Wipaire Wipline 2100 Service Manual And Instructions Download Page 5

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SERVICE MANUAL & ICA

WIPLINE 2100 & 2350 FLOATS

P/N 1002549

Revision N

Page 5

CONTENTS

INTRODUCTION ...............................................................................................................................................7

Summary of Contents for Wipline 2100

Page 1: ...2549 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 ...

Page 2: ...SERVICE MANUAL ICA WIPLINE 2100 2350 FLOATS Page 2 Revision N P N 1002549 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 3: ...t 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 Modified 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 ...

Page 4: ...SERVICE MANUAL ICA WIPLINE 2100 2350 FLOATS Page 4 Revision N P N 1002549 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 5: ...T 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 TROUBLESHOOTI...

Page 6: ...T 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 ...

Page 7: ...er 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...

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Page 9: ...SERVICE MANUAL ICA WIPLINE 2100 2350 FLOATS P N 1002549 Revision N Page 9 CHAPTER 1 GENERAL INFORMATION CONTENTS 1 0 GENERAL 10 ...

Page 10: ... 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 ...

Page 11: ...SERVICE MANUAL ICA WIPLINE 2100 2350 FLOATS P N 1002549 Revision N Page 11 CHAPTER 2 FLOAT HULL MAINTENANCE CONTENTS 2 1 GENERAL 12 2 2 CLEANING 12 2 3 HARD LANDING AND DAMAGE INVESTIGATION 12 ...

Page 12: ...ockers At night or when the floatplane 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 al...

Page 13: ...SERVICE MANUAL ICA WIPLINE 2100 2350 FLOATS P N 1002549 Revision N Page 13 CHAPTER 3 CORROSION CONTENTS 3 0 CORROSION 14 ...

Page 14: ...ay be removed by light hand sanding or chromic acid Moderate and severe corrosion blistering flaking 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 finish prime and ename...

Page 15: ...L ICA WIPLINE 2100 2350 FLOATS P N 1002549 Revision N Page 15 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 ...

Page 16: ...ir Training and Pilot Shop has this hoisting rig available for purchase Contact Wipaire Customer Service for additional guidance in removal or installation of floats CAUTION Make sure nothing is under or above the airplane or floats when hoisting the aircraft 1 Raise aircraft high enough to place float cradle under floats as shown in Figure 4 4 2 Lower aircraft onto float cradle as shown in Figure...

Page 17: ...n in Figure 4 2 NOTE If desired to prevent possible cosmetic damage to float use material to separate cradle and float 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...

Page 18: ... MANUAL ICA WIPLINE 2100 2350 FLOATS Page 18 Revision N P N 1002549 FIGURE 4 3 FLOAT SECURING LOCATIONS ALTERNATE JACKING METHOD IF WIPAIRE JACKING FIXTURE IS NOT AVAILABLE 8000A model shown for reference only ...

Page 19: ...eighted bags are still located above the nose gear 4 Position 1 person at each fore and aft of each float and 1 person at the jacking location of one float 5 Remove all fore and aft supports as shown in Figure 4 3 and Figure 4 4 6 Using modified jack saddle as shown in Figure 4 1 center jack saddle in center of cradle on 1 of the floats 7 Lift aircraft to clear fore and aft cradle stands and remov...

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Page 21: ... WIPLINE 2100 2350 FLOATS P N 1002549 Revision N Page 21 CHAPTER 5 GEAR RETRACT SYSTEM OPERATION AND MAINTENANCE CONTENTS 5 1 DESCRIPTION AND OPERATION 22 5 2 ADJUSTMENT TEST 22 5 3 LANDING GEAR MALFUNCTION PROCEDURES 23 ...

Page 22: ...ded At the top of each float deck just forward of the step a visual indicator is provided for the main gear Nose gear up and down may be determined visually for position An emergency hand pump is provided in case of total electric pump failure or loss of fluid The reservoir has additional hydraulic fluid available only to the hand pump The main gear has an over center lock in both up and down posi...

Page 23: ...while traveling in the down direction 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 If the reservoir empties i e fluid disappears in sight glass stop the cycle by pulling the circuit breaker on the control panel Fill the reservoir again and complete the cycle Continue this pro...

