Brake Assembly 32-48-10

2004 Page T-1Nov 1/0432-48-10

Aircraft Wheels & BrakesGoodrich CorporationP.O. Box 340Troy, Ohio 45373U.S.ATEL: 937-339-3811FAX: 937-440-2055

CAGE 97153

COMPONENT MAINTENANCE MANUALWITH

ILLUSTRATED PARTS LIST

MAIN LANDING GEAR BRAKE ASSEMBLY

PART NUMBER

2-1700

GOODRICH CORPORATIONCOMPONENT MAINTENANCE MANUAL

BRAKE ASSEMBLY, P/N 2-1700

RECORD OF REVISIONS

Page RR-1Nov 1/0432-48-10

Put revised pages into the manual. Write the revision number and the revision date of the manual, and the date that you put the pages into the manual. Write the initials of the person that put the revised pages into the manual.

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REVISIONDATE

DATEINCLUDEDINTO THEMANUAL

INITIALS REV.NO.REVISION

DATE


INITIALS

Issued Nov 1/04

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RECORD OF TEMPORARY REVISIONS

Put each temporary revision page into the manual opposite the affected page. Write the temporary revision number, the affected page numbers, and the date that the pages are put into the manual. Write the initials of the person that put the temporary revision pages into the manual. Do not remove the yellow sheets until the manual is revised to include this data.

TEMPORARYREVISIONNUMBER

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RECORD OF SERVICE BULLETINS

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This record shows when a Service Bulletin or Service Letter is included into a revision of the manual. Service Letters are shown because they can contain added procedures and modification data.

SERVICEBULLETINNUMBER

SERVICELETTERNUMBER

REV.NO.

DATE ISSUED

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DESCRIPTION



TABLE OF CONTENTS

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SECTION PAGE

DESCRIPTION AND OPERATIONDescription . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

TESTING AND FAULT ISOLATIONPreparation for Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101High-Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Static Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104Dynamic Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104Clearance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Shuttle Valve Assembly Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105Set the Length of the Wear Indicator Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107Fault Isolation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

DISASSEMBLYBrake Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301Preparation for Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301Heat Sink Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302Torque Plate Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303Piston Housing Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304Adjuster Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

Piston Assembly Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306Sleeve Assembly Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

CLEANINGCleaning Metal Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402Cleaning Non-metal Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403Paint Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403

Abrasive Blast Piston Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403Abrasive Blast Torque Plate, Pressure Plate, and Stator Disk . . . . . . . . . . . . . . 404Chemical Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404

CHECKGeneral Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501Rotor Carrier Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502Stator Carrier Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503Torque Plate Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505Pressure Plate Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507Wear Plate Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509Adjuster Assembly Parts Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510

Spring Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510Piston Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512Adjuster Sleeve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513

Piston Housing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514



TABLE OF CONTENTS

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SECTION PAGE

CHECK ContdHeli-Coil Insert Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515

Miscellaneous Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516Bolt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516Nut Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516Washer Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516

REPAIRRotor Carrier Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601Stator Carrier Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601Torque Plate Assembly Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603Pressure Plate Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606Piston Housing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607

Heli-Coil Insert Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609Apply Conversion Coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611Piston Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612Adjuster Sleeve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613Paint Piston Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614

ASSEMBLYAssemble Adjusters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701

Sleeve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701Assemble Piston Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 705

Assemble Piston Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 706Install Bleeder Adapter and Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 706Install Shuttle Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708

Installation of the Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 709Finish Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710Install the Wear Indicator Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711Adjust the Wear Indicator Pin Bushing (with all new heat sink parts). . . . . . . . . . . . 712Adjust the Wear Indicator Pin Bushing (with used heat sink parts) . . . . . . . . . . . . . 712Storage Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714

FITS AND CLEARANCESTorque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801

SPECIAL TOOLS, FIXTURES, EQUIPMENT, AND CONSUMABLESSpecial Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901Aqueous Cleaner Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 909Other Consumables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 912



TABLE OF CONTENTS

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SECTION PAGE

ILLUSTRATED PARTS LISTNotice of Disclaimer of Liabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001Explanation and Usage of Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001Vendor Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1105Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1006Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1007



