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WIPLINE MODEL 8000 SERVICE MANUAL

1002554 • Rev H Page

39

of

62

(CONT.) CESSNA 208 FLOAT REMOVAL INSTRUCTIONS/PROCEEDURES MECHANIC

INSP.

THIS IS INTENDED AS A GENERAL GUIDE. EACH INSTALLATION MAY HAVE
SUBTLE DIFFERENCES. ALWAYS USE THE INSTALLATION DRAWINGS AS
THE FINAL REFERENCE. ALL WORK SHOULD BE DONE BY CERTIFIED
AIRCRAFT TECHNICIONS.

Right

Left

14. connect brake lines and bleed for air bubbles

15. Install main gear belly plate and fairings

16. Remove front strut fittings

17. Install pilot and co-pilot step assemblies

18. Replace Cargo Door Cable Assy. (2) P/N S2837-2 with original Cable Assy. (2)
P/N S2837-1 (OPTIONAL)

19. Install tail cone and tail hatch cover

20. Install lower LT. cowling

21. Install all nose gear fittings

22. Install all floor plates and carpet

23. Install aft bulkhead

24. Install any seats previously removed

25. Remove aircraft from hoist & add air to tires as required

26. Install wing-root fairings

27. Check all placards to conform to landplane category

28. Make logbook entry

NOTES

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Summary of Contents for WIPLINE 8000

Page 1: ...NTENANCE PAINT REFINISHING 1700 Henry Ave Fleming Field KSGS South St Paul MN 55075 Ph 651 451 1205 Fax 651 457 7858 www wipaire com SERVICE MANUAL and INSTRUCTIONS FOR CONTINUED AIRWORTHINESS for the WIPLINE MODEL 8000 AMPHIBIOUS AND SEAPLANE FLOATS Revised December 2015 ...

Page 2: ...WIPLINE MODEL 8000 SERVICE MANUAL Page 2 of 62 1002554 Rev H THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 3: ...HEELS AND BRAKES 19 5 1 3 SERVICE MAIN GEAR OLEO 19 5 2 ADJUSTMENT TEST 21 5 2 1 NOSE GEAR 21 5 2 2 NOSE BOX TRACK WEAR 21 5 2 3 SERVICE MAIN GEAR RETRACTION SYSTEM 21 5 2 4 BLEEDING HYDRAULIC SYSTEM AFTER SERVICE 22 5 3 MAIN AND NOSE GEAR REMOVAL AND DISASSEMBLY 23 5 3 1 REMOVAL OF MAIN GEAR OLEO 23 5 3 2 REMOVAL OF MAIN GEAR RETRACTION CYLINDER 28 5 3 3 REMOVAL OF MAIN GEAR DRAG LINK 28 5 3 4 RE...

Page 4: ...R RETRACTION AND STEERING SYSTEM 51 6 1 DESCRIPTION 51 6 2 ADJUSTMENT 51 6 3 SERVICE SCHEDULE 51 7 0 REPAIRING FLOAT HULL SKINS BULKHEADS AND SHEET METAL 52 FIGURE 7 1 TYPICAL SKIN REPAIR 53 FIGURE 7 2 TYPICAL SKIN REPAIR 54 FIGURE 7 3 TYPICAL SKIN REPAIR 55 FIGURE 7 4 TYPICAL REPAIR BOTTOM SKIN TO KEEL INSTRUCTIONS 56 FIGURE 7 5 TYPICAL REPAIR BOTTOM SKIN TO KEEL INSTRUCTIONS 57 FIGURE 7 6 TYPICA...

Page 5: ...nd additional minor changes to the inspection checklist 5 31 08 F 29 36 46 Changed water rudder cable tensions 8 15 08 G 5 6 12 1321 Changed main gear oleo servicing information Added enhanced customer information pages and cleaning and corrosion pages 7 15 09 H ALL Reformat of entire document Add green grease as approved grease update to float procedures with clarification on rear door support ca...

Page 6: ... Number Purchasing Contact Phone Number E Mail Fax Number Accounts Payable Contact Phone Number E Mail 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 651 306 0666 Phone 651 306 0459 CustomerService wipaire com ...

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Page 10: ...y this manual contact Wipaire Customer Service 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 1700 Henry Avenue Fleming Field South St Paul MN 55075 Telephone 651 306 0459 Fax 651 306 0666 Website www wipaire com E...

Page 11: ...d 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 diff...