Page 24: ...s to position landing gear as desired 12 Landing Gear Motor Circuit Breaker FULL 13 Landing Gear Switch DESIRED POSITION 14 Hand Pump Position Selector PLACE IN DESIRED POSITION 15 Emergency Hand Pump PUMP until resistance becomes heavy may be 100 or more cycles 16 Gear Position CONFIRM VISUALLY WARNING Do not attempt to land on water unless all four wheels are fully retracted 17 Refer to Section ...

Page 25: ...SERVICE MANUAL ICA WIPLINE 2100 2350 FLOATS P N 1002549 Revision N Page 25 FIGURE 5 1 SCHEMATIC HYDRAULIC SYSTEM ...

Page 26: ...SERVICE MANUAL ICA WIPLINE 2100 2350 FLOATS Page 26 Revision N P N 1002549 FIGURE 5 2 SCHEMATIC ELECTRICAL SYSTEM ...

Page 27: ...SERVICE MANUAL ICA WIPLINE 2100 2350 FLOATS P N 1002549 Revision N Page 27 FIGURE 5 3 MAIN GEAR ACTUATION ...

Page 28: ...SERVICE MANUAL ICA WIPLINE 2100 2350 FLOATS Page 28 Revision N P N 1002549 FIGURE 5 4 NOSE GEAR RETRACTION SYSTEM ...

Page 29: ...SERVICE MANUAL ICA WIPLINE 2100 2350 FLOATS P N 1002549 Revision N Page 29 FIGURE 5 5 MAIN GEAR WHEEL ASSEMBLY ...

Page 30: ...SERVICE MANUAL ICA WIPLINE 2100 2350 FLOATS Page 30 Revision N P N 1002549 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 31: ...SERVICE MANUAL ICA WIPLINE 2100 2350 FLOATS P N 1002549 Revision N Page 31 CHAPTER 6 GEAR OPERATION AND MAINTENANCE CONTENTS 6 1 DESCRIPTION AND OPERATION 32 6 2 SERVICE SCHEDULE 33 ...

Page 32: ...l between up and down positions If the fluid level continues to decline during gear cycles check for external leaks If pump cycles on and off during gear cycle it may be necessary to select hand pump to UP Cycle gear UP with electric pump then select gear DOWN on hand pump and cycle gear DOWN with electric pump Repeat if necessary This manually bleeds system NOTE Fluid level in reservoir in UP pos...

Page 33: ...s 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 Protection of nuts bolts hydraulic lines or metal surfaces Zip D 5029NS Corrosion Inhibiting Compound Zip Chemical Company CRC SP400 Soft Seal CRC Indus...

Page 34: ...nes General Electric SIKAFLEX 201 or 252 Sika Manufacturing Bolt Torque Bolts in Critical Areas For common correct torque when installed or when visual inspection indicates a need for a torque check Nut torque should be applied depending on the hardware application unless the torque is specified for a certain joint in this manual or installation drawings A Torque of 80 should be used when Tef Gel ...

Page 35: ...aks cracks dents kinks chafing security corrosion and deterioration Metal Parts For security of attachment cracks metal distortion broken welds corrosion condition of paint and any other apparent damage Wiring For security chafing burning defective insulation loose or broken terminals corroded terminals Bolts in Critical Area For corrosion correct torque when installed or when visual inspection in...

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Page 37: ... 7 1 REMOVAL AND DISSASSEMBLY OF MAIN GEAR 38 7 2 INSTALLATION AND ASSEMBLY OF MAIN GEAR 39 7 3 DISSASSEMBLY OF SHOCK STRUT 40 7 4 SERVICING HYDRAULIC ACTUATOR CYLINDERS NOSE OR MAIN ACTUATORS 40 7 5 HAND PUMP OPERATION 42 7 6 GEAR SELECTOR 42 7 7 MAIN WHEELS AND BRAKES 42 7 8 VISUAL POSITION INDICATORS MAIN AND NOSE GEAR 42 ...

