Wipaire WIPLINE 13000 Service Manual Download

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SERVICE MANUAL & ICA

WIPLINE 13000 FLOATS

P/N 1002548

Revision H

Page 1

SERVICE MANUAL

FOR THE

WIPLINE MODEL 13000

AMPHIBIOUS AND SEAPLANE FLOAT

ON THE

DHC-6 TWIN OTTER

Revision H

WIPLINE FLOATS • SKIS • MODIFICATIONS • AIRCRAFT SALES

AVIONICS • INTERIOR • MAINTENANCE • PAINT REFINISHING

Summary of Contents for WIPLINE 13000

Page 1: ...ATS P N 1002548 Revision H Page 1 SERVICE MANUAL FOR THE WIPLINE MODEL 13000 AMPHIBIOUS AND SEAPLANE FLOAT ON THE DHC 6 TWIN OTTER Revision H WIPLINE FLOATS SKIS MODIFICATIONS AIRCRAFT SALES AVIONICS INTERIOR MAINTENANCE PAINT REFINISHING ...

Page 2: ...SERVICE MANUAL ICA WIPLINE 13000 FLOATS Page 2 Revision H P N 1002548 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 3: ...nty Claim Form Corrected Oil amount 1900 was 1140 5 26 2015 E 5 15 56 59 Added Dow Corning DC4 Corrosion X and Mobil Aviation Grease SHC 100 to approved product list Modified torque limit section 12 4 2015 F 8 Added reference for Structural Repair Manual part number 1008274 in introduction 5 1 2019 G 15 18 37 56 Added information about corrosion limits Added note about STA Lube Updated drawing for...

Page 4: ...SERVICE MANUAL ICA WIPLINE 13000 FLOATS Page 4 Revision H P N 1002548 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 5: ...age 5 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: ... OVERVIEW 16 FIGURE 2 1 HYDRAULIC SYSTEM SCHEMATIC 31 FIGURE 2 2 SCHEMATIC ELECTRICAL SYSTEM 32 FIGURE 2 3 LAYOUT MAIN GEAR 33 FIGURE 2 4 CARRIAGE ASSEMBLY MAIN GEAR 34 FIGURE 2 5 ASSEMBLY MAIN GEAR SHOCK STRUT 35 FIGURE 2 6 ASSEMBLY MAIN GEAR CYLINDER 36 FIGURE 2 7 ASSEMBLY MAIN GEAR DRAG LINK 37 FIGURE 2 8 ASSEMBLY MAIN GEAR WHEEL AND BRAKE 38 FIGURE 2 9 ASSEMBLY NOSE GEAR BOX AND RETRACTION 39 ...

Page 7: ...want that care to extend beyond your purchase Our customer service department WipCaire is available for your questions 24 hours a day 7 days a week wherever you are in the world Wipaire Inc 1700 Henry Avenue Fleming Field South St Paul MN 55075 Telephone 651 306 0459 Fax 651 306 0666 Website www wipaire com Email CustomerService wipaire com In this service manual we have worked hard to include man...

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 ...

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Page 11: ...FLOATS P N 1002548 Revision H Page 11 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: ... 50 x 10 8 ply tires and the nose landing gear has one 6 00 x 6 8 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 differential braking The nose wheels are full castering Access to the float interior is accomplished by removing covers on the ...

Page 13: ...allation 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 1 4 2 Lower aircraft onto float cradle as shown in Figure 1 4 3 Place fore and aft supports as shown in Figure 1 3 and Figure 1 4 1 5 LEVELING See applicable aircraft maintenance service manual 1 6 JACKIN...

Page 14: ...in Figure 1 2 NOTE If desired to prevent possible cosmetic damage to float use material to separate cradle and float FIGURE 1 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 t...

Page 15: ...CE MANUAL ICA WIPLINE 13000 FLOATS P N 1002548 Revision H Page 15 FIGURE 1 3 FLOAT SECURING LOCATIONS ALTERNATE JACKING METHOD IF WIPAIRE JACKING FIXTURE IS NOT AVAILABLE 8000A model shown for reference only ...

Page 16: ... adjacent to each gear Hydraulic system fluid level should be checked periodically by viewing the sight glass for fluid level in the upper one third of the range If fluid is low fill with MIL H 5606 or equivalent Aft Cradle Stand Fore Cradle Stand Cradle Fore Support Aft Support 8000A MODEL SHOWN FOR REFERENCE ONLY FIGURE 1 4 FLOAT SECURING LOCATIONS OVERVIEW 1 7 JACK REMOVAL Make sure nothing is ...

Page 17: ...luminated when the landing gear is in transit Two 2 red indicator lights labeled PUMP ON 1 and 2 illuminate when current is supplied to the landing gear motors If the motors continue running during flight or on and off repeatedly the motors should be shut off by pulling AMPHIBIAN PUMP 1 AND AMPHIBIAN PUMP 2 circuit breakers Continual running of the motors can result in premature motor failure Prio...

Page 18: ...ts of attachment should be examined carefully for distortion and security of fastenings in the primary and secondary damaged areas at locations beyond the local damage Cleaning The outside of the float 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 wa...

