Wipaire WIPLINE 13000 User manual

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

SERVICE MANUAL & ICA
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LOG OF REVISIONS
Rev Pages Description Date
A 11, 26 Added an inspection time limit and tolerances for the Nose Block Track wear. 4/18/2006
B13-14,
44, 55
Updated to Maintenance Manual per 23-8. Added 3-view images of oatplane. Added section
4.1 regarding rivet replacement. Added section 4.4 regarding bulkhead holes for maintenance. 11/22/2010
C All Reformat of entire document. Add green grease as approved grease. 4/18/2013
D 22, 56, 59 Added Shear Torque Chart, PR 1440 C Sealant and Tef-Gel. Removed Warranty Claim Form.
Corrected Oil amount 1900 was 1140. 5/26/2015
E5, 15,
56, 59
Added Dow Corning DC4, Corrosion X, and Mobil Aviation Grease SHC 100 to approved
product list. Modied torque limit section. 12/4/2015
F 8 Added reference for Structural Repair Manual part number 1008274 in introduction. 5/1/2019
G15, 18,
37, 56
Added information about corrosion limits. Added note about STA-Lube. Updated drawing for
Nose Gear Lower End Assembly. Added STA-Lube to Brake Caliper Grease. 8/3/2020
H All
Reformatted manual in new software. Added sections 1.3 through 1.7. Removed Comet
Industries GP-730A. Removed content in Chapter 4 and replaced with note about SRM.
Removed Figures 4.1 through 4.10 as content is found in SRM.
2/3/2021
View most current revision of this ICA at www.wipaire.com.

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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

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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 – 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
FIGURE 2.10 ASSEMBLY – NOSE GEAR LOWER END ......................................................................40

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WIPLINE 13000 FLOATS
P/N 1002548 Revision H Page 7
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 oatplane, and to provide technical data and servicing specics to maintenance professionals charged with
servicing the oats.
When performing standard repairs for Wipline Aluminum Floats, 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 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 oats 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, Inc.
1700 Henry Avenue – Fleming Field
South St. Paul, MN 55075
Telephone: [phone]
Fax: [phone]
Website: www.wipaire.com
Email: [email protected]
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 oats in working order.
When a oat part is signicantly changed or an additional inspection recommended or required, often a service
letter and/or kit is issued. If a warranty is issued, most commonly it is for an 18 month time period, so it is crucial
to check for service letters specic to your oat 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 website www.wipaire.com at no
charge.
CHECKING FOR THESE UPDATES SHOULD BE A PART OF ROUTINE MAINTENANCE

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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

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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 oat installation the following changes are made to
the landplane:
1. The hydraulic landing gear retraction system components and cockpit controls are added*
2. The landing gear emergency gear operation hand pump and system are added*
3. Auxiliary Vertical Fins are added
*Note: Amphibian oat models only
1.2 FLOATS
The model 13000 seaplane or amphibious oat is an all aluminum-constructed oat with watertight compartments.
The actual displacement in fresh water for each oat is 12844 pounds buoyancy for the seaplane and 12442
pounds buoyancy for the amphibian. The amphibian oat 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 di󰀨erential braking. The nose wheels are full castering.
Access to the oat interior is accomplished by removing covers on the top deck and six covers inside the wheel
well. When necessary, water inside the oat hulls may be removed through pump-out cups located on the
outboard edge of each oat top skin.
FLOAT HULL MAINTENANCE
GENERAL
The oat 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
nished with a urethane color paint or equivalent.
1.3 TOWING
When towing the amphibian aircraft, 2 lugs are provided on the lower forward side of the nose spring.
On land, a rigid “V” frame can be fabricated to attach to these lugs for towing the aircraft with a tractor. Lake & Air
Training and Pilot Shop has this tow bar available for purchase.

