Wipaire WIPLINE 8000 User manual

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

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SERVICE MANUAL & ICA
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LOG OF REVISIONS
Rev Pages Description Date
A 3 Revised aircraft jacking position. 3/16/2005
B 12,18 Added greasing zerk to tasks and changed drawing. 9/28/2005
C 7, 12 Added an inspection time limit and tolerances for the Nose Block Track wear. 4/18/2006
D 19-22 Made several additions to the inspection checklist. 1/18/2007
E9, 10,
15,16
Changes to the Cleaning, Corrosion and Main gear lubrication procedures and additional minor
changes to the inspection checklist. 5/31/2008
F 29, 36, 46 Changed water rudder cable tensions. 8/15/2008
G5, 6, 12,
13, 21
Changed main gear oleo servicing information. Added enhanced customer information pages
and cleaning and corrosion pages. 7/15/2009
H All Reformat of entire document, Add green grease as approved grease, update to oat
procedures with clarication on rear door support cables. 4/18/2013
J 30, 31 Added Shear Torque Chart, PR 1440 C Sealant and Tef-Gel, Removed Warranty Claim Form. 5/26/2015
K5, 14, 30,
31
Added Dow Corning DC4, Corrosion X, and Mobil Aviation Grease SHC 100 to approved
product list. Modied torque limit section. 12/4/2015
L
18, 22, 28,
33-35, 42,
46
New document formatting (multiple pages renumbered). Changed main gear tire pressure
from 45 +/- 5 PSI to 50 +/- 5 PSI. Replaced electrical schematic drawing for legibility. Added
inspection for main gear cracking at annual. Changed silicone to Teon spray. Added brake
grease, corrected 6P-730A Teon 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.
11/7/2017
M 7 Added reference for Structural Repair Manual part number 1008274 in introduction. 5/1/2019
N11, 16, 18,
31-37
Added information about corrosion limits. Added circuit breaker note to section 4.4 and Added
note about STA-Lube. Updated details in Inspection Checklist about spreader bars and
y wires and emergency gear extension and retraction. Removed inspection column from
Maintenance Checklist.
8/3/2020
P18-21,
32, 34
Added sections 3.1 through 3.5. Changed gasket sealer to Tef Gel in section 5.3.1 Removal of
Main Gear Oleo. Removed GP-730A from Comet Industries. 2/3/2021
View most current revision of this ICA at www.wipaire.com.

SERVICE MANUAL & ICA
WIPLINE 8000 FLOATS ON CESSNA 208
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WIPLINE 8000 FLOATS ON CESSNA 208
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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
CHAPTER 6 WATER RUDDER RETRACTION AND STEERING SYSTEM...............................................61

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WIPLINE 8000 FLOATS ON CESSNA 208
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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
FIGURE 5.3 ASSEMBLY MAIN GEAR RETRACTION SYSTEM .........................................................55
FIGURE 5.4 ASSEMBLY – MAIN GEAR SHOCK STRUT ....................................................................56
FIGURE 5.5 ASSEMBLY MAIN GEAR AND BRAKE..............................................................................57
FIGURE 5.6 ASSEMBLY NOSE GEAR SYSTEM .................................................................................58

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This manual describes the general servicing and maintenance for the Model 8000 oat, including hull and landing
gear. For services and repairs 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
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CHAPTER 1 GENERAL INFORMATION
CONTENTS
1.0 GENERAL..................................................................................................................................................12

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1.0 GENERAL
The model 8000 seaplane or amphibious oat is an all aluminum constructed oat with watertight compartments.
The actual displacement in fresh water for each oat is 8108 pounds buoyancy for the seaplane and 7922 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 600 x 6 8-ply tires and the nose landing gear has one 500 x 5 10-ply tire. The
gear system is hydraulically actuated and driven by two hydraulic pumps. 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 six 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.

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CHAPTER 2 FLOAT HULL MAINTENANCE
CONTENTS
2.1 GENERAL..................................................................................................................................................14

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Hard Landing and Damage Investigation
After a thorough cleaning of the suspected 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, deformed skins or bulkheads. Points of attachment should be examined
carefully for distortion and security of fasteners in the primary and secondary damaged areas as
locations beyond the local damage. Inspect aircraft tubes in area of oat tting for signs of bending,
cracked welds, or any other damage.
2.1 GENERAL
The oat 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. Surfaces are then primed with an epoxy-based primer and nished with enamel color
paint.
Cleaning
The outside of the oat should be kept clean by washing with soap and water.
Special care should be taken to remove engine exhaust trails, waterline marks, and barnacle
deposits. After saltwater operation, washing with fresh water should be done daily with special
attention to hard-to-reach places such as: seams, wheel wells, etc.
Alternatively, water taxiing in FRESH WATER at step-speed can help to ush the entire system.
OPERATORS IN SALTWATER ARE STRONGLY CAUTIONED – RINSING THE ENTIRE
AIRCRAFT & FLOATS WITH FRESH WATER AT THE END OF EACH DAY OR PERIODICALLY IS
CRITICAL. FAILING IN THIS CLEANING CAN SEVERLY SHORTEN THE LIFE OF THE FLOATS.
The oat interior should be ushed if salt water enters the compartments. If the oats are being
stored inside, remove inspection covers so the interior will dry out.
THE ABOVE CLEANING TECHNIQUES ARE VITAL FOR KEEPING CORROSION TO A
MINIMUM. SALTWATER OPERATIONS AND ENVIRONMENT ARE STRONGLY LINKED TO
CORROSION AND MUST BE ADDRESSED PROACTIVELY.

SERVICE MANUAL & ICA
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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.
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 Par-al-ketone. Under saltwater conditions, bolts should be removed at least once a year and
grease reapplied to the shafts, heads and nuts.
THE ABOVE CLEANING TECHNIQUES ARE VITAL FOR KEEPING CORROSION TO A
MINIMUM. SALTWATER OPERATIONS AND ENVIRONMENT ARE STRONGLY LINKED TO
CORROSION AND MUST BE ADDRESSED PROACTIVELY.

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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

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3.1 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.
3.2 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 3.4.
2. Lower aircraft onto oat cradle as shown in Figure 3.4.
3. Place fore and aft supports as shown in Figure 3.3 and Figure 3.4.
3.3 LEVELING
See applicable aircraft maintenance/service manual.
3.4 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 3.1.

SERVICE MANUAL & ICA
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P/N 1002554 Revision P Page 19
(X = WIDTH OF CRADLE)
FIGURE 3.1 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 3.2.
NOTE: If desired to prevent possible cosmetic damage to oat, use material to separate cradle and oat.
FIGURE 3.2 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 3.3 and Figure 3.4.

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FIGURE 3.3 FLOAT SECURING LOCATIONS
ALTERNATE JACKING METHOD IF WIPAIRE
JACKING FIXTURE IS NOT AVAILABLE
(8000A model shown for reference only)