Page 19: ...nd pitting may be removed by heavy sanding or grinding and applying chromic acid If significant loss of skin material thickness will result in corrosion treatment reinforcement or replacement of the affected area may be necessary After removing the corroded area restore area to original finish prime and enamel BOESHIELD T9 Corrosion X or ACF 50 may also be applied to stop corrosion Refer to manufa...

Page 20: ...SERVICE MANUAL ICA WIPLINE 13000 FLOATS Page 20 Revision H P N 1002548 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 21: ...PTER 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 2 6 MAIN AND NOSE GEAR REMOVAL AND DISASSEMBLY 30 ...

Page 22: ...Retraction takes place when pressure is exerted on the actuator piston driving the collar along the slide tube The lock is tripped when the follower slides up the contoured track in the actuator as shown in figure 2 4 A reverse process affects extension Gear position light proximity switches are closed when the appropriate hook containing the magnetic material nests over the locking bar Shock abso...

Page 23: ...ant grease is recommended At brake installation apply STA Lube synthetic brake and caliper grease or equivalent to brake caliper pins The dual piston brakes need no special care other than to maintain the brake disc free of rust which causes premature brake lining wear Bleeding is carried out in the usual manner from the bottom up Although since the line is T ed to the double brake one must rememb...

Page 24: ...ity 3 The metering tube does not need to be taken apart from the end cap of the inside cylinder unless extensive cleaning is desired If it is disassembled a To return the metering tube height and condition to factory preset first apply blue Loctite to the threads of the inner end cap threads that hold the metering pin for added security until next removal The metering pin is threaded until the mea...

Page 25: ...nd cap with Vaseline Also lube the inside of the outer cylinder where the end cap seats for ease of assembly NOTE Use petroleum jelly Vaseline or equivalent as it dissolves in hydraulic fluid 6 Install the end cap bolts with gasket sealer on the threads for added security Tighten to 25 30 in lbs making sure not to over tighten damaging the T seal Set this part of the unit aside and move on to next...

Page 26: ...ase of assembly c Install the T seal into the end cap again using Vaseline for lube d Install the inner cylinder into the end cap the end of the tube without holes 8 For piston install place the piston onto the metering tube using hydraulic fluid for lube to prevent damage to the threads a Using a spanner wrench tighten the piston to the inner cylinder b Install the jam nut onto the piston end of ...

Page 27: ...nd 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 11 Install the inner cylinder into the outer assembly making sure that the gland is seated against the piston 12 Re install the center bolts using gasket sealer ...

Page 28: ...to the end cap and tighten 14 Install the O ring onto the Schrader valve and install onto the outside of the end cap NOTE Align Schrader valve 180 degrees from the Placard NOTE Double check the plugs and bolts for proper installation and security before adding gas charge 15 Fill the strut with nitrogen to 250 psi 10 psi and close the valve and cap ...

Page 29: ...oosen the jamb nut adjust and tighten jamb nut The service intervals on the Main Gear Actuators should be every 25 hours if the aircraft is regularly taxiing on sand and gravel Otherwise they should be cleaned and serviced according to the checklists from the back of this manual Clean the slide tube with clean solvent remove any buildup of dry or dirty lubricants Inspect the slide tube for erosion...

Page 30: ...ad Axle is heat shrunk to drag link and is not removable REMOVAL OF NOSE GEAR TROLLEY ASSEMBLY FROM NOSE BOX Gear must be in down position Unbolt the spring from the trolley Relieve the pressure in system place gear selector handle in neutral position lever between up and down and remove rear hydraulic line Remove 4 bolts on forward end of cylinder Drain fluid Pull aft to expose internal piston ro...

Page 31: ...SERVICE MANUAL ICA WIPLINE 13000 FLOATS P N 1002548 Revision H Page 31 FIGURE 2 1 HYDRAULIC SYSTEM SCHEMATIC ...

Page 32: ...SERVICE MANUAL ICA WIPLINE 13000 FLOATS Page 32 Revision H P N 1002548 FIGURE 2 2 SCHEMATIC ELECTRICAL SYSTEM ...

Page 33: ...SERVICE MANUAL ICA WIPLINE 13000 FLOATS P N 1002548 Revision H Page 33 FIGURE 2 3 LAYOUT MAIN GEAR ...

Page 34: ...SERVICE MANUAL ICA WIPLINE 13000 FLOATS Page 34 Revision H P N 1002548 FIGURE 2 4 CARRIAGE ASSEMBLY MAIN GEAR ...

Page 35: ...SERVICE MANUAL ICA WIPLINE 13000 FLOATS P N 1002548 Revision H Page 35 FIGURE 2 5 ASSEMBLY MAIN GEAR SHOCK STRUT ...

Page 36: ...SERVICE MANUAL ICA WIPLINE 13000 FLOATS Page 36 Revision H P N 1002548 FIGURE 2 6 ASSEMBLY MAIN GEAR CYLINDER ...

Page 37: ...SERVICE MANUAL ICA WIPLINE 13000 FLOATS P N 1002548 Revision H Page 37 FIGURE 2 7 ASSEMBLY MAIN GEAR DRAG LINK ...