LIST OF EFFECTIVE PAGES

Page LEP-1Nov 1/0432-48-10

SUBJECT PAGE DATE

Title Page T-1 Nov 1/04

Record of RR-1 Nov 1/04Revisions

Record of TR-1 Nov 1/04TemporaryRevisions

Record of SB-1 Nov 1/04ServiceBulletins

List of LEP-1 Nov 1/04Effective 2 Nov 1/04Pages

Table of TC-1 Nov 1/04Contents 2 Nov 1/04

3 Nov 1/04

Introduction INTRO-1 Nov 1/042 Nov 1/043 Nov 1/04

Description and 1 Nov 1/04Operation 2 Nov 1/04

3 Nov 1/044 Nov 1/045 Nov 1/04

Testing and 101 Nov 1/04Fault Isolation 102 Nov 1/04

103 Nov 1/04104 Nov 1/04105 Nov 1/04106 Nov 1/04107 Nov 1/04108 Nov 1/04109 Nov 1/04

SUBJECT PAGE DATE

Disassembly 301 Nov 1/04302 Nov 1/04303 Nov 1/04304 Nov 1/04305 Nov 1/04306 Nov 1/04307 Nov 1/04308 Nov 1/04

Cleaning 401 Nov 1/04402 Nov 1/04403 Nov 1/04404 Nov 1/04

Check 501 Nov 1/04502 Nov 1/04503 Nov 1/04504 Nov 1/04505 Nov 1/04506 Nov 1/04507 Nov 1/04508 Nov 1/04509 Nov 1/04510 Nov 1/04511 Nov 1/04512 Nov 1/04513 Nov 1/04514 Nov 1/04515 Nov 1/04516 Nov 1/04517 Nov 1/04



LIST OF EFFECTIVE PAGES

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SUBJECT PAGE DATE

Repair 601 Nov 1/04602 Nov 1/04603 Nov 1/04604 Nov 1/04605 Nov 1/04606 Nov 1/04607 Nov 1/04608 Nov 1/04609 Nov 1/04610 Nov 1/04611 Nov 1/04612 Nov 1/04613 Nov 1/04614 Nov 1/04615 Nov 1/04

Assembly 701 Nov 1/04702 Nov 1/04703 Nov 1/04704 Nov 1/04705 Nov 1/04706 Nov 1/04707 Nov 1/04708 Nov 1/04709 Nov 1/04710 Nov 1/04711 Nov 1/04712 Nov 1/04713 Nov 1/04714 Nov 1/04

Fits and 801 Nov 1/04Clearances

SUBJECT PAGE DATE

Special Tools, 901 Nov 1/04Fixtures and 902 Nov 1/04Equipment 903 Nov 1/04

904 Nov 1/04905 Nov 1/04906 Nov 1/04907 Nov 1/04908 Nov 1/04909 Nov 1/04910 Nov 1/04911 Nov 1/04912 Nov 1/04913 Nov 1/04914 Nov 1/04

Illustrated 1001 Nov 1/04Parts List 1002 Nov 1/04

1003 Nov 1/041004 Nov 1/041005 Nov 1/041006 Nov 1/041007 Nov 1/041008 Nov 1/041009 Nov 1/041010 Nov 1/04



INTRODUCTION

Page INTRO-1Nov 1/0432-48-10

This manual gives maintenance procedures that can keep the brake assembly in an airworthy condition. Other maintenance procedures can be used, but the overhaul facility is responsible for these other procedures. The facility must make sure these other procedures are safe, keep the brake assembly airworthy, and obey applicable government regulations.

This manual uses the word "damage" many times. Cracks, dents, and bent areas are typical types of "damage". Other types of damage are possible.

Refer to the TABLE OF CONTENTS for the page numbers of sections and data in the sections.

Refer to the Introduction in the ILLUSTRATED PARTS LIST section for a description of how to use that section.

Weights and measurements in this manual are in U.S. (English) units. S.I. (International System of Units) metric units are shown in parentheses. English units have a period for the decimal point. Metric units have a comma for the decimal point.

Federal and MIL specifications are available from:

NAVAL PUBLICATIONS AND FORMS CENTER Telephone: 215-697-6257 700 ROBBINS AVENUE http://astimage.daps.dla.mil/online BLDG 4 SECTION D PHILADELPHIA, PENNSYLVANIA 19120

AMS specifications are available from:

SAE INTERNATIONAL Telephone: 724-776-4841 400 COMMONWEALTH DRIVE www.sae.org WARRENDALE, PENNSYLVANIA 15096-0001 U.S.A.

