Model 13000 Service Manual
Contents
1. INC 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 Issued August 1992 Revised December 2015 1700 Henry Ave Fleming Field KSGS South St Paul MN 55075 Ph 651 451 1205 Fax 651 457 7858 www wipaire com WIPLINE MODEL 13000 SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Page 2 of 61 1002548 Rev D WIPLINE MODEL 13000 SERVICE MANUAL TABLE OF CONTENTS SECTION PAGE EOCr ORF ai persos e Ot Las Dive 5 INTRODUCTION amp 0 1 151781 4 185 11 1 550460 a 11 3 _ 332322333 _ 11 I I 1 1 FLOAT HANDLING JACKING AND AIRCRAFT ICVIMC 12 13 AMPHIBIAN LANDING GEAR SYSTEM I2 LANDING GEAR HANDLE d recae 13 INDICATOR LIGHTS ea 13 LANDING GEAR tnis ho hd bu detiene 14 EMERGENCY PUMP HANDLE ado ana nunana amia mnsa N a aaa 14 2 MA2. VE 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 steps 7 the gland assembly insert the inside T seal and wiper again using Vaseline on the T seal 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 into the end cap the end of the tube without holes a 1002548 Rev C Page 21 of 61 WIPLINE MODEL 13000 SERVICE MANUAL 8 For piston install place the piston onto the metering tube using hydraulic fluid for lube to prevent damage to the threads a Usinga spanner wrench tighten the piston to the inner cylinder b 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 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 11 Install the inner cylinder into the outer assembly making sure that the gland is seated against the piston Page 22 of 61 1002548 Rev D
3. 2 The landing gear emergency gear operation hand pump and system are added 3 Auxiliary Vertical Fins are added Note Amphibian float models only 1 2 FLOATS The model 13000 seaplane or amphibious float is an all aluminum constructed float with watertight compartments The actual displacement in fresh water for each float is 12844 pounds buoyancy for the seaplane and 12442 pounds buoyancy for the amphibian The amphibian float is geometrically the same as the seaplane except for the addition of landing gear The main landing gear has dual 8 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 top deck and six covers inside the wheel well When necessary water inside the float hulls may be removed through pump out cups located on the outboard edge of each float top skin FLOAT HULL MAINTENANCE GENERAL The float structure side top skins and bottom skins are 6061 T6 aluminum and extrusions are 6061 T6 aluminum keel chine etc Skins are alodined and primed after being cleaned and acid etched Exterior is finished with a urethane color paint or equivalent 1002548 Rev E Page 11 of
4. Nose gear proximity switches are located on clips that are mounted on the outer cylinder body one on each end The most forward switch is for the gear down lights and most aft is for the gear up position lights Set the proximity switch mounting clip along outer cylinder body to a position such that the light goes out when the over center track is about 1 4 inch from bottomed position while traveling in the up direction Lights should come on about 1 8 inch from the bottomed position while traveling in the down direction The cylinder piston has a magnet that will activate the proximity switches MAIN GEAR The main gear actuator cylinder is not adjustable These are pre set at the factory to ensure that the main gear is locked at the end of each stroke and that correct indication is given on the cockpit console The up and down lock may be adjusted so the lock is fully engaged by adjusting the set screws shown in figure 2 4 Loosen 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 and or nicks and protrusions caused by gravel or debris being thrown by the Main Landing Gear tires Grease the actuator mech
5. Rev C Page 41 of 61 WIPLINE MODEL 13000 SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Page 42 of 61 1002548 Rev C WIPLINE MODEL 13000 SERVICE MANUAL 4 REPAIRS There are many ways to repair Wipline floats and each method depends on the degree and location of the damage The following figures are examples of some repairs For additional help contact Wipaire customer service at 651 306 0459 4 1 RIVET REPLACEMENT There are instances during float repair where replacement of solid rivets is not practical For these occasions Wipaire has composed a list of acceptable fastener substitutions Solid rivets may be replaced by the following 1 New solid rivet of the same or greater diameter 2 CherryMax blind rivets of equal or greater diameter 3 HuckLok blind rivets of equal or greater diameter 4 Hi Lok fasteners of equal or greater diameter NOTES 1 When installing any structural fasteners edge distance and rivet spacing guidelines per AC43 13 1B should be followed at all times 2 Inareas where solid rivets are smoking or missing blind rivets are an acceptable short term solution but should be replaced with solid rivets or Hi Lok fasteners or equivalent 3 Follow fastener manufacturer guidelines for installation 4 2 REPAIRING FLOAT STRUCTURE The float hull is manufactured from the following aluminum top and side skin bulkhead 1 through 14 040 6061 T6 The top and side skin bulkhead 14 through 18 063
