for the Nose Block Track wear. 4/18/2006
B All Reformat of entire document, Add green grease as approved grease. 4/16/2013
C 13-14 Added Shear Torque Chart, PR 1440 C Sealant and Tef-Gel, removed Warranty Claim Form. 5/26/2015
D 5, 13-14 Added Dow Corning DC4, Corrosion X, and Mobil Aviation Grease SHC 100 to approved
product list. Modied torque limit section. 12/4/2015
E 8 Added reference for Structural Repair Manual part number 1008274 in introduction. 5/1/2019
F10, 13,
15-17, 29
Added information about corrosion limits. Added note about STA-Lube. Removed inspection
column from Maintenance Checklist. Added STA-Lube to Brake Caliper Grease. 8/3/2020
G All
Reformatted manual in new software. Updated title page and headers. Added sections 4.0
through 4.4. Removed Comet Industries GP-730A. Removed content in Chapters 9 and 10 and
replaced with note about SRM. Removed Figures 9-1 through 9-6 and Figures 10-1 through
10-3 as content is found in SRM.
2/3/2021
View most current revision of this ICA at www.wipaire.com.

SERVICE MANUAL & ICA
WIPLINE 4000 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
P/N 1002552 Revision G Page 5
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
CHAPTER 7 NOSE GEAR ..............................................................................................................................43
CHAPTER 8 WATER RUDDER RETRACTION AND STEERING SYSTEM...............................................45
CHAPTER 9 REPAIRING FLOAT HULL SKINS............................................................................................47
CHAPTER 10 REPAIRING FLOAT HULL EXTRUSIONS.............................................................................49

SERVICE MANUAL & ICA
WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES
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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 ................................................................................23
FIGURE 5-2 SCHEMATIC: LANDING GEAR ELECTRICAL SYSTEM ................................................24
FIGURE 5-3 MAIN GEAR ACTUATION SYSTEM..................................................................................25
FIGURE 5-4 MAIN GEAR LOCKING SYSTEM ......................................................................................26
FIGURE 5-5 NOSE GEAR RETRACTION SYSTEM .............................................................................27
FIGURE 6-1 SECTION MAIN GEAR OLEO ...........................................................................................40
FIGURE 6-2 ASSEMBLY MAIN WHEEL AND BRAKE...........................................................................42

SERVICE MANUAL & ICA
WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES
P/N 1002552 Revision G Page 7
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 4000 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
P/N 1002552 Revision G Page 9
CHAPTER 1 GENERAL INFORMATION
CONTENTS
1.0 GENERAL..................................................................................................................................................10

SERVICE MANUAL & ICA
WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES
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1.0 GENERAL
The model 4000 seaplane or amphibious oat is an all aluminum constructed oat with watertight compartments.
The actual displacement in fresh water for each oat is 3802 pounds buoyancy for the seaplane and 3672 pounds
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 dual 5.00 x 5 6-ply tires and the nose landing gear has one 4.10 x 4 4-ply tire. The
gear system is hydraulically actuated and driven by one pump located on the engine rewall on a Cessna 185 and
in the aft fuselage at Sta. 159.3 on a Cessna 206. Brakes are hydraulic and have a caliper on each main wheel
for a total of four brakes.
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 and four covers inside the
wheel well. When necessary, water inside the oat hulls may be removed through pump out cups located on the
outboard edge of each oat top skin.

SERVICE MANUAL & ICA
WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES
P/N 1002552 Revision G Page 11
CHAPTER 2 FLOAT HULL MAINTENANCE
CONTENTS
2.1 GENERAL..................................................................................................................................................12
2.2 CLEANING.................................................................................................................................................12

SERVICE MANUAL & ICA
WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES
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2.1 GENERAL
The oat 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.
Exterior surfaces are cleaned and alodined. Surfaces are then primed with an epoxy-based primer and nished
with an enamel color paint.
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. After salt water 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. If storing inside, remove inspection covers
so interior will dry.

SERVICE MANUAL & ICA
WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES
P/N 1002552 Revision G Page 13
CHAPTER 3 CORROSION
CONTENTS
3.0 CORROSION.............................................................................................................................................14

SERVICE MANUAL & ICA
WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES
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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 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES
P/N 1002552 Revision G Page 15
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

SERVICE MANUAL & ICA
WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES
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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 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES
P/N 1002552 Revision G Page 17
(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.

SERVICE MANUAL & ICA
WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES
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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
WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES
P/N 1002552 Revision G 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.

SERVICE MANUAL & ICA
WIPLINE 4000 FLOATS ON CESSNA A185E, A185F, AND 206 SERIES
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