ASTM specifications are available from:

AMERICAN SOCIETY FOR TESTING AND MATERIALS Telephone: 610-832-9500 100 BARR HARBOR DRIVE www.astm.org WEST CONSHOHOCKEN, PENNSYLVANIA 19428 U.S.A.

Verified by Simulation:

Testing: Disassembly: Assembly:

Nov 1/04 Nov 1/04 Nov 1/04



INTRODUCTION


NOTICE OF DISCLAIMER OF LIABILITIES

ANY WARRANTIES OFFERED BY GOODRICH PERTAIN ONLY TO PARTS OR SYSTEMS MANUFACTURED BY GOODRICH OR SERVICES PROVIDED BY GOODRICH. GOODRICH ASSUMES NO LIABILITY WHATSOEVER, WHETHER CONTRACTUAL, WARRANTY, TORT OR OTHERWISE, FOR: - ANY FEDERAL AVIATION ADMINISTRATION SANCTIONS - PRODUCT MALFUNCTIONS - PROPERTY DAMAGE - PERSONAL INJURIES - SIMILAR INCIDENTS THAT OCCUR AFTER: - INSTALLATION OF PARTS THAT ARE NOT APPROVED BY GOODRICH - INSTALLATION OF PARTS WITH CHANGES THAT ARE NOT AUTHORIZED BY GOODRICH MANUALS OR OTHER WRITTEN PROCEDURES ISSUED BY GOODRICH

WARNING: USE ONLY GOODRICH-APPROVED REPLACEMENT PARTS. THESE REPLACEMENT PARTS ARE ONLY SHOWN IN THE ILLUSTRATED PARTS LIST OF THIS MANUAL OR IN SERVICE BULLETINS OR SERVICE LETTERS. THE USE OF REPLACEMENT PARTS THAT ARE NOT APPROVED BY GOODRICH CAN CAUSE PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.

WARNING: OBEY TORQUE LIMITS AND OTHER SPECIFIC VALUES THAT ARE GIVEN IN THIS MANUAL. THESE LIMITS AND VALUES THAT ARE NOT OBEYED CAN CAUSE PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE MANUFACTURERS INSTRUCTIONS, THE MATERIAL SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED. THE MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

NOTICE! Carefully read and obey CAUTION and WARNING statements in this manual. Refer to the descriptions of these statements that follow:

A CAUTION statement is given to prevent damage to the equipment. A WARNING statement is given to prevent personal injury. A NOTE statement is given to make a job easier.



INTRODUCTION


CADMIUM - Obey the warnings below before you touch or do maintenance on parts that are cadmium plated. Refer to the ILLUSTRATED PARTS LIST to identify the parts that are possibly cadmium plated. The Occupational, Safety, and Health Administration (OSHA) sets mandatory limits on exposure to cadmium dust (29 CFR 1910.1027).

WARNING: DO NOT GET CADMIUM IN YOUR MOUTH. CADMIUM THAT IS SWALLOWED CAN CAUSE KIDNEY OR REPRODUCTIVE SYSTEM DISEASE. AFTER YOU TOUCH CADMIUM PLATED PARTS, CLEAN YOUR HANDS BEFORE YOU EAT OR SMOKE. GET SAFETY INSTRUCTIONS FROM YOUR EMPLOYER. OBEY GOVERNMENT AND OSHA REGULATIONS WHEN YOU DISCARD THE PARTS THAT CONTAIN CADMIUM.

WARNING: DO NOT BREATHE CADMIUM PARTICLES, FUMES, OR DUST. THESE PARTICLES, FUMES, OR DUST CAN CAUSE LUNG OR KIDNEY DISEASE. IF MAINTENANCE PROCEDURES MAKE CADMIUM PARTICLES, FUMES, OR DUST, TELL YOUR EMPLOYER TO SUPPLY RESPIRATORS, VENTILATION, AND/OR PROCEDURES TO PREVENT EXPOSURE TO PERSONNEL.