Page 12: ...ts 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...

Page 13: ...n FRESH WATER at step speed can help to flush 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 float interior should be flushed if salt water enters the compartments If the floats are being stored inside remove...

Page 14: ...n X or ACF 50 may also be applied to stop corrosion Refer to manufacturer s instructions for application instructions Maintaining the float inside and outside finishes by washing after saltwater operations will help protect the float 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 ...

Page 15: ...he jack Raise only one float at a time with the opposite float landing wheels chocked Position a sawhorse under main and after body keel to keep aircraft from tipping fore and aft For raising the aircraft for float installation and removal use the lifting rings if provided or lift at front wing attach points Aircraft may be lifted by spreader bars with a launching dolly WITH CAUTION lift on both s...

Page 16: ...ry 100 hours Landing gear operation is initiated by movement of the landing gear handle When the handle is repositioned hydraulic pressure in the system will drop and pressure switches will automatically turn on the hydraulic pump motors to maintain operating pressure in the system When the gear cycle is completed the pump will automatically shut off If the pressure in the system drops to a preset...

Page 17: ...tomatically turn on The motors power the hydraulic pumps and actuate the gear actuator for each gear During operation of the landing gear motors the PUMP ON 1 and 2 indicator lights are illuminated When the gear cycle is completed pressure builds up in the hydraulic system and automatically shuts off the hydraulic motors Each gear operates independently of the other and therefore the position ligh...

Page 18: ... gear has fully retracted or extended 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 is mechanically locked in both up and down positions Locking and unlocking is done utilizing a small amount of lost motion of the actuator rod Retraction takes place when pressure ...

Page 19: ...ck should be cleaned and left dry or alternately cleaned and wiped with a rag with dry silicone spray on it The nose wheels contain grease nipples for the wheel bearings They should be greased every 25 hours Nose tires are standard 5 00 x 5 10 ply inflated to 60 5 psi 5 1 2 SERVICE MAIN WHEELS AND BRAKES Grease nipples are provided on all wheels and bearings and should be greased every 25 hours or...

Page 20: ... can be inflated to approximately 5 6 inches on an unloaded aircraft while sitting static on level ground SEALS Seals should be replaced whenever the oleo is disassembled or leaking CAUTION Release air pressure and remove air valve before attempting to disassemble oleo The seals are standard O rings or T seals whose part numbers are depicted in figure 5 4 ...

Page 21: ...ured for the amount of wear The tolerance for wear is 050 inches If the wear is or is less than the limit it can still be used If the wear in the track is greater than 050 inches the block must be replaced This check is to be done every 200 hours and is part of the maintenance checklist On the 8000 Series Floats Gear Track P N 8A07337 003 LT 004 RT 5 2 3 SERVICE MAIN GEAR RETRACTION SYSTEM As expl...

Page 22: ...ward side of the gear tunnel It is accessible through the top deck access cover The aft proximity switch is located on the float bulkhead just aft of the wheel well accessible though the float top deck cover The main gear proximity switches are adjusted loosening the mounting screws and positioning them as such that the light goes out when the lock hook is raised about 1 8 inch off its nested posi...

Page 23: ...assemble the strut removing both end caps Take apart the gland section and metering pin so the parts can be easily inspected for wear and replacement parts can installed as needed 2 Inspect all parts carefully after cleaning for wear and scoring especially the piston gland section and the inside of the outer cylinder Also make sure to check the bushings in the end caps for wear and security 3 The ...

Page 24: ...old style O rings are used c Tighten the associated jam nut at that end and stake it for added security d Set this metering tube assembly aside and move on to next steps 4 On the other end install the metering pin with Loctite onto the end cap and tighten to approx 30 ft lbs 5 Install outer T seal to end cap with Vaseline Also lube the inside of the outer cylinder where the end cap seats for ease ...

Page 25: ...de and move on to next steps 7 To assemble the gland assembly insert the inside T seal and wiper again using Vaseline on the T seal a The gland must be installed from the end cap side this is the side without the holes b Lube the outside of the inner cylinder with hydraulic fluid for ease of assembly c Install the T seal into the end cap again using Vaseline for lube d Install the inner cylinder i...

Page 26: ... Install the jam nut onto the piston end of the metering tube and stake for security c Install the 2 T seals onto the exterior of the piston and gland and lube with Vaseline 8 Gently clamp the outer tube end in a vise and add 1140 ml of hyd fluid 5606 or equivalent 9 Lube the inside of the outer cylinder where the gland and the piston will rest 10 Install the inner cylinder into the outer assembly...