6. 6061 T6 The top and side skin bulkhead 18 through 24 040 6061 T6 The bottom skin sister keel to keel 063 6061 T6 The bottom skin sister keel to chine 050 6061 T6 The nose bulkhead 100 6061 T6 17 bulkhead aft wheel well 063 6061 T6 remaining bulkheads 040 6061 T6 Main strut panel 125 6061 T6 Damage to the skins may be repaired per Figures 4 1 4 2 4 3 or any acceptable repair method listed in FAA Advisory Circular 43 13 1B Any float hull skin or part thereof can be purchased from Wipaire to aid in repair To simplify repairs the skins can be ordered precut to shape Skins may be reattached to extrusions by the method shown in Section 4 3 and Figures 4 5 4 6 4 7 4 8 and 4 9 1002548 Rev C Page 43 of 61 WIPLINE MODEL 13000 SERVICE MANUAL TYPICAL SKIN REPAIR 5 20 SPACED PATCH HOLE IN SKIN 9 20 USE AN470 OR 9 SPACED AN456 AD4 RIVETS TRIM HOLE TO THESE DIMENSIONS SEALANT AROUND PATCH EDGE USE AN470 OR AN456 A04 RIVETS FIGURE 4 1 TYPICAL SKIN REPAIR 1 Typical Skin Repair Trim hole as shown by dotted line 2 Patch material same thickness or one gage thicker as original skin Prime all bare surfaces 4 Seal between patch and skin 5 Rivet in place d Page 44 of 61 1002548 Rev C WIPLINE MODEL 13000 SERVICE MANUAL TYPICAL SKIN REPAIR 1 5 SEALANT AROUND PATCH 50 IN SKIN USE AN470 OR AN45
7. 61 WIPLINE MODEL 13000 SERVICE MANUAL FLOAT HANDLING JACKING AND AIRCRAFT TOWING To jack the floats for servicing tires brakes or doing retraction tests it is recommended that a floor type jack three ton minimum be used These jacks are commonly used for truck repair The jack should be positioned on the keel centerline on the first bulkhead forward of the step Example is shown on the picture proceeding this text The jack should contact the keel squarely and if room permits slip a board between the jack and keel Raise the float slowly making sure the aircraft stays balanced After raising block up the keel in several places and lower the 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 When towing the amphibian aircraft tow lugs 2 are provided on underside of the front spreader bar outboard ends A rigid V frame can be fabricated to attach to these lugs and aircraft towed with a tractor Wipaire Parts has this tow bar available On water the aircraft may be towed with a rope bridle arrangement from these lugs A lifting apparatus that will pick the aircraft up by 4 points will facilitate lifting of the entire aircraft on floats from a ceiling hoist A lifting beam that will pick up all four points is available at Wipaire Parts Dept 1 3 AMPHIBIAN LANDING GEAR SYSTEM The landing gear incorp
8. TO MAIN KEEL WITH AN3 BA AN960 10L WASHER AN960 10 WASHER AN365 1032 NUT 1 10 WIPLINE MODEL 13000 SERVICE MANUAL WIPLINE MODEL 13000 SERVICE MANUAL IC gt 6061 T6 ALUMINUM 38 PURCHASE FROM WIPAIRE MATERIA RNAL SPLICE SEAM EXT 75 FIGURE 4 8 AFT KEEL EXTRUSION REPAIR Page 52 of 61 1002548 Rev Page 53 of 61 1002548 Rev FIGURE 4 9 AFT CHINE EXTRUSION REPAIR 1 50 MATERIAL 6061 16 ALUMINUM OR WIPAIRE CHINE OR WIPAIRE MATERIAL RM 386 75 SPLICE SEAM EXTERNAL WIPLINE MODEL 13000 SERVICE MANUAL WIPLINE MODEL 13000 SERVICE MANUAL 4 4 BULKHEAD ACCESS HOLES During extensive float maintenance it may be desirable to cut an access hole in a solid bulkhead to enable replacement of neighboring float structure This type of access hole can be cut and then repaired according to figure 4 10 E EA RIVETS 6 M mero 5 9 6 9 ALLOWABLE AREAS MAINTENANCE ACCESS 2 ACCESS HOLES BULKHEAD NOTE S 1 ACCESS HOLES MAY BE CUT FOR THE PURPOSE OF MAINTENANCE 2 MAX 2 ACCESS HOLES PER BULKHEAD 3 RIVET PATCH OVER ACCESS HOLE ONCE MAINTENANCE IS COMPLETE 4 PATCH MUST BE OF THE SAME OR STRONGER ALLOY 6061 T6 OR 2024 T3 WITH THE SAME THICKNESS AS THE ORIGI
9. 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 1002548 Rev C Page 19 of 61 WIPLINE MODEL 13000 SERVICE MANUAL 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 Toreturn 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 measurement from the floor of the inside of the end cap to the end of the inserted metering tube is 12 037 inches if the new T seals are being used and 11 937 inches if the old style O rings are used Tighten the associated jam nut at that end and stake it for added security c Setthis metering tube assembly aside and move on to next steps _ i mm Page 20 of 1 1002548 Rev WIPLINE MODEL 13000 SERVICE MANUAL 4 the other end install the metering pin with Loctite onto the end cap and tighten to approx 30 ft Ibs 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 solves in hydraulic fluid NOTE Use petroleum jelly Vaseline or equivalent as it dis amsa ET z 7
10. 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 rod Loosen jamb nut on forward side of cylinder ram at rod end Turn piston from aft side of nose box out of rod end Push on trolley assembly to unlock and remove the bottom thru bolts Slide out of nose box Note On installation adjust piston so it bottoms out on aft flange at the same time as the bearings when nose gear is in locked position Also note orientation of trolley blocks The side with the most edge distance from hole is to go toward each other on inside of trolley See figure 2 9 for details Page 26 of 61 1002548 Rev C WIPLINE MODEL 13000 SERVICE MANUAL REMOVAL OF NOSE GEAR BOX Remove bolts securing forward box from nose bulkhead Remove bolts securing aft box from bulkhead 2 Slide box out from front of float Note Sealant will have to be cut for removal and replaced when installing REMOVAL OF LOWER NOSE GEAR FROM PIVOT BLOCK On top of pivot block remove cotter pin from retaining nut Remove nut On aft side of pivot block remove the 2 cap bolts on 25 thick cover Remove spring This will loosen retaining ball and lower fork will slide out Refer to figure 2 10 for assembly REMOVAL OF NOSE GEAR Remove the nose gear from the nos