Page 38: ...ark nut inboard or outboard for ease of reinstalling 14 Hold coupling nut with 1 inch wrench while removing bolt on outboard side then inboard side NOTE Just remove coupling nut leave bolts through gear tracks for now 15 Through top access unlock gear and by hand move to the down position 16 Under the float remove bolt on drag link holding the lower shock strut end 17 Through side access finish re...

Page 39: ...olts to align 3 16 inch bolt and each side to wheel well Do not tighten 11 Temporarily install retract arm through to 5 8 inch hole in tracks without going through retract yoke 12 Tighten all 3 16 inch bolts four 4 each side on tracks 13 After tightening 3 16 inch side bolts eight 8 remove retract arm and install through retract yoke upper bushing 14 Reinstall two 2 inch diameter bolts in retract ...

Page 40: ...lic cylinder body by running gear to down position slide switch bracket up so lights green are illuminated on selector head refer to Figure 6 12 31 By running gear to up position slide switch bracket down so lights blue are illuminated on selector head NOTE If lights have a double flash on off on move switch brackets further to outer ends so lights come on just once 32 After switch brackets are po...

Page 41: ... Be sure to look at all seals closely so they can be re installed correctly Reassembly 1 To reassemble first make sure you are using Mil H 5606 hydraulic fluid and pre lubricate all the new quad and O rings not the wiper with it 2 Thread the end cap onto the cylinder tube a couple threads Waiting to add a drop of medium strength Loctite until this point helps to keep it from contaminating the cyli...

Page 42: ...ar BLUE GEAR UP WATER GREEN GEAR DOWN LAND CAUTION Do not land on water with gear in extended position Aircraft will nose over 7 6 GEAR SELECTOR Grease zerks are provided on all wheels and bearings and should be greased every 25 hours or after an extended period of time in the water Water heat resistant grease is recommended At brake installation apply STA Lube synthetic brake and caliper grease o...

Page 43: ... CHAPTER 8 NOSE GEAR CONTENTS 8 1 DESCRIPTION 44 8 2 SERVICE SCHEDULE 44 8 3 NOSE TROLLEY REMOVAL FROM BOX ASSEMBLY 44 8 4 REASSEMBLE NOSE TROLLEY TO NOSE BOX 44 8 5 REMOVAL OF NOSE BOX FORK FROM PIVOT ASSEMBLY 45 8 6 NOSE BOX REMOVAL FROM FLOAT 45 8 7 NOSE BOX TRACK WEAR 45 ...

Page 44: ...ose box tracks for wear 8 Replace or inspect trolley axles and nylon blocks on nose gear trolley 9 Assemble in reverse order of removal and 7 3 8 3 NOSE TROLLEY REMOVAL FROM BOX ASSEMBLY 1 If installing rod end and trolley link to trolley note position of grease hole it has to be positioned up refer to Figure 8 3 2 Before inserting trolley in nose box take care to position nylon slide blocks Posit...

Page 45: ...se box assembly from the float NOTE Keep washers on cylinder for reinstallation 4 Remove two 2 bolts holding nose box to float bulkhead angles 5 Slide entire nose box forward NOTE Nose box may be removed by just removing hydraulic lines elbow fittings and proximity switches Then slide box out with cylinder attached 8 6 NOSE BOX REMOVAL FROM FLOAT Due the wear over time the roller slide block place...

Page 46: ...SERVICE MANUAL ICA WIPLINE 2100 2350 FLOATS Page 46 Revision N P N 1002549 FIGURE 8 1 NOSE BOX ACCESS LOCATION ...

Page 47: ...SERVICE MANUAL ICA WIPLINE 2100 2350 FLOATS P N 1002549 Revision N Page 47 FIGURE 8 2 FRONT VIEW NOSE BOX ...

Page 48: ...SERVICE MANUAL ICA WIPLINE 2100 2350 FLOATS Page 48 Revision N P N 1002549 FIGURE 8 3 POSITION OF TROLLEY TO NOSE BOX ...

Page 49: ...SERVICE MANUAL ICA WIPLINE 2100 2350 FLOATS P N 1002549 Revision N Page 49 CHAPTER 9 WATER RUDDER RETRACTION AND STEERING SYSTEM CONTENTS 9 0 DESCRIPTION 50 9 1 ADJUSTMENT 50 9 2 SERVICE SCHEDULE 50 ...

