Wipaire Wipline 4000 Service Manual Download

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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

Summary of Contents for Wipline 4000

Page 1: ...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 ...

Page 2: ...SERVICE MANUAL ICA WIPLINE 4000 FLOATS ON CESSNA A185E A185F AND 206 SERIES Page 2 Revision G P N 1002552 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 3: ...o approved product list Modified torque limit section 12 4 2015 E 8 Added reference for Structural Repair Manual part number 1008274 in introduction 5 1 2019 F 10 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 pa...

Page 4: ...SERVICE MANUAL ICA WIPLINE 4000 FLOATS ON CESSNA A185E A185F AND 206 SERIES Page 4 Revision G P N 1002552 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 5: ...ORMATION 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 ...

Page 6: ...CATION 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 ...

Page 7: ...loats 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 Se...

Page 8: ...SERVICE MANUAL ICA WIPLINE 4000 FLOATS ON CESSNA A185E A185F AND 206 SERIES Page 8 Revision G P N 1002552 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 9: ...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 ...

Page 10: ...leys 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 firewall 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 ...

Page 11: ...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 ...

Page 12: ...dined Surfaces are then primed with an epoxy based primer and finished with an enamel color paint 2 2 CLEANING The outside of the float 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 plac...

Page 13: ...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 ...

Page 14: ...ight corrosion may 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...

Page 15: ...PLINE 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 ...

Page 16: ...fications 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 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...

Page 17: ...mpresses as shown 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...

Page 18: ...INE 4000 FLOATS ON CESSNA A185E A185F AND 206 SERIES Page 18 Revision G P N 1002552 FIGURE 4 3 FLOAT SECURING LOCATIONS ALTERNATE JACKING METHOD IF WIPAIRE JACKING FIXTURE IS NOT AVAILABLE 8000A model shown for reference only ...

Page 19: ...ition 3 Verify weighted 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 ...

Page 20: ...SERVICE MANUAL ICA WIPLINE 4000 FLOATS ON CESSNA A185E A185F AND 206 SERIES Page 20 Revision G P N 1002552 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 21: ... A185E A185F AND 206 SERIES P N 1002552 Revision G Page 21 CHAPTER 5 RETRACT SYSTEM OPERATION AND MAINTENANCE CONTENTS 5 1 DESCRIPTION AND OPERATION 22 5 2 ADJUSTMENT TEST 28 5 3 SERVICE SCHEDULE 28 5 4 INSPECTION CHECKLIST 32 5 5 TROUBLE SHOOTING 36 ...

Page 22: ...up or gear down is accomplished by a cockpit mounted control valve Each float gear has individual indicator lights on the control valve allowing the pilot to confirm that each 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 me...

Page 23: ...SERVICE MANUAL ICA WIPLINE 4000 FLOATS ON CESSNA A185E A185F AND 206 SERIES P N 1002552 Revision G Page 23 FIGURE 5 1 SCHEMATIC HYDRAULIC SYSTEM ...

Page 24: ...SERVICE MANUAL ICA WIPLINE 4000 FLOATS ON CESSNA A185E A185F AND 206 SERIES Page 24 Revision G P N 1002552 FIGURE 5 2 SCHEMATIC LANDING GEAR ELECTRICAL SYSTEM ...

Page 25: ...SERVICE MANUAL ICA WIPLINE 4000 FLOATS ON CESSNA A185E A185F AND 206 SERIES P N 1002552 Revision G Page 25 FIGURE 5 3 MAIN GEAR ACTUATION SYSTEM ...

Page 26: ...SERVICE MANUAL ICA WIPLINE 4000 FLOATS ON CESSNA A185E A185F AND 206 SERIES Page 26 Revision G P N 1002552 FIGURE 5 4 MAIN GEAR LOCKING SYSTEM ...

Page 27: ...SERVICE MANUAL ICA WIPLINE 4000 FLOATS ON CESSNA A185E A185F AND 206 SERIES P N 1002552 Revision G Page 27 FIGURE 5 5 NOSE GEAR RETRACTION SYSTEM ...

Page 28: ...cient 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 procedure until the fluid level in the reservoir stabilizes it will vary in level betwe...

Page 29: ...e Green Grease Inc Rust Protection Boeshield T9 Rut Protection Boeing Company ACF 50 Rust Protection Corrosion X Corrosion Technologies Corp Hydraulic Fluid Mil H 5606 Tef Gel Ultra Safety Systems Inc Electrical Insulating Compound Dow Corning 4 DC4 Dow Corning Corporation Float Sealant 890 B2 or B4 Pro Seal Company PR 1440 C PPG Aerospace 1422 B2 B4 or B6 Pro Seal Company RTV Silicones General El...

Page 30: ... adjustment correct travel cracked fittings security of hinges defective bearings cleanliness corrosion deformation sealing and tension Fluid Lines and Hoses For leaks 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 burni...

Page 31: ...s Nose and Main Gear Tracks Clean and lubricate with a dry Teflon coating spray Joints Spray all joints with light penetrating oil such as LPS 3 to ensure lubrication at all times Electrical Connections Apply SP 400 SOFT SEAL or LPS 500 to all electrical connections to prevent corrosion Hydraulic Fluid For use in all hydraulic systems including brakes MIL H 5606 ...

Page 32: ... condition security operation excessive wear X Pumper Tube Installation inspect for condition security routing of hoses X Water Rudder System Water Rudder Boots inspect for cuts tears and condition 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 of rotation and cable guard pin...