11. reservoir and looking at couplings for 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 Page 40 of 61 1002548 Rev C WIPLINE MODEL 13000 SERVICE MANUAL 5 Problem Power pack cycles on and off during 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 located inside reservoir tank b Connect motor direct to 24 volt source and note its operation 11 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 1002548
12. 000 SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1002548 Rev Page 7 of 61 WIPLINE MODEL 13000 SERVICE MANUAL 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 The service products referred to throughout this manual are described by their trade names and may be purchased from the Wipaire Parts Department We at Wipaire thank you for your purchase and look forward to years of satisfying exchanges with you Your floats are built with pride and attention to detail but we 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 Customer Service 1700 Henry Ave South Saint Paul MN 55075 Phone 651 306 0459 Fax 651 306 0666 CustomerService wipaire com In this service manual we have worked hard to include many repair scenarios in addition to the recommended products practices and routine maintenance required to keep your floats in working order When a float part is significantly changed or an additional inspection recommended or required often a service letter and or kit is i
13. 10 SONTAVSE 95110 ONY 8 01 058 3811 8 31 0 aJNIVI3B 35 355 43385 9 3HN S3NNI 2510 6 vd 3228 31V I 218801 A SSV 33788 SONTAVSE 1 OYA WIPLINE MODEL 13000 SERVICE MANUAL 1002548 Rev Page 36 of 61 FIGURE 2 9 ASSEMBLY NOSE GEAR BOX AND RETRACTION BULKHEAD MOLNTING FLANGE RING AN6227 30 AS SHOWN FLANGE AFT 4 CYLINDER BIDY RING 52 771 314 RING ANB227 30 WIPER FELT D RING AN6227 25 MOUNTING FLANGE CYLINLER PLATE FLANGE BOX RAM NISE BEAR RING PISTON 5227 24 JAMB SPACER LP STOP ROD RII END RAM NOE ROO RETAINING ROLLER 2 DOW STOP RING 2 TROLLEY AXLE AXLE LINK NOSE GEAR TROLLEY NISE GEAR EN TRACK LINK RAM SLIDE BLOCK 4 WIPLINE MODEL 13000 SERVICE MANUAL WIPLINE MODEL 13000 SERVICE MANUAL PIVOT BLOCK UP STOP BEARING PLATE DETENT BALL BUSHING TUP THRUST 254 EE BEARING Ss SPRING N A ATR COVER LOWER BEARING PIN AND AXLE BLOCK ASS Y HEAT SHRINK FIT NOT REMOVABLE NOSE FORK LEGS SPACERS 6 00 X b 8 PLY TIRE FIGURE 2 10 ASSEMBLY NOSE GEAR LOWER END 1002548 Rev Page 37 o
14. 11 22 10 4 18 2013 5 26 2015 12 4 2015 Page 5 of 61 LOG OF REVISIONS DESCRIPTION Added an inspection time limit and tolerances for the Nose Block Track wear Updated to Maintenance Manual per 23 8 Added 3 view images of floatplane Added section 4 1 regarding rivet replacement Added section 4 4 regarding bulkhead holes for maintenance Reformat of entire document Add green grease as approved grease Added Shear Torque Chart PR 1440 C Sealant and Tef Gel Removed Warranty Claim Form Corrected Oil amount 1900 was 1140 Added Dow Corning DC4 Corrosion X and Mobil Aviation Grease SHC 100 to approved product list Modified torque limit section 1002548 Rev E EFFECTIVE PAGES 11 26 13 14 44 55 ALL 22 56 59 5 15 56 59 REV NO WIPLINE MODEL 13000 SERVICE MANUAL XN A _ SWIPAIRE INC NEW CUSTOMER INFORMATION Customer Name Billing Address Shipping Address Phone Number Fax 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 Page 6 of 61 1002548 Rev C WIPLINE MODEL 13
15. 4 FIGURE 2 8 ASSEMBLY MAIN GEAR WHEEL AND BRAKE 35 1002548 Rev D Page 3 of 61 WIPLINE MODEL 13000 SERVICE MANUAL FIGURE 2 9 ASSEMBLY NOSE GEAR BOX AND RETRACTION FIGURE 2 10 ASSEMBLY NOSE GEAR LOWER ENLD 3 HYDRAULIC PUMP SYSTEM DISASSEMBLY AND SERVICE 3 1 OPERATION TROUBLESHOOTING 7 4 1 RIVET REPLACEMENT 4 2 REPAIRING FLOAT STRUCTURE FIGURE 4 1 TYPICAL SKIN REPAIR 1 FIGURE 4 2 TYPICAL SKIN FIGURE 4 3 TYPICAL SKIN REPAIR 3 EXTRUSION a FIGURE 4 4 SKIN REPAIR AT 4 3 REPAIRING FLOAT HULL EXTRUSIONS FIGURE 4 5 GUNNEL EXTRUSION FIGURE 4 6 FORWARD CHINE EXTRUSION FIGURE 4 7 MAIN KEEL EXTRUSION REPAIR eene FIGURE 4 8 AFT KEEL EXTRUSION REPAIR mme FIGURE 4 9 AFT CHINE EXTRUSION REPAIR nne 44 BULKHEAD ACCESS HOLES aa FIGURE 4 10 BULKHEAD ACCESS HOLES RN 5 CONTINUED AIRWORTHINESS 5 1 RECOMMENDED LUBRICANTS AND CORROSION PRODUCTS THE DHC 6 AMPHIBIAN 002548 Rev D 6 WEIGHING PROCEDURES FOR Page 4 of 1 1 WIPLINE MODEL 13000 SERVICE MANUAL DATE 4 18 06
16. 6 A04 RIVETS 2 20 EN SPACED 30 SEALANT AROUND PATCH HOLE IN SKIN 2 20 EH SPACED 1 00 MAX USE AN470 OR AN456 A04 RIVETS FIGURE 4 2 TYPICAL SKIN REPAIR 2 Typical Skin Repair Trim hole as shown by dotted line 2 Patch material same thickness or one gage thicker as original skin Prime all bare surfaces 4 Seal between patch and skin 5 Rivet in place 122 1002548 Rev Page 45 of 61 WIPLINE MODEL 13000 SERVICE MANUAL TYPICAL SKIN REPAIR 3 20 EN SPACED SEALANT PATCH 3 USE 470 OR AN456 AD4 RIVETS HOLE IN SKIN f 4 20 30 TYP SPACED x SEALANT ARDUND PATCH O 20 EB SPACED 4 USE AN470 OR AN456 AD4 RIVETS HULE IN SKIN FIGURE 4 3 TYPICAL SKIN REPAIR 3 Typical Skin Repair Trim hole as shown by dotted line 2 Patch material same thickness or one gage thicker as original skin Prime all bare surfaces 4 Seal between patch and skin 5 Rivetin place 59 Page 46 of 61 1002548 Rev Page 47 of 1 1002548 Rev C FIGURE 4 4 SKIN REPAIR AT EXTRUSION N33A138 I3AT3 38 ONY SNI HDLYd 30115 10 NI SISA MMI15IX3 Tied 0 1 T X V NIISTISTX3 dAl 52904 A38 WIPLINE MODEL 13000 SERVICE MANUAL WIPLINE MODEL 13000 SERVICE MANUAL 4 33