Page 50: ...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 centerline Cables should be tensioned to 10 pounds 5 psi Retraction cables should be rigged such that the rudder blade is in the up position and that the cables are just slack in the down position 9 1 ADJUSTMENT Cables inspect for fraying an...

Page 51: ...SERVICE MANUAL ICA WIPLINE 2100 2350 FLOATS P N 1002549 Revision N Page 51 CHAPTER 10 REPAIRING FLOAT HULL SKINS EXTRUSIONS CONTENTS 10 0 REPAIRING FLOAT HULL SKINS EXTRUSIONS 52 ...

Page 52: ... WIPLINE 2100 2350 FLOATS Page 52 Revision N P N 1002549 For all float skin and extrusion structural repairs refer to Wipaire s Structural Repair Manual SRM part number 1008274 10 0 REPAIRING FLOAT HULL SKINS EXTRUSIONS ...

Page 53: ...ES FOR PIPER PA 12 FLOATPLANE 55 11 2 WEIGHING PROCEDURES FOR CUB CRAFTERS CC 18 AND CC 19 FLOATPLANE 56 11 3 WEIGHING PROCEDURES FOR THE HUSKY A 1 A 1A A 1B OR A 1C FLOATPLANE 57 11 4 WEIGHING PROCEDURE FOR CESSNA 172 FLOATPLANE 58 11 5 WEIGHING PROCEDURE FOR CESSNA 170 FLOATPLANE 59 11 6 WEIGHING PROCEDURE FOR CESSNA 175 FLOATPLANE 60 11 7 WEIGHING PROCEDURE FOR 8GCBC SCOUT FLOATPLANE 61 ...

Page 54: ...he distance from 0 0 to each nose wheel center This is X1 and X2 Measure the distance from 0 0 to each main wheel center This is Y1 and Y2 Use this table for the calculations 11 0 WEIGHING PROCEDURES FOR PIPER PA 18 FLOATPLANE Totals Notes 1 Zero out or deduct tare weights at the Y arms 2 If using an overhead hoist and load cell pick up aircraft at the center line of the front spar wing butt fitti...

Page 55: ...istance from 0 0 to each nose wheel center This is X1 and X2 Measure the distance from 0 0 to each main wheel center This is Y1 and Y2 If the floats are seaplane floats the scales go under the step point in the rear and a point towards the front of the float These distances are measured and become the same X and Y as for the amphibian Use this table for the calculations 11 1 WEIGHING PROCEDURES FO...

Page 56: ...e line and mark a line This 2nd line is the datum 0 0 Measure the distance from 0 0 to each nose wheel center This is X1 and X2 Measure the distance from 0 0 to each main wheel center This is Y1 and Y2 Use this table for the calculations 11 2 WEIGHING PROCEDURES FOR CUB CRAFTERS CC 18 AND CC 19 FLOATPLANE Totals Notes 1 Zero out or deduct tare weights at the Y arms 2 If using an overhead hoist and...

Page 57: ...mark a line This line is the datum 0 0 Measure the distance from 0 0 to each nose wheel center This is X1 and X2 Measure the distance from 0 0 to each main wheel center This is Y1 and Y2 Use this table for the calculations 11 3 WEIGHING PROCEDURES FOR THE HUSKY A 1 A 1A A 1B OR A 1C FLOATPLANE Totals Notes 1 Zero out or deduct tare weights at the Y arms 2 If using an overhead hoist and load cell p...

Page 58: ...re the distance from 0 0 to each main wheel center This is Y1 and Y2 If the floats are seaplane floats the scales go under the step point in the rear and a point towards the front of the float These distances are measured and become the same X and Y as for the amphibian Use this table for the calculations 11 4 WEIGHING PROCEDURE FOR CESSNA 172 FLOATPLANE Totals Notes 1 Zero out or deduct tare weig...