Page 27: ...ring onto the fill drain plug before installing the plug onto the end cap and tighten 14 Install the O ring onto the Schraider valve and install onto the outside of the end cap NOTE Align Schraider valve 180 degrees from the Placard NOTE Double check the plugs and bolts for proper Installation and security before adding gas charge ...

Page 28: ... of access cover Remove 25 dia retention bolt Remove piston by pulling aft See figure 5 3 for part breakdown 5 3 3 REMOVAL OF MAIN GEAR DRAG LINK Remove drag link from trunnions on step bulkhead Axle is heat shrunk to drag link and is not removable 5 3 4 REMOVAL OF NOSE GEAR FROM NOSE BOX Gear must be in down position Relieve pressure in system place gear selector handle in neutral position lever ...

Page 29: ...tems which may require servicing at more frequent intervals When conducting an inspection at 25 hours all items marked for 25 hours would be accomplished When conducting an inspection at 50 hours the 25 and 50 hour items would be accomplished When conducting an inspection at 100 hours the 25 50 and 100 hour items would be accomplished When conducting an inspection at 200 hours the 25 50 100 and 20...

Page 30: ...eral Electric SIKAFLEX 201 or 252 Sika Manufacturing Telflon Spray 6P 730A Comet Industries Electrical Insulating Compound Dow Corning 4 DC4 Dow Corning Corporation If existing grease cannot be identified you must lubri flush all float grease fittings until visibly exhausting all old grease and new grease is coming out Additionally if you cannot determine existing grease in wheel bearings complete...

Page 31: ...450 500 1 2 20 480 690 9 16 18 800 1 000 5 8 18 1 100 1 300 3 4 16 2 300 2 500 7 8 14 2 500 3 000 1 14 3 700 4 500 1 1 8 12 5 000 7 000 1 1 4 12 9 000 11 000 Shear Application Nut Bolt Size Torque Limits In lbs Min Max 8 36 7 9 10 32 12 15 1 4 28 30 40 5 16 24 60 85 3 8 24 95 110 7 16 20 270 300 1 2 20 290 410 9 16 18 480 600 5 8 18 600 780 3 4 16 1 300 1 500 7 8 14 1 500 1 800 1 14 2 200 3 300 1 ...

Page 32: ...d for cleaning 1 Relieve the pressure in the hydraulic system by placing the gear selector handle in the neutral position 2 On the forward lower side of the reservoir remove drain plug to drain most of the hydraulic fluid 3 Remove the 4 screws on each tank 2 on upper side of the reservoir 4 Dump out remaining oil and clean reservoir 5 Unscrew stand pipe with the filter attached 6 Clean filter 7 If...

Page 33: ... the center section fairings for access Struts and attach fittings clean upper attach fittings and dog bone saddle area If off aircraft re grease bolts and return X X Disassemble and grease the flying wire clevis bolts pins and fittings Spreader Bars inspect for loose screws and cracks seal between fairing and side skin Insp fairings for cracking and loose screws X On the aircraft and floats re co...

Page 34: ... AN3 6A for wear Check top and bottom rollers for rotation and lube with LPS 2 or similar product Tension cables to 30 lbs 5 X X On the aircraft remove clean inspect and grease the aux finlets on the horizontal stabilizer X Electrical System Pump and indicator light wiring inspect for chafing broken or loose terminals and general condition X X Solenoids inspect wiring mounting and general conditio...

Page 35: ...aulic fluid screen clean and inspect NOTE If floats sit for extended periods of time I e If removed during winter months screen should be cleaned before putting floats back into service Hydraulic fluid in reservoir should be checked for moisture or other contaminates and changed if necessary X X Insp FWD slide tube mounting bolt for corrosion and wear when the gear are out Clean and lube the slide...

Page 36: ...tion security and leaks X X Brake system plumbing inspect for leaks condition and security X X Main gear oleos Check for static compression leaks and proper pressure The oleo should be fully serviced or replaced with overhauled as required If full servicing is required use 5606 hydraulic fluid Nitrogen Refer to section 5 2 X X Perform retraction test Inspect main gear up and down lock hooks for pr...