17. GHING 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 Drop plumb bob from wing leading edge on either side of the plane to the floor and mark This 1s the datum line station 0 0 Draw another line between the nose wheel centers and 3 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 the calculations Scale Reading Dist from 0 0 Weight x Arm Weight X Arm Moment x x X Left Front Right Front Left Rear Right Rear Totals Notes 1 Zero out or deduct tare weights at the Y arm 1002548 Rev Page 61 of 61
18. IN AND NOSE GEAR OPERATION REMOVAL AND SERVICE 17 2 1 DESCRIPTION AND OPERATION 22 SERVICE NOSE GEAR aa Sas 18 NOSE BOX TRAC KW DAR 18 2 3 SERVICE MAIN WHEELS AND 18 2 4 SERVICE MAIN GEAR OLEQO 18 2 5 SERVICE NOSE AND MAIN GEAR RAMS 25 25 25 MAIN GEAR 23 BLEEDING HYDRAULIC SYSTEM AFTER SERVICE 26 2 6 MAIN AND NOSE GEAR REMOVAL AND DISASSEMBLY 26 REMOVAL OF MAIN GEAR OLEO Ne 26 REMOVAL OF MAIN GEAR RETRACTION CYLINDER eee 26 REMOVAL OF MAIN GEAR DRAG eese 26 REMOVAL OF NOSE GEAR TROLLEY ASSEMBLY FROM NOSE BOX 26 REMOVAL OF NOSE GEAR BOX 27 REMOVAL OF LOWER NOSE GEAR FROM PIVOT BLOCK 27 REMOVAL NOSE GEAR 27 FIGURE 2 1 HYDRAULIC SYSTEM 28 FIGURE 2 2 SCHEMATIC ELECTRICAL 20 FIGURE2 3 LAYOUT MAIN GEAR 30 FIGURE 2 4 CARRIAGE ASSEMBLY MAIN GEAR eee 31 FIGURE 2 5 ASEMBLY MAIN GEAR SHOCK STRUT 32 FIGURE 2 6 ASSEMBLY MAIN GEAR CYLINDER rr 33 FIGURE 2 7 ASSEMBLY MAIN GEAR DRAG s 3
19. N gt Zor LOWER X 4115B01TP037 T SEAL PISTON 8 og 4115B001TP037 T SEAL OUTSIDE RETAINER PISTON 5 G s OUTER CYLINDER 41158001 8035 T SEAL INSIDE RETAINER gt gt lt SG 5 a 5 EN METERING TUBE INNER CYLINDER 2 i RETAINER CAUTION REMOVE PRESSURE BEFORE DIASSEMBLY ENT m BEARING gt 4 4115B001TR035 T SEAL COL IL e AN62278 9 FILL PLUG WIPLINE MODEL 13000 SERVICE MANUAL Page 33 of 1 1002548 FIGURE 2 6 ASSEMBLY MAIN GEAR CYLINDER INIA amp SC ZLCCBNV AJANI UJ 4181 39NY H AJANI HNILIId dddIA 11 CWADW3S 3017S N04 1 DNI 2801 201 15 820 NULSId ININ 0 VC 2C9MV AUNT UJ JJNY 13 340115 NIS 0 VIE SLLECSW LAASNI 2 QS QNILLI4 9904 3017S NANO WIPLINE MODEL 13000 SERVICE MANUAL WIPLINE MODEL 13000 SERVICE MANUAL BEARINGS WHEEL GREASE INSERT BEARINGS WHEEL GREASE INSERT AXLE DRAG LINK ASS AXLE HEAT SHRINK FIT FIGURE 2 7 ASSEMBLY MAIN GEAR DRAG LINK Page 34 of 61 1002548 Rev C Page 35 of 61 1002548 FIGURE 2 8 ASSEMBLY MAIN GEAR WHEEL IM 823 68 25 83
20. NAL PANEL OR ONE GAGE THICKNESS GREATER 4 USE SOLID RIVETS OF SAME DIAMETER AS EXISTING RIVETS OR 1 SIZE LARGER ALTERNATELY USE CHERRY MAX OR EQUIVALENT FASTENER OF SAME DIAMETER OR 1 SIZE LARGER KEY D DIAMETER RADIUS FIGURE 4 10 BULKHEAD ACCESS HOLES Page 54 of 61 1002548 Rev WIPLINE MODEL 13000 SERVICE MANUAL 5 CONTINUED AIRWORTHINESS As coded in the Inspection Time Limits chart in this section there are items to be checked each 25 50 100 and 200 hours Also there are notes on special items 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 200 hour items would be accomplished A complete inspection Annual Inspection would include all 25 50 100 200 hour items As general inspection guidelines each of the following areas should be inspected for their own unique attributes Movable Parts For lubrication servicing security of attachment binding excessive wear safetying proper operation proper adjustment correct travel cracked fittings security of hinges defective bearings clea
21. REPAIRING FLOAT HULL EXTRUSIONS All extrusions in the float hull are formed 6061 T6 aluminum alloy extrusions may be repaired by splicing as shown in figures 4 5 4 9 Sections of extrusion for splicing or capping may be purchased from Wipaire in any length needed Skins may be purchased pre cut to simplify repairs Page 48 of 61 1002548 Rev C WIPLINE MODEL 13000 SERVICE MANUAL CdAL SL JSYHJ Ad 11 anod 2111 1 59 JaIVdIM WOX 811335 WOX 951 FIGURE 4 5 GUNNEL EXTRUSION REPAIR 1002548 Rev C Page 49 of 61 9111 Wa 1 d3l1VdIM WINIWITIV 91 1909 1 1002548 Rev Page 50 of 61 FIGURE 4 6 FORWARD CHINE EXTRUSION REPAIR d 1 3 dalvdIM 91 1909 8 1 hee al 08 7 08 T C 1 WVJS 1 dS ML NTININWTIV 961 cL WIPLINE MODEL 13000 SERVICE MANUAL Page 51 of 1 1002548 Rev FIGURE 4 7 MAIN KEEL EXTRUSION REPAIR 75 30 TYP 158 1 50 1 50 MATERIAL 5061 15 ALUMINUM OR PURCHASE FROM WIPAIRE WEAR STRIP MAY BE PURCHASED FROM WIPAIRE STRIP IS BOLTED
22. WIPLINE MODEL 13000 SERVICE MANUAL 12 Re install the center bolts using gasket sealer 13 Install the O ring onto the fill drain plug before installing the plug onto the end cap and tighten 1002548 Rev C Page 23 of 61 WIPLINE MODEL 13000 SERVICE MANUAL 14 Install the O ring onto 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 24 of 61 1002548 Rev C WIPLINE MODEL 13000 SERVICE MANUAL 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 ADJUSTMENT TEST NOSE GEAR Adjustment of actuator stroke is provided at the ends of the piston rods The length of the nose gear rod is adjusted such that the over center knuckle brass rollers just bottom out on the down side and the piston just bottoms out on the mounting flange at the same time The up stops nests in the up stop bolt See figure 2 9 and 2 10 for locations and assembly