Page 38: ...SERVICE MANUAL ICA WIPLINE 13000 FLOATS Page 38 Revision H P N 1002548 FIGURE 2 8 ASSEMBLY MAIN GEAR WHEEL AND BRAKE ...

Page 39: ...SERVICE MANUAL ICA WIPLINE 13000 FLOATS P N 1002548 Revision H Page 39 FIGURE 2 9 ASSEMBLY NOSE GEAR BOX AND RETRACTION ...

Page 40: ...SERVICE MANUAL ICA WIPLINE 13000 FLOATS Page 40 Revision H P N 1002548 FIGURE 2 10 ASSEMBLY NOSE GEAR LOWER END ...

Page 41: ...MANUAL ICA WIPLINE 13000 FLOATS P N 1002548 Revision H Page 41 CHAPTER 3 HYDRAULIC PUMP SYSTEM DISASSEMBLY SERVICE CONTENTS 3 0 HYDRAULIC PUMP SYSTEM DISASSEMBLY AND SERVICE 42 3 1 OPERATION TROUBLESHOOTING 42 ...

Page 42: ...and install seals to top of reservoir before installing on pump 8 Install drain plug and fill with clean MIL H 5606 hydraulic fluid through the breather pipe 9 Fluid level should be in the upper 2 3 of the sight gauge 11 If the fluid is not a clean red color it should be replaced with new fluid 3 1 OPERATION TROUBLESHOOTING 1 Problem Power pack does not run after gear selection PROBABLE CAUSE a Ci...

Page 43: ... oil leaks If no external leaks are found disconnect and cap off the hydraulic actuators one at a time and find the leaky one by process of elimination If isolating entire system still indicates internal leak power pack check valve located in pressure port of pump is bad and needs replacement or reseating b Visually inspect lines cylinders and hoses and replace as necessary 5 Problem Power pack cy...

Page 44: ...t source and note its operation if good wire connection is bad if operation poor motor needs overhaul c Covered in b above d Replace pump 7 Problem Circuit breaker pops during cycle PROBABLE CAUSE a Wire connections bad or corroded b Bad motor brushes c Bad circuit breaker REMEDY a Clean and protect terminal with grease b Overhaul motor c Replace circuit breaker ...

Page 45: ...SERVICE MANUAL ICA WIPLINE 13000 FLOATS P N 1002548 Revision H Page 45 CHAPTER 4 REPAIRS CONTENTS 4 0 REPAIRING FLOAT SKINS AND EXTRUSIONS 46 ...

Page 46: ...ICA WIPLINE 13000 FLOATS Page 46 Revision H P N 1002548 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 47: ...AL ICA WIPLINE 13000 FLOATS P N 1002548 Revision H Page 47 CHAPTER 5 CONTINUED AIRWORTHINESS CONTENTS 5 0 CONTINUED AIRWORTHINESS 48 5 1 RECOMMENDED LUBRICANTS AND CORROSION PRODUCTS 48 5 2 INSPECTION CHECKLIST 51 ...

Page 48: ...n sealing and tension Fluid Lines and Hoses 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 burning defective insulation loose or broken terminals corroded terminals Bolts in Critical Areas...

Page 49: ...ivot and Rod Ends HCF Grease P N 605 HCF Industries Aeroshell 22 Shell Global Solutions Green Grease Multi purpose Green Grease Inc Aviation Grease SHC 100 ExxonMobil Aviation Lubricants Rust Protection Boeshield T9 Rust Protection Boeing Company ACF 50 Rust Protection Corrosion X Corrosion Technologies Corp Tef Gel Ultra Safety Systems Inc Float Sealant 890 B2 or B4 Pro Seal Company PR 1440 C PPG...

Page 50: ...rning 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: ... condition security and seal X Pumper Tube Installation inspect for condition security routing of hoses X Electrical System Pump and indicator light wiring inspect for chafing broken or loose terminals and general condition X Solenoids inspect for wiring mounting and general condition X Pressure Switches inspect wiring mounting and general condition X Pump motors inspect wiring mounting and genera...

Page 52: ... X Hydraulic 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 changes if necessary X Main and Nose Gear Actuator assemblies inspect for condition lubrication leakage corrosion and cle...

Page 53: ...pped inspect for condition security and leaks X Brake System Plumbing inspect for leaks condition and security X Main Gear Oleos Service X Perform reaction test Inspect main gear up and down lock 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 wh...

Page 54: ... 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 is applied to the bolt 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...

Page 55: ...SERVICE MANUAL ICA WIPLINE 13000 FLOATS P N 1002548 Revision H Page 55 CHAPTER 6 WEIGHT AND BALANCE CONTENTS 6 0 WEIGHING PROCEDURES FOR THE DHC 6 AMPHIBIAN 56 ...

Page 56: ...main gear wheels to level aircraft Drop plumb bob from wing leading edge on either side of the plane to the floor and mark This is the datum line station 0 0 Draw another line between the nose wheel centers and a 3rd line between the main wheel centers Measure the distance from 0 0 to the nose wheel line This is X Measure the distance from 0 0 to the main wheel line This is Y Use this table for th...

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