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On water, a rope bridle arrangement can used to tow the aircraft from the lugs described above.
1.4 HOISTING
Hoisting the aircraft can be performed using a lifting rig that attaches to the aircraft with lifting rings that are
installed at the wing attach points. If the lifting rings are not installed, reference applicable aircraft maintenance/
service manual for additional hoisting specications. 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
oats.
CAUTION!
Make sure nothing is under or above the airplane or oats when hoisting the aircraft
1. Raise aircraft high enough to place oat cradle under oats as shown in Figure 1.4.
2. Lower aircraft onto oat 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 JACKING PROCEDURES
CAUTION!
Make sure nothing is under or above the airplane or oats when jacking the aircraft.
1. Turn o󰀨 fuel.
2. Place weighted bags above the nose gear (approximately 100 lbs. on each oat to start, more may be
added as needed).
3. Position 1 person at each fore and aft of each oat, and 3 people at the jacking location of one oat.
4. Modify jack saddle of a 3 ton minimum jack by welding as shown in Figure 1.1.

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(X = WIDTH OF CRADLE)
FIGURE 1.1 JACK CRADLE RECOMMENDED MODIFICATION
NOTE: This is not required and Wipaire does not have the parts for modication. It is recommended a similar
modication be performed to the jack saddle to prevent the slippage of the cradle.
1. Center cradle on saddle and position so cradle is as far aft on the main keel as possible without interfering
with main gear as it decompresses as shown in Figure 1.2.
NOTE: If desired to prevent possible cosmetic damage to oat, use material to separate cradle and oat.
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 the cradle and stands to gently contact the ground.
3. Repeat previous procedure to the other oat.
NOTE: A smaller jack may be needed to slightly lift the oat into a high enough position for the main jack.
4. Secure oats with fore and aft supports as shown in Figure 1.3 and Figure 1.4.

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FIGURE 1.3 FLOAT SECURING LOCATIONS
ALTERNATE JACKING METHOD IF WIPAIRE
JACKING FIXTURE IS NOT AVAILABLE
(8000A model shown for reference only)

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1.8 AMPHIBIAN LANDING GEAR SYSTEM
The landing gear incorporated within the amphibious oats 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.
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 di󰀨erential 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 uid level should be checked periodically
by viewing the sight glass for uid level in the upper one-third of the range. If uid is low, ll 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 under or above the airplane or oats when removing the jacks from the aircraft
1. Turn o󰀨 fuel.
2. Verify landing gear is in the down and locked position.
3. Verify weighted bags are still located above the nose gear.
4. Position 1 person at each fore and aft of each oat, and 1 person at the jacking location of one oat.
5. Remove all fore and aft supports as shown in Figure 1.3 and Figure 1.4.
6. Using modied jack saddle as shown in Figure 1.1, center jack saddle in center of cradle on 1 of the oats,
7. Lift aircraft to clear fore and aft cradle stands and remove fore and aft cradle stands of lifted oat.
8. Slowly lower oat to the ground, remove jack from under oat, and remove cradle from jack saddle.
9. Repeat previous procedure to the other oat.
10. Remove weighted bags from oats.

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Landing gear operation is initiated by movement of the landing gear handle. When the handle is repositioned,
hydraulic pressure in the system will drop and pressure switches will automatically turn on the hydraulic
pump motors to maintain operating pressure in the system. When the gear cycle is completed, the pump will
automatically shut o󰀨. 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-o󰀨 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 oat and right-hand lights for the right
oat), 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 oat and right-hand lights for the right oat), 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 to the landing gear motors.
If the motors continue running during ight or on and o󰀨 repeatedly, the motors should be shut o󰀨 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.
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 is 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 o󰀨 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 oor 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 electric 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.

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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 oat 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 oat interior should be ushed if salt water enters the compartments. If the oats 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.

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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.
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,
aking, and pitting) may be removed by heavy sanding or grinding, and applying chromic acid. If signicant loss
of skin material thickness will result in corrosion treatment, reinforcement or replacement of the a󰀨ected area may
be necessary.
After removing the corroded area, restore area to original nish (prime and enamel). BOESHIELD T9, Corrosion
X, or ACF-50 may also be applied to stop corrosion. Refer to manufacturer’s instructions for application
instructions.
Maintaining the oat inside and outside nishes by washing after saltwater operations will help protect the oat
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.

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