The Occupational, Safety, and Health Administration (OSHA) has an applicable DANGER warning (29 CFR 1910.1027 (m)(3)(ii)) as follows:

DANGER: CONTAINS CADMIUM. CANCER HAZARD. AVOID CREATING DUST. CAN CAUSE LUNG AND KIDNEY DISEASE.



DESCRIPTION AND OPERATION

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1. Description

A. The 2-1700 brake assembly is a piston-operated multiple disk brake. The brake assembly operates from the aircraft hydraulic system and uses MIL-H-5606 orMIL-PRF-83282 hydraulic fluid. The brake operates at a maximum pressure of 3000 psi (206,8 bar) with a back pressure of 30 psi (2,1 bar).

B. The brake assembly has three primary parts, the piston housing assembly, the heat sink, and torque plate assembly (refer to Figure 1).

C. The piston housing assembly performs the actuation, retraction, and clearance adjustment functions of the brake. The piston housing assembly is attached to the torque plate assembly (115) with five bolts (105) and washers (110).

(1) The aluminum piston housing assembly (280) contains four adjuster assemblies (200), a hydraulic bleeder valve assembly (20), a bleeder fitting (40), a bleeder adapter (50), and a shuttle valve assembly (75).

D. A preformed packing (45) is installed on the bleeder fitting (40) to seal against fluid leakage. A preformed packing (55) and a packing retainer (60) are installed on the bleeder adapter (50) and the shuttle valve assembly (75) to seal against fluid leakage. The bleeder adapter (50) and the shuttle valve assembly (75) are interchanged between ports, to install the brake assembly on the right or left side of the strut.

E. A lining wear indicator is located on the bottom of the piston housing assembly (280) and is used as a visual means to determine lining wear. The wear indicator consists of a wear indicator pin (95), bushing (90), spring (100) and a self-locking nut (85). The spring is used to keep the head of the pin against the pressure plate assembly (165). The self-locking nut prevents pin loss when the brake is fully worn. The bushing is used to adjust the length of the wear pin and threads into a Heli-Coil insert (295) which is installed in the piston housing assembly (280).

F. A hydraulic shuttle valve assembly (75) is attached to the piston housing assembly (280) with two bolts (65) and washers (15). The shuttle valve assembly gives emergency operation of the brake assembly if the primary source of hydraulic pressure stops. A preformed packing (55), and packing retainer (60) seal the unit against fluid leakage. The adapters (70) are installed on the shuttle valve to install the aircraft hydraulic and pneumatic lines.

NOTE: Send shuttle valve assemblies that malfunction to Goodrich Corporation for repairs. The removal of the lead seal from the unit cancels the warranty.

G. Each adjuster assembly (200) contains a backup ring (205), pin retainer (210), piston assembly (215), packing assembly (T-Seal) (245), scraper ring assembly (250), and sleeve assembly (255) (refer to Figure 2).




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H. A lock pin (80) installed in the piston housing assembly (280) holds the brake assembly on the axle when the wheel assembly is removed.

I. The heat sink includes all the parts that have friction surfaces which cause the brake assembly to stop the rotation of the wheel. These parts include one pressure plate assembly (165), three rotor carriers (140), two stator carrier assemblies (145), and one steel torque plate assembly (115).

(1) The pressure plate assembly (165) has drive lugs on the inner diameter that engage the slots on the torque plate assembly (115). Twelve wear plates (175) are attached to the pressure plate with rivets (170). The pressure plate assembly does not turn, but slides as necessary on the torque plate assembly as the brake assembly operates.

(2) The rotor carriers (140) have drive slots on the outside diameter that engage the torque lug inserts in the wheel assembly. Each rotor carrier has a steel carrier with lining material that is sintered to each side. The rotor carrier turns with the wheel, and slide as necessary on the wheel insert as the brake assembly operates.

(3) The stator carrier assemblies (145) have drive lugs on the inner diameter that engage drive slots in the torque plate assembly (115). Twenty-four wear plates (155) are attached to a steel carrier with rivets (150). The stator carrier assemblies do not turn, but slide on the torque plate assembly as the brake assembly operates.

J. The steel torque plate assembly (115) that is bolted to the piston housing assembly (280) holds the pressure plate assembly and stator carrier assemblies in correct alignment with the rotor carriers. Twelve wear plates (125) are attached to the backleg of the torque plate with rivets (120).