23. ains pressure in the system while the pump is off The pump has an internal relief valve which directs oil back to the pump reservoir when the line pressure exceeds 1450 psi The system also has an internal relief valve to protect against thermal expansion when line pressure exceeds 2000 psi A cockpit mounted control valve accomplishes the selection of gear up or gear down 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 mechanically locked in both up and down positions Locking and unlocking is effected utilizing a small amount of lost motion of the actuator rod 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 absorption for the main landing gear is provided by a hydraulically dampened air spring Figure 2 5 shows the main components The oil and air share a common chamber When the oleo is collapsed the oil is force
24. anism with HCF grease p n 605 or equivalent and wipe the slide tube down with a clean rag soaked in lubricant The main gear proximity switches are located on each end of the gear stroke The forward switch is located on the forward 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 position and comes on again upon nesting 1002548 Rev C Page 25 of 61 WIPLINE MODEL 13000 SERVICE MANUAL BLEEDING HYDRAULIC SYSTEM AFTER SERVICE 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 The fluid level should be maintained in the upper one third 1 3 of the sight glass If the reservoir empties 1 fluid disappears in sight glass stop the cycle pulling the circuit breaker on the control panel Hill the reservoir again and complete the cycle Continue this procedure until the fluid level in the reservoir stabilizes it will vary in level between up and down positions If the fluid level continues to decline during gear cycles check for external leaks Generally the fluid level in th
25. d through the main orifice compressing the air in the upper cylinder Extension reverses this process The extended oleo 18 initially set at the factory to 250 psi no load In field adjustment of air pressure and oil volume is described in section 2 2 The nose gear has an over center down lock Retraction occurs when pressure is applied to the forward face of the actuator piston and the carriage is drawn along the tracks in the nose box as shown in figure 2 9 Gear position light proximity switches are closed when the piston containing the magnetic material has reached either end of its travel The nose gear consists of composite fiberglass beams that are attached at the bottom to castering blocks Inside the block is a castering pin that is set into the machined fork assembly The castering pin allows the nose wheel to pivot in a complete circle The geometry is such that no shimmy dampers are necessary A spring loaded ball rides in a groove machined in the castering pin This groove is a round pocket on the back face with the result that the cam provides retention of the pin the block and self centering of the wheel A thrust bearing is on top of the castering pin along with a lower bearing 1002548 Rev C Page 17 of 61 WIPLINE MODEL 13000 SERVICE MANUAL 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 li
26. e box by unbolting the spring 4 bolts 1002548 Rev C Page 27 of 61 WIPLINE MODEL 13000 SERVICE MANUAL SCHEMATIC HYDRAULIC SYSTEM CONTROL VALVE EMERGENCY HAND PUMP FUSELAGE FITTINGS L FUSELAGE FITTINGS R MANIFOLD INST PUMP MANIFOLD ASSY HYDRAULIC PUMP ASSY FIGURE 2 1 HYDRAULIC SYSTEM SCHEMATIC Page 28 of 61 1002548 Rev C WIPLINE MODEL 13000 SERVICE MANUAL SCHEMATIC ELECTRICAL SYSTEM 2 8 15 z 8 e E 8 ja J 3 FIGURE 2 2 SCHEMATIC ELECTRICAL SYSTEM 1002548 Rev C Page 29 of 61 1002548 Rev Page 30 of 1 FIGURE2 3 LAYOUT MAIN GEAR SEE FIGURE 2 6 FIGURE 2 8 SEE FIGURE 2 7 SEE FIGURE 2 4 SEE FIGURE 2 5 WIPLINE MODEL 13000 SERVICE MANUAL WIPLINE MODEL 13000 SERVICE MANUAL MAGNET SENSOR LOK ATTACH NET NEREW B i 5 B COVER SPRING DOWN LOCK SET SCREW SPRING RETAINER BOLT BEARING BOLT TOP STRUT ATTACH 9 97 SET SCREW MAENET SENSHR MAIN GEAR LARRIAGE SET SCREW 5 EE 8 5 RAM ROO CONNECTING REMOVE SLIDE RAM FROM CARRIAGE FIGURE 2 4 CARRIAGE ASSEMBLY MAIN GEAR 1002548 Rev Page 31 of 61 1002548 Rev Page 32 of 1 FIGURE 2 5 ASSEMBLY MAIN GEAR SHOCK STRUT AN6227 14 O RING METERING PI
27. e site glass should be about 34 full when the gear 15 down 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 This must be accomplished to remove the top oleo bolt In order to remove the lower bolt it is necessary to remove the wheel on the head side of the bolt REMOVAL OF MAIN GEAR RETRACTION CYLINDER Relieve pressure in system place gear selector handle in neutral position lever between up and down and remove hydraulic lines Remove end cap from end of cylinder Drain fluid Remove forward end of cylinder from bulkhead flange Remove both cylinder support rings from the bulkhead NOTE Piston to be in the up position for cylinder removal Remove cylinder from piston and up through top float inspection cover To remove piston remove top inspection cover on top forward end of gear tunnel accessible from top float inspection cover forward of step Pull back piston to expose top of carriage in center of access cover Remove 25 dia retention bolt Remove piston by pulling aft See figure 2 6 for part breakdown 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 REMOVAL OF NOSE GEAR TROLLEY ASSEMBLY FROM NOSE BOX Gear must be in
