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Wipaire WIPLINE 13000 Service Manual

Amphibious and seaplane float on the dhc-6 twin otter
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SERVICE MANUAL & ICA
WIPLINE 13000 FLOATS
WIPLINE FLOATS • SKIS • MODIFICATIONS • AIRCRAFT SALES
AVIONICS • INTERIOR • MAINTENANCE • PAINT REFINISHING
AMPHIBIOUS AND SEAPLANE FLOAT
P/N 1002548
SERVICE MANUAL
FOR THE
WIPLINE MODEL 13000
ON THE
DHC-6 TWIN OTTER
Revision H
Revision H
Page 1

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  • Page 1 SERVICE MANUAL & ICA WIPLINE 13000 FLOATS WIPLINE FLOATS • SKIS • MODIFICATIONS • AIRCRAFT SALES AVIONICS • INTERIOR • MAINTENANCE • PAINT REFINISHING SERVICE MANUAL FOR THE WIPLINE MODEL 13000 AMPHIBIOUS AND SEAPLANE FLOAT ON THE DHC-6 TWIN OTTER...
  • Page 2 SERVICE MANUAL & ICA WIPLINE 13000 FLOATS THIS PAGE INTENTIONALLY LEFT BLANK Page 2 Revision H P/N 1002548...
  • Page 3 Industries GP-730A. Removed content in Chapter 4 and replaced with note about SRM. 2/3/2021 Removed Figures 4.1 through 4.10 as content is found in SRM. View most current revision of this ICA at www.wipaire.com. P/N 1002548 Revision H Page 3...
  • Page 4 SERVICE MANUAL & ICA WIPLINE 13000 FLOATS THIS PAGE INTENTIONALLY LEFT BLANK Page 4 Revision H P/N 1002548...

  • Page 5: Table Of Contents

    SERVICE MANUAL & ICA WIPLINE 13000 FLOATS CONTENTS INTRODUCTION ...............................7 CHAPTER 1 GENERAL INFORMATION .......................11 CHAPTER 2 MAIN AND NOSE GEAR OPERATION, REMOVAL & SERVICE ...........21 CHAPTER 3 HYDRAULIC PUMP SYSTEM, DISASSEMBLY & SERVICE ..........41 CHAPTER 4 REPAIRS ............................45 CHAPTER 5 CONTINUED AIRWORTHINESS .....................47 CHAPTER 6 WEIGHT AND BALANCE ......................55...
  • Page 6 SERVICE MANUAL & ICA WIPLINE 13000 FLOATS LIST OF FIGURES FIGURE 1.1 JACK CRADLE RECOMMENDED MODIFICATION ............14 FIGURE 1.2 JACKING LOCATION ......................14 FIGURE 1.3 FLOAT SECURING LOCATIONS ..................15 FIGURE 1.4 FLOAT SECURING LOCATIONS OVERVIEW ..............16 FIGURE 2.1 HYDRAULIC SYSTEM SCHEMATIC .................31 FIGURE 2.2 SCHEMATIC –...

  • Page 7: Introduction

    WIPLINE 13000 FLOATS INTRODUCTION This manual is provided for the owners of Wipaire model 13000 Floats as installed on the DHC-6 Twin Otter. It has two main priorities, to inform owners of the level and amount of servicing required to properly maintain their floatplane, and to provide technical data and servicing specifics to maintenance professionals charged with servicing the floats.
  • Page 8 SERVICE MANUAL & ICA WIPLINE 13000 FLOATS Page 8 Revision H P/N 1002548...
  • Page 9 SERVICE MANUAL & ICA WIPLINE 13000 FLOATS P/N 1002548 Revision H Page 9...
  • Page 10 SERVICE MANUAL & ICA WIPLINE 13000 FLOATS THIS PAGE INTENTIONALLY LEFT BLANK Page 10 Revision H P/N 1002548...

  • Page 11: Chapter 1 General Information

    SERVICE MANUAL & ICA WIPLINE 13000 FLOATS CHAPTER 1 GENERAL INFORMATION CONTENTS 1.1 AIRPLANE ..............................12 1.2 FLOATS ..............................12 1.3 TOWING ..............................12 1.4 HOISTING ..............................13 1.5 LEVELING ..............................13 1.6 JACKING PROCEDURES ........................13 1.7 JACK REMOVAL ............................16 1.8 AMPHIBIAN LANDING GEAR SYSTEM ....................16...