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Figure 1. Main Brake Assembly Description




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Figure 2. Adjuster Assembly Description




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2. Operation

Brake Operation.

A. Pressurized hydraulic fluid in the piston housing assembly moves the four pistons and insulators against the pressure plate assembly, which causes the pressure plate assembly to move forward.

B. As the pistons and pressure plate assembly moves forward, the three rotor carriers, and two stator carrier assemblies are pushed between the pressure plate assembly and torque plate assembly. The friction caused by the turning and non-turning parts make the stopping effect.

C. When the brake assembly is operated, each piston moves forward which causes the pin and pin retainer to compress the spring in the sleeve assembly. The pin retainer bottoms against the sleeve assembly and holds the pin. Any more movement of the piston (caused by the brake wear) makes the pin move through the adjuster tube, which gives the brake a constant running clearance after each brake release. When the pressure is released, the sleeve assembly spring pushes the pin retainer, pin, and piston back a distance equal to the travel from the initial position, to give a constant running clearance after each brake release. The distance that the tube is pulled through the adjuster pin adjusts for brake wear.



TESTING AND FAULT ISOLATION

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Equipment And Materials

NOTE: Equivalent replacements are permitted for the items that follow:

- 4550 psi (313,7 bar) pressure source- Hydraulic fluid (MIL-H-5606 or MIL-PRF-83282)- Shims (Figure 901)

1. Preparation For Functional Test

A. Assemble the brake assembly (refer to the ASSEMBLY section).

WARNING: BEFORE YOU USE HYDRAULIC FLUID, READ, UNDERSTAND, AND OBEY ALL SAFETY INSTRUCTIONS FOR HYDRAULIC FLUID. THESE INCLUDE MANUFACTURERS INSTRUCTIONS, THE MATERIAL SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS. HYDRAULIC FLUID MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW TO SAFELY USE, KEEP, AND DISCARD HYDRAULIC FLUID. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW TO SAFELY USE, KEEP, AND DISCARD HYDRAULIC FLUID.

B. Put the brake assembly on a work surface and fill it with hydraulic fluid.

C. Connect the pressure source to one of the inlet adapters (70) on the shuttle valve assembly (75).

D. Put the brake assembly in the same position as it is on the aircraft.




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E. Remove the screw (25) and washer (30) from the bleeder valve (35). The screw, washer, and bleeder valve can contain cadmium.

F. Install a bleeder hose to the bleeder valve (35).

G. Put the end of the bleeder hose into a fluid waste container.

H. Pressurize the brake assembly to 30 psi (2,1 bar) or lower.

I. Loosen the hydraulic bleeder valve (35) and bleed the brake assembly until the hydraulic fluid flows with no air bubbles.

J. Tighten the hydraulic bleeder valve (35).

K. Decrease the brake pressure to 0 psi (0 bar).




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2. High Pressure Test

CAUTION: USE THE SHIMS TO MAKE SURE THAT STRUCTURAL MOVEMENT DOES NOT CAUSE A LOSS OF BRAKE RUNNING CLEARANCE.

NOTE: Do a high-pressure leak test on a brake assembly when a Lee plug (285) is replaced. If a Lee plug was not replaced, go to paragraph 3, FUNCTIONAL TEST.

A. Install the 0.030 - 0.050 inch (0,76 - 1,27 mm) thick, full circle split shim (refer to Figure 901) between the pressure plate assembly (165) and the first rotor carrier (140).

B. Cover the heat sink with a material that will not let the hydraulic fluid touch the steel parts.

WARNING: PUT A PROTECTIVE SHIELD AROUND THE BRAKE ASSEMBLY. A LEE PLUG AND HYDRAULIC FLUID CAN BE EJECTED WITH MUCH FORCE DURING A HIGH-PRESSURE LEAK TEST.

C. Put a protective shield around the brake assembly.

D. Pressurize the brake assembly to 4500 - 4550 psi (310,3 - 313,7 bar).

E. Hold the pressure for five minutes.

F. At the end of five minutes, decrease the pressure to 0 psi (0 bar).

G. Remove the protective shield.

H. Examine the brake assembly for leakage. No leakage that can be measured is permitted (less than one drop). Reject the brake assembly if leakage is found.