28. ectric hydraulic pumps Select UP and DOWN using the normal landing gear selector handle Pump the attached handle back and forth approximately 400 cycles When a gear reaches the selected position its indicator light will illuminate After all four 4 gears are in the selected position there is a noted increase in resistance of hand pump operation 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 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 rivets elongated bolt holes or canned skins or bulkheads Points 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 water should be done daily with special attention to hard to reach places such as seams wheel well etc The float interior sho
29. eriods of time l e if removed during winter months screen should be cleaned before putting floats back into service X Hydraulic fluid in reservoir should be checked for moisture or other contaminates and changes if necessary Landing Main and Nose Gear Actuator assemblies Gear inspect for condition lubrication leakage Systems corrosion and cleanliness X Nose gear springs scotch ply springs inspect for cracks de lamination and paint X Main Gear Drag Link garlock bushings inspect for condition lubrication corrosion Main Gear Oleos inspect for evidence of leakage proper extension check cylinder for corrosion X pitting cleanliness and security Hydraulic Lines amp Fittings inspect for leaks condition and security X Hydraulic manifolds if equipped inspect for condition security and leaks X Brake System Plumbing inspect for leaks condition and security X Main Gear Oleos Service X Page 58 of 61 1002548 Rev C WIPLINE MODEL 13000 SERVICE MANUAL 50 100 200 25 Inspect gear up and down lock hooks for proper engagement Inspect nose gear trolley for proper Inspect nose gear for excessive side play in the down position Perform emergency gear extension INSPECTION TIME LIMITS travel if equipped Perform reaction test Nose and main wheel bearings disassemble and inspect Bolts in Crit
30. f 61 WIPLINE MODEL 13000 SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Page 38 of 61 1002548 Rev C WIPLINE MODEL 13000 SERVICE MANUAL 3 HYDRAULIC PUMP SYSTEM DISASSEMBLY AND SERVICE The hydraulic pump 1 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 These pressures are set with factory test equipment and are recommended to be sent back for overhaul or repair The unit may be disassembled for cleaning Relieve the pressure in the hydraulic system by placing the gear selector handle in the neutral position 2 Onthe 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 Dump out remaining oil and clean reservoir Unscrew stand pipe with the filter attached Clean filter If filter 18 removed from stand pipe a new filter should be used Reinstall tank and install seals to top of reservoir before installing on pump 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 po cM UA ES 3 1 OPERATION TROUBLESHOOTING 1 Problem Power pack does not run af
31. ghtly greased Apply grease to a cloth on a stick or rod and run along tracks inside of the nose box both sides The nose gear pivot bearings are matched to bearing and race If replacement is necessary replace entire bearing The nose wheels contain grease zerks for the wheel bearings They should be greased every 25 hours Nose tires are standard 6 00 x 6 8 ply inflated to 50 5 psi NOSE BOX TRACK WEAR Due to the wear the roller slide block places on the track as the gear are retracted the block needs to be measured for the amount of wear The tolerance for wear is 070 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 070 inches the block must be replaced This check is to be done every 200 hours and is part of the maintenance checklist On the 13000 Series Floats Gear Track P N 13 07104 001 LT 002 RT 2 3 SERVICE MAIN WHEELS AND BRAKES Grease nipples 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 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 remember to bleed one segment of the Y first then finish the entire job through t
32. he remaining segment Main wheel tires are standard 8 50 x 10 8 ply type III aircraft tires inflated to 50 5 psi Refer to figure 2 10 2 4 SERVICE MAIN GEAR OLEO Oil Level The correct level is best set by draining and refilling with the correct quantity of fluid 1900 ml This should be done with the oleo removed from the float CAUTION Release air pressure and remove air valve before attempting to service oleo After filling refit valve and cap then pressurize to 250 psi NOTE Use only MIL H 5606 hydraulic fluid Air Pressure The correct air pressure is 250 psi 10 psi on a fully extended oleo no load or it can be inflated to approximately 3 4 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 rings whose part numbers are depicted in figure 2 5 NOTE When reinstalling the main gear oleo bolts tighten so oleo is free to rotate Page 18 of 61 1002548 Rev C WIPLINE MODEL 13000 SERVICE MANUAL 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 2 Inspect all parts carefully after