Page 37: ... installation before connecting lifting bar to the aircraft 4 Attach ropes and ballast to tie down rings as required to keep aircraft level while lifting 5 Lower aircraft so wheels just touch and relieve hydraulic pressure before Pulling pump circuit breakers Install tie wrap to shank for safety 6 Remove from aircraft Nose gear cover plate Lower left cowling Steering bungee from nose gear attach F...

Page 38: ...cables Fairleads from under the cabin floor Elevator down spring and cable Hydraulic lines at the RT front strut location and cap Retract cable Secure in main gear well Break lines and cap Electrical cannon plug in main wheel well Steering cables in tail Remove rudder horn or clamp to main rudder Cables 7 Assemble main gear if needed 8 Install nose gear and attach steering bungee 9 Assemble suppor...

Page 39: ... Install main gear belly plate and fairings 16 Remove front strut fittings 17 Install pilot and co pilot step assemblies 18 Replace Cargo Door Cable Assy 2 P N S2837 2 with original Cable Assy 2 P N S2837 1 OPTIONAL 19 Install tail cone and tail hatch cover 20 Install lower LT cowling 21 Install all nose gear fittings 22 Install all floor plates and carpet 23 Install aft bulkhead 24 Install any se...

Page 40: ...nd co pilot steps 6 Install front strut fittings 7 Disconnect brake lines and cap 8 Cut tie wrap from pump circuit breakers 9 Tie ropes from tie down rings Connect lifting bar to hoist and inspect Aircraft lifting rings for proper assembly before connecting to aircraft Use Ballast from tie down ropes to ensure level lifting 10 Raise aircraft until wheels are just touching the ground and assemble C...

Page 41: ...e time down Check for leaks 21 Hand pump the gear down and up and check for leaks again 22 Install springs for steering cables in the tail of the aircraft 23 Route and rig the steering cables water rudder retract cables 30lbs 5 24 Install step struts 25 Replace Cargo Door Cable Assy 2 P N S2837 1 with Cargo Door Cable Assy 2 P N S2837 2 26 Install break lines and bleed for air bubbles 27 Install e...

Page 42: ...ts 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 Powerpack 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 relief valve 3 PROBLEM...

Page 43: ...E 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 c Poor motor d Worn pump gears REMEDY a Clean intake screen located inside reserv...

Page 44: ...WIPLINE MODEL 8000 SERVICE MANUAL Page 44 of 62 1002554 Rev H FIGURE 5 1 SCHEMATIC HYDRAULIC SYSTEM ...

Page 45: ...WIPLINE MODEL 8000 SERVICE MANUAL 1002554 Rev H Page 45 of 62 FIGURE 5 2 SCHEMATIC ELECTRICAL SYSTEM ...

Page 46: ...WIPLINE MODEL 8000 SERVICE MANUAL Page 46 of 62 1002554 Rev H FIGURE 5 3 ASSEMBLY MAIN GEAR RETRACTION SYSTEM ...

Page 47: ...15B001TR035 T SEAL INNER CYLINDER WIPER 4115B001TR035 T SEAL INSIDE RETAINER RETAINER METERING TUBE 4115B001TP037 T SEAL OUTSIDE RETAINER PISTON PISTON OUTER CYLINDER 4115B01TP037 T SEAL LOWER CAP AN6227 14 O RING METERING PIN CAUTION REMOVE PRESSURE BEFORE DIASSEMBLY FIGURE 5 4 ASSEMBLY MAIN GEAR SHOCK STRUT ...

Page 48: ...WIPLINE MODEL 8000 SERVICE MANUAL Page 48 of 62 1002554 Rev H FIGURE 5 5 ASSEMBLY MAIN GEAR AND BRAKE Refer to Parts Manual for complete parts list ...

Page 49: ...WIPLINE MODEL 8000 SERVICE MANUAL 1002554 Rev H Page 49 of 62 FIGURE 5 6 ASSEMBLY NOSE GEAR SYSTEM DETAIL A SCALE 1 1 8 T SEAL T SEAL T SEAL ...

Page 50: ...ation 100 00 Measure 100 00 inches forward of this point this is the datum 0 0 Draw another line between the nose wheel centers and a 4th line between the main wheel centers Measure the distance from 0 0 to the nose wheel line This is X1 and X2 Measure the distance from 0 0 to the main wheel line This is Y1 and Y2 If the floats are seaplane floats the scales go under the step point in the rear and...