I. Remove the split shims.

J. Do the FUNCTIONAL TEST (refer to paragraph 3).




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3. Functional Test

A. Static Leakage Test

NOTE: Paragraphs 3.A.(2) thru 3.A.(7) are not necessary if paragraph 2, HIGH PRESSURE TEST, is completed.

WARNING: PUT A PROTECTIVE SHIELD AROUND THE BRAKE ASSEMBLY. A LEE PLUG AND HYDRAULIC FLUID CAN BE EJECTED WITH MUCH FORCE DURING A PRESSURE LEAK TEST.

(1) Cover the heat sink with a material that will not let the hydraulic fluid touch the steel parts.

(2) Put a protective shield around the brake assembly.

(3) Pressurize the brake assembly to 3000 - 3050 psi. (206,8 - 210,3 bar).

(4) Hold the pressure for five minutes.

(5) At the end of five minutes, decrease the pressure to 0 psi (0 bar).

(6) Remove the protective shield.

(7) Examine the brake assembly for leakage. No leakage that can be measured is permitted (less than one drop). Reject the brake assembly if leakage is found.

(8) Pressurize the brake assembly to 3 - 7 psi (0,2 - 0,5 bar).

(9) Hold the pressure for five minutes.

(10) At the end of five minutes, decrease the pressure to 0 psi (0 bar).


B. Dynamic Leakage Test

(1) Put a protective shield around the brake assembly.

(2) Pressurize the brake assembly to 3000 - 3050 psi (206,8 - 210,3 bar) and decrease to 0 psi (0 bar) for 25 cycles.

(3) Examine the brake assembly for equal retraction of each piston (240).

(4) At the end of 25 cycles, decrease the pressure to 0 psi (0 bar).




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(5) Remove the protective shield.


C. Clearance Test

(1) Put a shield around the brake assembly.

(2) Pressurize the brake assembly to 3000 - 3050 psi (206,8 - 210,3 bar). Decrease the pressure to 70 - 80 psi (4,8 - 5,5 bar) and hold the pressure.

(3) Remove the protective shield and turn the first rotor 360 degrees with hand force. If the first rotor cannot be turned, reject the brake assembly.

4. Shuttle Valve Assembly Test

WARNING: PUT A PROTECTIVE SHIELD AROUND THE BRAKE ASSEMBLY. A LEE PLUG AND HYDRAULIC FLUID CAN BE EJECTED WITH MUCH FORCE DURING A SHUTTLE VALVE ASSEMBLY LEAK TEST.

A. Connect the hydraulic source to one of the inlet adapters on the shuttle valve assembly (75) if necessary.

B. Cover the heat sink with a material that will not let the hydraulic fluid touch the steel parts.

C. Put a protective shield around the brake assembly.

D. Pressurize the brake assembly to 100 - 150 psi (6,9 - 10,3 bar).

E. Decrease the pressure to 45 - 55 psi (3,1 - 3,8 bar) and hold for one minute. Hydraulic fluid leakage is permitted when you apply the pressure. When the 45 - 55 psi (3,1 - 3,8 bar) is obtained, no leakage that can be measured is permitted (less than one drop) from the unconnected fitting on the shuttle valve assembly. Replace the shuttle valve assembly if a leak is found.

F. Pressurize the brake assembly to 3000 - 3050 psi (206,8 - 210,3 bar) and hold for one minute. No leakage is permitted that can be measured (less than one drop) from the unconnected fitting on the shuttle valve assembly. Replace the shuttle valve assembly if leakage is found.

G. Decrease the pressure to 0 psi (0 bar).

H. Remove the protective shield.




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I. Remove the hydraulic source from the inlet adapter (70) fitting on the shuttle valve assembly.

J. Connect the hydraulic source to the other inlet adapter (70) fitting on the shuttle valve assembly.

K. Put a protective shield around the brake assembly.

L. Pressurize the brake assembly to 100 - 150 psi (6,9 - 10,3 bar).

M. Decrease the pressure to 45 - 55 psi (3,1 - 3,8 bar) and hold for one minute. Hydraulic fluid leakage is permitted when you apply the pressure. When the 45 - 55 psi (3,1 - 3,8 bar) is obtained, no leakage that can be measured is permitted (less than one drop) from the unconnected fitting on the shuttle valve assembly. Replace the shuttle valve assembly if leakage is found.