  • Page 12: Airplane

    SERVICE MANUAL & ICA WIPLINE 13000 FLOATS 1.1 AIRPLANE The DHC-6 Twin Otter is a high wing, all metal, twin turbo prop aircraft originally manufactured by de Havilland Canada and currently produced by Viking Air. As part of the float installation the following changes are made to the landplane: 1.

  • Page 13: Hoisting

    If the lifting rings are not installed, reference applicable aircraft maintenance/ service manual for additional hoisting specifications. 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.

  • Page 14: Figure 1.1 Jack Cradle Recommended Modification

    (X = WIDTH OF CRADLE) FIGURE 1.1 JACK CRADLE RECOMMENDED MODIFICATION NOTE: This is not required and Wipaire does not have the parts for modification. It is recommended a similar modification be performed to the jack saddle to prevent the slippage of the cradle.

  • Page 15: Figure 1.3 Float Securing Locations

    SERVICE MANUAL & ICA WIPLINE 13000 FLOATS FIGURE 1.3 FLOAT SECURING LOCATIONS ALTERNATE JACKING METHOD IF WIPAIRE JACKING FIXTURE IS NOT AVAILABLE (8000A model shown for reference only) P/N 1002548 Revision H Page 15...

  • Page 16: Figure 1.4 Float Securing Locations Overview

    SERVICE MANUAL & ICA WIPLINE 13000 FLOATS Fore Cradle Cradle Stand Aft Cradle Fore Stand Support Support (8000A MODEL SHOWN FOR REFERENCE ONLY) FIGURE 1.4 FLOAT SECURING LOCATIONS OVERVIEW 1.7 JACK REMOVAL Make sure nothing is under or above the airplane or floats when removing the jacks from the aircraft 1.
  • Page 17 SERVICE MANUAL & ICA WIPLINE 13000 FLOATS 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.
  • Page 18 SERVICE MANUAL & ICA WIPLINE 13000 FLOATS 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.
  • Page 19 WIPLINE 13000 FLOATS 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.
  • Page 20 SERVICE MANUAL & ICA WIPLINE 13000 FLOATS THIS PAGE INTENTIONALLY LEFT BLANK Page 20 Revision H P/N 1002548...

  • Page 21: Chapter 2 Main And Nose Gear Operation, Removal & Service

    SERVICE MANUAL & ICA WIPLINE 13000 FLOATS CHAPTER 2 MAIN AND NOSE GEAR OPERATION, REMOVAL & SERVICE CONTENTS 2.1 DESCRIPTION AND OPERATION ......................22 2.2 SERVICE – NOSE GEAR .........................23 2.3 SERVICE – MAIN WHEELS AND BRAKES ....................23 2.4 SERVICE – MAIN GEAR OLEO .......................23 2.5 SERVICE NOSE AND MAIN GEAR RAMS .....................29...

  • Page 22: Description And Operation

    SERVICE MANUAL & ICA WIPLINE 13000 FLOATS 2.1 DESCRIPTION AND OPERATION Retraction and extension of the main and nose landing gear is effected by a hydraulic actuation system shown schematically in figure 2.1. The gear system is hydraulically actuated and driven by two hydraulic pumps located on the fuselage bulkhead 60.00.

  • Page 23: Service - Nose Gear

    SERVICE MANUAL & ICA WIPLINE 13000 FLOATS 2.2 SERVICE – NOSE GEAR The nose gear pivot assembly should be cleaned and greased every 25 hours or more frequently whenever in water for extended period of time. Nose gear tracks to be lightly greased. Apply grease to a cloth on a stick or rod and run along tracks inside of the nose box, both sides.
  • Page 24 SERVICE MANUAL & ICA WIPLINE 13000 FLOATS Shock Strut Servicing NOTE: RELEASE PRESSURE IN STRUT BEFORE DISASSEMBLY!! 1. Disassemble 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.
  • Page 25 SERVICE MANUAL & ICA WIPLINE 13000 FLOATS 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 of assembly.
  • Page 26 SERVICE MANUAL & ICA WIPLINE 13000 FLOATS 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).
  • Page 27 SERVICE MANUAL & ICA WIPLINE 13000 FLOATS 9. Gently clamp the outer tube end in a vise and add 1900 ml of hyd. fluid (5606 or equivalent). 10. Lube the inside of the outer cylinder where the gland and the piston will rest.
  • Page 28 SERVICE MANUAL & ICA WIPLINE 13000 FLOATS 13. Install the O-ring onto the fill/drain plug before installing the plug onto the end-cap and tighten. 14. Install the O-ring onto the Schrader valve and install onto the outside of the end-cap.