Page 33: ...n X Pressure switches inspect wiring mounting and general condition X Landing Gear Systems Lubricate nose gear tracks X Nose gear Box Block tracks measured at slide route for wear 050 inches or less wear tolerance X Nose gear pivot blocks and forks inspect for condition lubrication corrosion paint X Nose and main wheel bearing grease Zerk fittings X Inspect and measure wear on Nose Gear Track Box ...

Page 34: ...d changed if necessary X Main and nose gear actuator assemblies inspect for condition lubrication leakage corrosion and cleanliness X Nose gear springs scotch ply springs inspect for cracks delamination and paint X Main gear drag link garlock bushings inspect for condition lubrication corrosion X Main gear oleos inspect for evidence of leakage proper extension check cylinder for corrosion pitting ...

Page 35: ...fluid pressure X Landing Gear Systems Perform retraction test Inspect main gear up and down hooks for proper engagement X Inspect nose gear trolley for proper travel X Inspect nose gear 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 INSPECTION TIME LIMITS HOURS MECH INITIALS 25 50 100 200 RT LT ...

Page 36: ...solenoid pressure switch d If c above does 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 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 Repl...

Page 37: ...ng 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 c Poor motor d Worn pump gears REMEDY a Clean intake screen ...

Page 38: ...SERVICE MANUAL ICA WIPLINE 4000 FLOATS ON CESSNA A185E A185F AND 206 SERIES Page 38 Revision G P N 1002552 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 39: ...NE 4000 FLOATS ON CESSNA A185E A185F AND 206 SERIES P N 1002552 Revision G Page 39 CHAPTER 6 MAIN GEAR CONTENTS 6 1 MAIN OLEO 40 6 1 1 DESCRIPTION 40 6 1 2 REMOVAL INSTALLATION 41 6 1 3 SERVICE 41 6 2 MAIN WHEELS AND BRAKES 41 ...

Page 40: ...ly dampened air spring Figure 6 1 shows the main components The oil and air share a common chamber When the oleo is collapsed the oil is forced through the main orifice compressing the air in the upper cylinder Extension reverses this process The extended oleo is initially set at the factory to 350 psi no load In field adjustment of air pressure is described in section 6 1 3 FIGURE 6 1 SECTION MAI...

Page 41: ...fluid Air Pressure The correct air pressure is 350 psi 10 psi on a fully extended oleo no load or it can be inflated to approximately 2 inches on an unloaded aircraft while sitting static on level ground Note Pressure varies 60 lbs between 70 degrees F and 0 degrees F Seals Seals should be replaced whenever the oleo is disassembled or leaking Caution Release air pressure and remove air valve befor...

Page 42: ...SERVICE MANUAL ICA WIPLINE 4000 FLOATS ON CESSNA A185E A185F AND 206 SERIES Page 42 Revision G P N 1002552 FIGURE 6 2 ASSEMBLY MAIN WHEEL AND BRAKE ...

Page 43: ...RVICE MANUAL ICA WIPLINE 4000 FLOATS ON CESSNA A185E A185F AND 206 SERIES P N 1002552 Revision G Page 43 CHAPTER 7 NOSE GEAR CONTENTS 7 1 DESCRIPTION 44 7 2 SERVICE SCHEDULE 44 7 3 NOSE BOX TRACK WEAR 44 ...

Page 44: ...A nylon thrust washer is on top of the castoring pin 7 2 SERVICE SCHEDULE The nose gear pivot assembly should be cleaned and greased every 25 hours or more frequently whenever in water for extended period of time The nose wheels contain grease nipples for the wheel bearings They should be greased every 25 hours Nose tires are standard 4 10 x 4 4 ply inflated to 38 5 psi 7 3 NOSE BOX TRACK WEAR Due...

Page 45: ... ICA WIPLINE 4000 FLOATS ON CESSNA A185E A185F AND 206 SERIES P N 1002552 Revision G Page 45 CHAPTER 8 WATER RUDDER RETRACTION AND STEERING SYSTEM CONTENTS 8 1 DESCRIPTION 46 8 2 ADJUSTMENT 46 8 3 SERVICE SCHEDULE 46 ...

Page 46: ...ng 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 10 pounds 5 psi 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...

Page 47: ...SERVICE MANUAL ICA WIPLINE 4000 FLOATS ON CESSNA A185E A185F AND 206 SERIES P N 1002552 Revision G Page 47 CHAPTER 9 REPAIRING FLOAT HULL SKINS CONTENTS 9 0 REPAIRING FLOAT HULL SKINS 48 ...

Page 48: ...PLINE 4000 FLOATS ON CESSNA A185E A185F AND 206 SERIES Page 48 Revision G P N 1002552 9 0 REPAIRING FLOAT HULL SKINS For all float skin structural repairs refer to Wipaire s Structural Repair Manual SRM part number 1008274 ...

Page 49: ...SERVICE MANUAL ICA WIPLINE 4000 FLOATS ON CESSNA A185E A185F AND 206 SERIES P N 1002552 Revision G Page 49 CHAPTER 10 REPAIRING FLOAT HULL EXTRUSIONS CONTENTS 10 0 REPAIRING FLOAT HULL EXTRUSIONS 50 ...

Page 50: ... 4000 FLOATS ON CESSNA A185E A185F AND 206 SERIES Page 50 Revision G P N 1002552 10 0 REPAIRING FLOAT HULL EXTRUSIONS For all float extrusion structural repairs refer to Wipaire s Structural Repair Manual SRM part number 1008274 ...

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