N. Pressurize the brake assembly to 3000 - 3050 psi (206,8 - 210,3 bar) and hold for one minute. No leakage that can be measured is permitted (less than one drop) from the unconnected fitting on the shuttle valve assembly. Replace the shuttle valve assembly if leakage is found.

O. Decrease the pressure to 0 psi (0 bar).

P. Remove the protective shield.

NOTE: Send damaged shuttle valve assemblies to the Goodrich Corporation for repairs. The removal of the lead seal from the unit cancels the warranty.

Q. Remove the bleeder hose from bleeder valve (35).

R. Install the screw (25), washer (30) into the bleeder valve (35). The screw, washer, and bleeder valve can contain cadmium.

S. Tag or mark the brake assembly to show that it passed, or failed the functional test.

T. Examine a defective brake assembly (refer to Figure 102, Fault Isolation Chart).




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5. Set the Length of the Wear Indicator Pin

WARNING: DO NOT TURN THE BUSHING (90) ON A BRAKE THAT IS NOT FULLY WORN AND WILL GO BACK IN SERVICE. WHEN THE BUSHING IS TURNED, THE WEAR INDICATOR PIN (95) LENGTH IS CHANGED.

A. Put a shield around the brake assembly.

B. Pressurize the brake assembly at 3000 - 3050 psi (206,8 - 210,3 bar) and hold that pressure.

C. Adjust the bushing (90) until the wear indicator pin (95) measures 0.75 inch (19,05 mm) on a brake assembly with a new heat sink parts (refer to Figure 101). Measure from the top of the bushing (90) to the bottom of the nut (85).

D. Decrease the pressure to zero psi (0 bar).

E. Remove the protective shield.

F. Disconnect the brake assembly.

Figure 101. Set the Length of the Wear Indicator Pin




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Figure 102 (Sheet 1 of 2). Fault Isolation Chart

FAULT PROBABLE CAUSE CORRECTION

NOTE: Hydraulic fluid leakage that can not be measured is permitted (less than one drop).

Hydraulic fluid leaking from adjuster assembly area.

Worn preformed packing (185), packing assembly (245), and backup ring (205).

Replace the defective preformed packings, or backup rings

Damaged piston (240) or adjuster sleeve (275).

Repair or replace damaged parts.

Fluid leakage from a Lee plug.

Lee plugs (285) damaged or not installed correctly.

Replace a Lee plug that leaks.

Hydraulic fluid leaking from bleeder valve, adapter, or bleeder adapter.

Loose bleeder valve (35), bleeder fitting (40), or bleeder adapter (50).

Check the torque on bleeder valve, bleeder fitting and bleeder adapter bolts

Damaged bleeder valve (35) seats. Damaged bleeder adapter (50), preformed packings (45, 55), or packing retainers (60).

Replace bleeder valve. Replace bleeder fitting, bleeder adapter, preformed packings or packing retainers.

Hydraulic fluid leaking from shuttle valve.

Loose shuttle valve bolts, (65) or adapters (70).

Check the torque on shuttle valve bolts, and adapters.

Damaged shuttle valve (75), shuttle valve threaded ports, or preformed packings (45, 55), or packing retainers (60).

Replace shuttle valve, preformed packings (45, 55), or packing retainers (60).

Dragging or non-releasing brake.

First rotor carrier cannot be turned with hand force.

Weak springs (270). Measure spring load as shown in Figure 506. Replace a defective spring.

Soft or split adjuster tube (230).

Replace all adjuster tubes (230)

The brake is out of adjustment Replace all adjuster tubes (230)

Broken adjuster pin (235). Replace defective parts.

Brake will not operate when emergency or hydraulic system is applied.

Damaged shuttle valve assembly (75).

Replace a defective shuttle valve assembly.




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Figure 102 (Sheet 2 of 2). Fault Isolation Chart

FAULT POSSIBLE CAUSE CORRECTION

The Shuttle Valve assembly (75) has leakage.

Damaged preformed packing (55) or packing retainer (60).