  • Page 29: Service Nose And Main Gear Rams

    SERVICE MANUAL & ICA WIPLINE 13000 FLOATS 2.5 SERVICE NOSE AND MAIN GEAR RAMS Lubricate the nose and main gear cylinder mounting flanges with MIL-H-5606 Hydraulic Fluid thru the oilers. The nose has a flip-lip type oiler and the mains have a ball-needle type oiler. The purpose is to wet the felt wiper so it pre-lubes the penetration rams and enables the seals inside to work and not become damaged over time.

  • Page 30: Main And Nose Gear Removal And Disassembly

    SERVICE MANUAL & ICA WIPLINE 13000 FLOATS 2.6 MAIN AND NOSE GEAR REMOVAL AND DISASSEMBLY REMOVAL OF MAIN GEAR OLEO Jack the aircraft by method described in section 1.2. With main wheels off the ground (both sides), run the gear up so that the main carriage is approximately 2 inches forward of down lock position.

  • Page 31: Figure 2.1 Hydraulic System Schematic

    SERVICE MANUAL & ICA WIPLINE 13000 FLOATS FIGURE 2.1 HYDRAULIC SYSTEM SCHEMATIC P/N 1002548 Revision H Page 31...

  • Page 32: Figure 2.2 Schematic - Electrical System

    SERVICE MANUAL & ICA WIPLINE 13000 FLOATS FIGURE 2.2 SCHEMATIC – ELECTRICAL SYSTEM Page 32 Revision H P/N 1002548...

  • Page 33: Figure 2.3 Layout - Main Gear

    SERVICE MANUAL & ICA WIPLINE 13000 FLOATS FIGURE 2.3 LAYOUT – MAIN GEAR P/N 1002548 Revision H Page 33...

  • Page 34: Figure 2.4 Carriage Assembly - Main Gear

    SERVICE MANUAL & ICA WIPLINE 13000 FLOATS FIGURE 2.4 CARRIAGE ASSEMBLY – MAIN GEAR Page 34 Revision H P/N 1002548...

  • Page 35: Figure 2.5 Assembly - Main Gear Shock Strut

    SERVICE MANUAL & ICA WIPLINE 13000 FLOATS FIGURE 2.5 ASSEMBLY – MAIN GEAR SHOCK STRUT P/N 1002548 Revision H Page 35...

  • Page 36: Figure 2.6 Assembly - Main Gear Cylinder

    SERVICE MANUAL & ICA WIPLINE 13000 FLOATS FIGURE 2.6 ASSEMBLY – MAIN GEAR CYLINDER Page 36 Revision H P/N 1002548...

  • Page 37: Figure 2.7 Assembly - Main Gear Drag Link

    SERVICE MANUAL & ICA WIPLINE 13000 FLOATS FIGURE 2.7 ASSEMBLY – MAIN GEAR DRAG LINK P/N 1002548 Revision H Page 37...

  • Page 38: Figure 2.8 Assembly - Main Gear Wheel And Brake

    SERVICE MANUAL & ICA WIPLINE 13000 FLOATS FIGURE 2.8 ASSEMBLY – MAIN GEAR WHEEL AND BRAKE Page 38 Revision H P/N 1002548...

  • Page 39: Figure 2.9 Assembly - Nose Gear Box And Retraction

    SERVICE MANUAL & ICA WIPLINE 13000 FLOATS FIGURE 2.9 ASSEMBLY – NOSE GEAR BOX AND RETRACTION P/N 1002548 Revision H Page 39...

  • Page 40: Figure 2.10 Assembly - Nose Gear Lower End

    SERVICE MANUAL & ICA WIPLINE 13000 FLOATS FIGURE 2.10 ASSEMBLY – NOSE GEAR LOWER END Page 40 Revision H P/N 1002548...