Page 51: ...Rigging 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 center line Cables should be tensioned to 30 lbs 5 Retraction cables should be rigged such that the top of the rudder blade is against the rudder stop on the rudder posts in the up position and that the cables are just slack in the d...

Page 52: ... Figures 7 1 7 2 7 3 or any acceptable repair method listed in FAA Advisory Circular 43 13 1A Any float hull skin or bulkhead or part thereof can be purchased from Wipaire to aid in repair To simplify repairs the skins can be ordered precut to shape All outside hull skins are bonded to the extrusions with a special heat pressure 3M adhesive This bond adheres skins to the inside of all extrusions S...

Page 53: ...L 1002554 Rev H Page 53 of 62 FIGURE 7 1 TYPICAL SKIN REPAIR 1 TRIM HOLE AS SHOWN BY DOTTED LINE 2 PATCH MATERIAL TO BE AT LEAST SAME THICKNESS AS ORIGINAL SKIN 3 PRIME ALL BARE SURFACES 4 SEAL BETWEEN PATCH AND SKIN 5 RIVET IN PLACE ...

Page 54: ...WIPLINE MODEL 8000 SERVICE MANUAL Page 54 of 62 1002554 Rev H FIGURE 7 2 TYPICAL SKIN REPAIR ...

Page 55: ...WIPLINE MODEL 8000 SERVICE MANUAL 1002554 Rev H Page 55 of 62 FIGURE 7 3 TYPICAL SKIN REPAIR ...

Page 56: ...TTOM SKIN TO KEEL INSTRUCTIONS Preferred method 1 REMOVE ORIGINAL DAMAGED SKIN CUT FLUSH WITH EXTRUSION 2 REMOVE CAULKING FROM GROOVE OF EXTRUSION 3 APPLY SEALANT IN GROOVE BE SURE TO USE PLENTY OF SEALANT 4 INSERT REPAIR SKIN INTO EXTRUSION 5 DRILL AND COUNTERSINK HOLES AND RIVET INTO PLACE ...

Page 57: ... KEEL INSTRUCTIONS 1 REMOVE ORIGINAL DAMAGED SKIN FROM EXTRUSION 2 REMOVE CAULKING FROM GROOVE OF EXTRUSION 3 APPLY SEALANT IN GROOVE BE SURE TO USE PLENTY OF SEALANT 4 INSERT REPAIR SKIN INTO EXTRUSION 5 INSTALL SPACER BETWEEN REPAIR SKIN AND EXTRUSION 6 DRILL AND COUNTERSINK HOLES AND RIVET INTO PLACE ...

Page 58: ...OTTOM SKIN TO KEEL ALT INSTRUCTIONS ALTERNATE METHOD 1 REMOVE ORIGINAL DAMAGED SKIN LEAVING APPROXIMATELY 1 OF SKIN PROTRUDING FROM EXTRUSION 2 REMOVE CAULKING FROM GROOVE IN EXTRUSION 3 INSTALL SEALANT IN GROOVE BE SURE TO USE PLENTY OF SEALANT 4 INSERT REPAIR SKIN IN GROOVE APPROXIMATELY ...

Page 59: ...ng is done when only the outside of an extrusion is damaged such as the main keel during gear up landings on pavement Capping also is done when the original skin is still bonded to the inside of the extrusion Sections of extrusion for splicing or capping may be purchased from Wipaire in any length needed Stub skins can also be bonded on extrusion sections if desired to simplify the repair There ar...

Page 60: ...WIPLINE MODEL 8000 SERVICE MANUAL Page 60 of 62 1002554 Rev H FIGURE 8 1 TYPICAL REPAIR SPLICE OF KEEL ...

Page 61: ...WIPLINE MODEL 8000 SERVICE MANUAL 1002554 Rev H Page 61 of 62 FIGURE 8 2 TYPICAL REPAIR SPLICE OF CHINE ...

Page 62: ...1 LAYOUT NEW REPAIR CAP ON DAMAGED EXTRUSION 2 REMOVE OUTSIDE OF DAMAGED EXTRUSION BY FILING OR GRINDING TO INSIDE SHAPE OF REPAIR CAP 3 MATCH DRILL OR LAYOUT AND DRILL HOLE PATTERN AS SHOWN 4 RIVET OUTSIDE CAP AND SPACER TO EXISTING INSIDE EXTRUSION 5 APPLY KEEL WEAR STRIP WITH ANY GOOD 2 PART EPOXY ...

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