33. ical 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 Tension Application Shear Application Nut Torque Limits Nut Torque Limits Bolt Size Bolt Size Min Max Min Max 8 36 12 15 8 36 7 9 10 32 20 25 10 32 12 15 1 4 28 50 70 1 4 28 30 40 5 16 24 100 140 5 16 24 60 85 3 8 24 160 190 3 8 24 95 110 7 16 20 450 500 7 16 20 270 300 1 2 20 480 690 1 2 20 290 410 9 16 18 800 1 000 9 16 18 480 600 5 8 18 1 100 1 300 5 8 18 600 780 2 6 2 300 2 500 2 6 1 300 1 500 7 8 14 2 500 3 000 7 8 14 1 500 1 800 1 14 3 700 4 500 1 14 2 200 3 300 1 1 8 12 5 000 7 000 1 1 8 12 3 000 4 200 1 1 4 12 9 000 11 000 11412 5 400 6 600 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 5606 Page 59 of 61 1002548 Rev E WIPLINE MODEL 13000 SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Page 60 of 61 1002548 Rev C WIPLINE MODEL 13000 SERVICE MANUAL 6 WEI
34. 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 year and grease reapplied to the shafts heads and nuts THE ABOVE CLEANING TECHNIQUES ARE VITAL FOR KEEPING CORROSION TO A MINIMUM SALTWATER OPERATIONS AND ENVIRONMENT ARE STRONGLY LINKED TO CORROSION AND MUST BE ADDRESSED PROACTIVELY 1002548 Rev E Page 15 of 61 WIPLINE MODEL 13000 SERVICE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Page 16 of 61 1002548 Rev C WIPLINE MODEL 13000 SERVICE MANUAL 2 MAIN AND NOSE GEAR OPERATION REMOVAL AND SERVICE 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 A pressure of between 525 and 1250 psi is maintained in the supply line When the pressure falls below 525 psi the pressure switch activates the pump solenoid providing power to the pump When the pressure reaches 1150 1250 psi the pressure switch deactivates the solenoid and the pump motor stops Figure 2 2 shows the electrical schematic of the system check valve on the output side of the pump ret
35. mended if trying different products to inspect them frequently so as to Corrosion X Corrosion Technologies Corp Tef Gel Ultra Safety Systems Inc Float Sealant 890 B2 or 4 Pro Seal Company PR 1440 C PPG Aerospace 1422 B2 B4 or B6 Pro Seal Company RTV Silicones General Electric SIKAFLEX 201 or 252 Sika Manufacturing Telflon Spray 6P 730A Comet Industries Hydraulic Fluid Mil H 5606 Electrical Insulating Compound Dow Corning 4 DC4 Dow Corning Corporation determine their effectiveness Protection of nuts bolts hydraulic lines or metal surfaces Zip D 5029NS Corrosion Inhibiting Compound Zip Chemical Company CRC 56400 Soft Seal CRC Industries General Lubricants LPS 1 LPS 2 and LPS 3 LPS Industries Wheel Bearings Main Gear Retract Mechanism Nose Gear Pivot 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 f 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 56 of 61 1002548 Rev E 200 Nose Gear Box Block T
36. nliness corrosion deformation sealing and tension Fluid Lines and Hoses For leaks cracks dents kinks chafing security corrosion and deterioration 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 For corrosion correct torque when installed or when visual inspection indicates a need for a torque check Some additional general maintenance areas are as follows Main Gear Locks Clean and lubricate as necessary to keep grease present at all times Water resistant grease is recommended 1002548 Rev C Page 55 of 61 WIPLINE MODEL 13000 SERVICE MANUAL Joints Spray all Joints with light penetrating oil such as LPS 3 to ensure lubrication at all times Electrical Connections Apply SOFT SEAL or LPS 100 paste to all electrical connections to prevent corrosion 5 1 RECOMMENDED LUBRICANTS AND CORROSION PRODUCTS Below is 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 recom
37. o 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 Prior to landing the circuit breakers should be pushed in to reactivate the circuits Troubleshoot hydraulic problem per section 3 1 1002548 Rev E Page 13 of 61 WIPLINE MODEL 13000 SERVICE MANUAL LANDING GEAR OPERATION To retract or extend the landing gear pull out on the landing gear handle and move it to the desired position When the handle 1 positioned pressure on the hydraulic system reduces to where the hydraulic motors automatically 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 lights illuminate at various times EMERGENCY PUMP HANDLE An emergency hand pump is located on the floor to the left side of the seat for use in the event the normal hydraulic system fails This hand pump may be used to retract or extend the land gear Prior to utilizing the emergency hand pump pull the AMPHIB PUMP 1 and 2 circuit breakers to deactivate the el
38. ompleted the pump will automatically shut off If the pressure in the system drops to a preset value the pressure switches turn the pump motors back on and build up the pressure to the limit again Eight 8 position indicator lights four 4 gear UP and four 4 gear DOWN are provided to show landing gear position Two 2 additional indicator lights show when the landing gear pump motors are operating LANDING GEAR HANDLE The landing gear handle controls a hydraulic selector valve within the control unit on the left hand side of cockpit by fuel shut off handle and has two 2 positions UP and DOWN LAND which give a mechanical indication of the gear position selected From either position the handle must be pulled out to clear a detent before it can be repositioned INDICATOR LIGHTS Ten 10 indicator lights are mounted on the landing gear control unit adjacent to the landing gear handle Four 4 blue indicator lights labeled NOSE and MAIN left hand lights for the left float and right hand lights for the right float show by their illumination that the landing gear is up and locked The four 4 green indicator lights labeled NOSE and MAIN left hand lights for the left float and right hand lights for the right float are illuminated when the landing gear is down and locked Neither set of lights is illuminated when the landing gear is in transit Two 2 red indicator lights labeled PUMP ON 1 and 2 illuminate when current is supplied t