  • Page 41: Chapter 3 Hydraulic Pump System, Disassembly & Service

    SERVICE MANUAL & ICA WIPLINE 13000 FLOATS CHAPTER 3 HYDRAULIC PUMP SYSTEM, DISASSEMBLY & SERVICE CONTENTS 3.0 HYDRAULIC PUMP SYSTEM, DISASSEMBLY AND SERVICE ............42 3.1 OPERATION TROUBLESHOOTING .......................42 P/N 1002548 Revision H Page 41...
  • Page 42 SERVICE MANUAL & ICA WIPLINE 13000 FLOATS 3.0 HYDRAULIC PUMP SYSTEM, DISASSEMBLY AND SERVICE The hydraulic pump is factory preset to the following pressures: Pressures switch operates below 525 psi and shuts off at 1250 psi. The pump also has an internal relief valve that opens at 1450 psi and a thermal relief valve that opens at 2000 psi.
  • Page 43 SERVICE MANUAL & ICA WIPLINE 13000 FLOATS REMEDY a. Replace pressure switch. b. Clean and check relief valve. 3. Problem - Powerpack shuts off before gear reaches position. PROBABLE CAUSE a. Binding or jammed gear retractor, which causes pressure to build up (and stay up), and pressure switch shuts off powerpack.
  • Page 44 SERVICE MANUAL & ICA WIPLINE 13000 FLOATS REMEDY a. Clean intake screen located inside reservoir tank. b. Connect motor direct to 24 volt source and note its operation; if good, wire connection is bad; if operation poor, motor needs overhaul.

  • Page 45: Chapter 4 Repairs

    SERVICE MANUAL & ICA WIPLINE 13000 FLOATS CHAPTER 4 REPAIRS CONTENTS 4.0 REPAIRING FLOAT SKINS AND EXTRUSIONS ..................46 P/N 1002548 Revision H Page 45...
  • Page 46 SERVICE MANUAL & ICA WIPLINE 13000 FLOATS 4.0 REPAIRING FLOAT SKINS AND EXTRUSIONS For all float skin and extrusion structural repairs, refer to Wipaire's Structural Repair Manual (SRM) part number 1008274. Page 46 Revision H P/N 1002548...

  • Page 47: Chapter 5 Continued Airworthiness

    SERVICE MANUAL & ICA WIPLINE 13000 FLOATS CHAPTER 5 CONTINUED AIRWORTHINESS CONTENTS 5.0 CONTINUED AIRWORTHINESS ......................48 5.1 RECOMMENDED LUBRICANTS AND CORROSION PRODUCTS .............48 5.2 INSPECTION CHECKLIST........................51 P/N 1002548 Revision H Page 47...
  • Page 48 Below is a list of recommended lubricants and “protection” products when servicing float hull and amphibious components. This lists products used by Wipaire during assembly of the floats. There may be equivalent products just as satisfactory for protection. However, it is recommended if trying different products, to inspect them frequently so as to determine their effectiveness.
  • Page 49 SERVICE MANUAL & ICA WIPLINE 13000 FLOATS Protection of nuts, bolts, hydraulic lines or metal surfaces Zip D-5029NS Corrosion Inhibiting Compound Zip Chemical Company CRC – SP400 Soft Seal CRC Industries General Lubricants LPS 1, LPS 2 and LPS 3...
  • Page 50 SERVICE MANUAL & ICA WIPLINE 13000 FLOATS Electrical Insulating Compound Dow Corning 4 (DC4) Dow Corning Corporation Brake Caliper Grease STA-Lube *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, completely clean and repack bearings with new grease.
  • Page 51 SERVICE MANUAL & ICA WIPLINE 13000 FLOATS 5.2 INSPECTION CHECKLIST P/N 1002548 Revision H Page 51...
  • Page 52 SERVICE MANUAL & ICA WIPLINE 13000 FLOATS Page 52 Revision H P/N 1002548...
  • Page 53 SERVICE MANUAL & ICA WIPLINE 13000 FLOATS P/N 1002548 Revision H Page 53...
  • Page 54 SERVICE MANUAL & ICA WIPLINE 13000 FLOATS Bolts in Critical Areas – For corrosion, 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.

  • Page 55: Chapter 6 Weight And Balance

    SERVICE MANUAL & ICA WIPLINE 13000 FLOATS CHAPTER 6 WEIGHT AND BALANCE CONTENTS 6.0 WEIGHING PROCEDURES FOR THE DHC-6 AMPHIBIAN ..............56 P/N 1002548 Revision H Page 55...
  • Page 56 SERVICE MANUAL & ICA WIPLINE 13000 FLOATS 6.0 WEIGHING PROCEDURES FOR THE DHC-6 AMPHIBIAN Level aircraft per manufacturer’s instructions. Place scales under the right and left nose and main gear wheels. Place blocking under right and left main gear wheels to level aircraft.

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