Page 59: ...This is X1 and X2 Measure the distance from 0 0 to each main wheel center This is Y1 and Y2 If the floats are seaplane floats the scales go under the step point in the rear and a point towards the front of the float These distances are measured and become the same X and Y as for the amphibian Use this table for the calculations 11 5 WEIGHING PROCEDURE FOR CESSNA 170 FLOATPLANE Totals Notes 1 Zero ...

Page 60: ...This is X1 and X2 Measure the distance from 0 0 to each main wheel center This is Y1 and Y2 If the floats are seaplane floats the scales go under the step point in the rear and a point towards the front of the float These distances are measured and become the same X and Y as for the amphibian Use this table for the calculations 11 6 WEIGHING PROCEDURE FOR CESSNA 175 FLOATPLANE Totals Notes 1 Zero ...

Page 61: ...s line is the datum 0 0 Measure the distance from 0 0 to each nose wheel center This is X1 and X2 Measure the distance from 0 0 to each main wheel center This is Y1 and Y2 If the floats are seaplane floats the scales go under the step point in the rear and a point towards the front of the float These distances are measured and become the same X and Y as for the amphibian Use this table for the cal...

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Page 63: ...SERVICE MANUAL ICA WIPLINE 2100 2350 FLOATS P N 1002549 Revision N Page 63 CHAPTER 12 INSPECTION CHECKLIST TROUBLESHOOTING CONTENTS 12 1 INSPECTION CHECKLIST 64 12 2 TROUBLESHOOTING 68 ...

Page 64: ... excessive wear Remove inspection plates baggage floor to inspect bulkhead flanges X Pumper Tube Installation inspect for condition security routing of hoses X Water Rudder System Water Rudder Hinges inspect freedom of rotation X Water Rudder Steering and Retract Systems inspect the following cables for broken wire cable fittings for cable slippage cracks and distortion cable pulleys for freedom o...

Page 65: ...al condition X Pressure Switches Inspect wiring mounting and general condition X Pump Motors inspect wiring mounting and general condition X Landing Gear Systems Main and Nose Gear Tracks lubricate X Nose Gear Box Block Tracks measured at slide route for wear 020 inches or less wear tolerance X Nose Gear Pivot Blocks and Forks inspect for condition lubrication corrosion paint Inspect Pivot Bolt X ...

Page 66: ... checked for moisture or other contaminates and changed if necessary X Main and Nose Gear Actuator Assemblies inspect for condition lubrication leakage corrosion and cleanliness X Nose Gear Springs scotchply springs inspect for cracks delamination and paint X Main Gear Drag Link inspect for condition lubrication corrosion check attach bolts for wear X Main Gear Shock Strut inspect for evidence of ...

Page 67: ...rity X Perform Retraction Test Main Gear inspect up and down for proper engagement X Nose Gear Trolley inspect for proper travel X Nose Gear inspect for excessive side play in the down position X Perform emergency gear extension if equipped X Nose and Main Wheel Bearings disassemble and inspect X Inspect and measure wear on Nose Gear Track Box X INSPECTION TIME LIMITS HOURS MECH INITIALS 25 50 100...

Page 68: ...oes not produce results and it is verified that voltage was actually applied to motor it can be assumed motor is bad or not properly grounded e Check motor ground 2 PROBLEM Power pack does not shut off after gear reaches position PROBABLE CAUSE a Faulty pressure switch b Faulty or dirty pressure relief valve allowing insufficient pressure buildup REMEDY a Replace pressure switch b Clean and check ...

Page 69: ...ring gear cycle PROBABLE CAUSE a Binding in retraction unit b Pressure switch cut off limit too low REMEDY a Investigate for free operation Check gear that retracts last b Replace pressure switch 6 PROBLEM Slow gear operation cycle considerably longer than 30 seconds PROBABLE CAUSE a Plugged oil screen b Poor electrical connection to motor Check ground c Poor motor d Worn pump gears REMEDY a Clean...

Page 70: ...ge 70 Revision N P N 1002549 8 PROBLEM Power pack does not cycle up or down PROBABLE CAUSE a Pressure build up in both sides of up and down lines REMEDY a Select hand pump to up and down position to relieve pressure Return to center and select gear ...

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