39. orated within the amphibious floats on this airplane is retractable quadricycle type with two swiveling nose or bow wheels and four 4 two 2 sets of dual main wheels Air oil shock struts on the two main landing gear assemblies provide shock absorption Page 12 of 61 1002548 Rev WIPLINE MODEL 13000 SERVICE MANUAL The main landing gear has dual 8 50 x 10 8 ply tires and the nose landing gear has 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 Landing gear extension and retraction is accomplished by two 2 electrically driven hydraulic pumps and four 4 hydraulic actuators one 1 for each gear The hydraulic pumps are located in the fuselage nose cone and the hydraulic actuators are located 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 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 c
40. racks WIPLINE MODEL 13000 SERVICE MANUAL HOURS 25 Page 57 of 61 INSPECTION TIME LIMITS 50 100 Float exterior inspect for damage wrinkled metal corrosion paint loss etc Struts amp attach fittings Spreader bars Float Structure interior Placards Float Installation Inspection Covers inspect for condition security and seal Pumper Tube Installation inspect for condition security routing of hoses Pump and indicator light wiring inspect for chafing broken or loose terminals and general condition Solenoids inspect for wiring mounting and general condition Pressure Switches inspect wiring mounting and general condition Pump motors inspect wiring mounting and general condition Lubricate nose gear tracks measured at slide route for wear 070 inches or less wear tolerance Nose gear pivot blocks and forks inspect for condition lubrication corrosion paint Nose and Main Wheel Bearing grease Zerk fittings Hydraulic Fluid Level Wheels and Tire inspect for wear pressure condition Brake Assemblies inspect for wear corrosion leakage 1002548 Rev C General Hulls amp Struts Electrical System Landing Gear Systems WIPLINE MODEL 13000 SERVICE MANUAL INSPECTION TIME LIMITS 25 50 100 200 Hydraulic Fluid Screen clean and inspect Note If floats sit for extended p
41. ssued If a warranty is issued most commonly it is for an 18 month time period so it is crucial to check for service letters specific to your float model at each periodic inspection to be eligible Service Manuals and the installation prints included are also revised periodically and also need to be kept updated Service letters service kits and Service manuals are available on our web site at no charge www wipaire com CHECKING FOR THESE UPDATES SHOULD BE A PART OF ROUTINE MAINTENANCE Page 8 of 61 1002548 Rev C WIPLINE MODEL 13000 SERVICE MANUAL 779 31 15962 zd 1002548 Rev E Page 9 of 61 WIPLINE MODEL 13000 SERVICE MANUAL 4 58316 610 16 Page 10 of 61 1002548 Rev WIPLINE MODEL 13000 SERVICE MANUAL 1 GENERAL 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 Viking Air As part of the float installation the following changes are made to the landplane 1 The hydraulic landing gear retraction system components and cockpit controls are added
42. ter gear selection PROBABLE CAUSE a Circuit breaker has failed b Pressure switch not pulling in at low cut in c Solenoid switch not pulling in d Faulty pump motor e Motor not properly grounded VERIFICATION AND REMEDY a Reset circuit breaker b Short across pressure switch leads and see if motor runs If motor operates replace pressure switch c Short across solenoid pressure switch leads and see if motor runs If motor operates replace 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 1002548 Rev C Page 39 of 61 WIPLINE MODEL 13000 SERVICE MANUAL 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 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 andstay up and pressure switch shuts off powerpack REMEDY a Repatr retractor 4 Problem Powerpack cycles on and off after gear is in position PROBABLE CAUSE a Internal hydraulic leak b External hydraulic leak REMEDY a Verify leak is not external by checking fluid level in
43. uld be flushed if salt water enters the compartments If the floats are being stored inside remove inspection covers so the interior will dry out THE ABOVE CLEANING TECHNIQUES ARE VITAL FOR KEEPING CORROSION TO A MINIMUM SALTWATER OPERATIONS AND ENVIRONMENT ARE STRONGLY LINKED TO CORROSION AND MUST BE ADDRESSED PROACTIVELY Page 14 of 61 1002548 Rev C WIPLINE MODEL 13000 SERVICE MANUAL Corrosion 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 The primary means of corrosion detection is visual The most obvious sign is a corrosive deposit of white powder Other signs are discoloration of the metal surface or bubbles and blisters under the painted surface Light 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 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 manufacturer s instructions for application
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