Replace a defective preformed packing or packing retainer.

The Shuttle Valve assembly has leakage from the unconnected port.

Damaged shuttle valve assembly (75).

Replace a defective shuttle valve assembly.



DISASSEMBLY

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NOTE: Refer to the TESTING AND FAULT ISOLATION section to find the most possible cause of the brake malfunction.

Equipment and Materials


- Arbor or Drill Press- Adjuster Sleeve Spring Removal and Installation Tool (Figure 902)

1. Brake Removal


A. Disconnect all hydraulic lines from the brake assembly.

B. Seal each open hydraulic port with a cap or plug.

WARNING: USE EYE PROTECTION WHEN YOU CUT THE LOCKWIRE. WHEN YOU CUT THE LOCKWIRE, PIECES THAT BREAK OFF CAN HIT YOUR EYES AND CAUSE INJURY.

C. Cut the lock wire (5) and remove the locking pin (80). Remove the brake assembly from the axle.

2. Preparation for Disassembly

A. Refer to the TESTING AND FAULT ISOLATION section for the procedures on how to pressurize the brake assembly.

WARNING: PUT A PROTECTIVE SHIELD AROUND THE BRAKE ASSEMBLY. A LEE PLUG AND HYDRAULIC FLUID CAN BE EJECTED WITH MUCH FORCE WHEN A BRAKE ASSEMBLY IS PRESSUREIZED.

B. Put a protective shield around the brake assembly.

C. Pressurize the brake assembly to 3000 - 3050 psi (206,8 - 210,3 bar) and hold.



DISASSEMBLY

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D. Measure the length of the wear indicator pin (95) from the end of the wear indicator bushing (90) to the bottom of the nut (85) on the end of the pin (refer to Figure 301). Measure to the nearest 1/32 inch (0,8 mm) and record the length.

E. Decrease the brake pressure to 0 psi (0 bar).

F. Remove the protective shield.

G. Remove the hydraulic source from the brake assembly.

Figure 301. Measurement of Wear Indicator Pin

3. Heat Sink Removal

A. Put the brake assembly on a clean work surface with the piston housing assembly (280) on top.

NOTE: Brakes that are removed from the aircraft for reasons other than wear should not have heat sink parts disturbed unless necessary. Return the brakes to service with the same wear indicator pin length.

NOTE: If heat sink disks will be removed, but will be installed again, identify each disk so that it can be installed again in the same position. The friction surfaces of the disks must touch the same friction surfaces of mating disks that they touched before the disks were removed.



DISASSEMBLY

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NOTE: It is not necessary for the locking pin to remain with the brake assembly. Brake assemblies sent to overhaul with a locking pin will be returned with a locking pin. Brake assemblies that are sent for overhaul with no locking pin will be returned with no locking pin.





B. Remove the bolts (105) and washers (110) from the piston housing assembly (280). The bolts and washers can contain cadmium.

C. Remove the piston housing assembly (280) from the torque plate assembly (115).

D. Remove the pressure plate assembly (165), rotor carriers (140), stator carrier assemblies (145), from the torque plate assembly (115).

NOTE: Refer to the REPAIR section for the removal and the installation of the wear plates.

4. Torque Plate Disassembly

NOTE: Refer to the REPAIR section for the removal and the installation of the wear plates.

NOTE: Do not remove a Heli-Coil insert (130) unless it is damaged (refer to the REPAIR section).



DISASSEMBLY

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5. Piston Housing Disassembly


WARNING: MAKE SURE THAT THE EJECTED HYDRAULIC FLUID DRAINS INTO A CONTAINER. PISTONS THAT ARE PUSHED INTO THE PISTON HOUSING CAN CAUSE FLUID TO BE EJECTED.

NOTE: Replace the preformed packings (45, 55, 185), packing assembly (T-seal) (245), and scraper rings (250) at each lining change. Replace packing retainers (60) and backup rings (205) only if damaged.

A. Install a temporary drain tube to the inlet port on the shuttle valve or use other procedures to make sure that the drained hydraulic fluid goes into a fluid container.

B. Clean the exposed part of each piston (240).

C. Use hand force to push each piston fully into the piston housing assembly (280) to force out the hydraulic fluid.







DISASSEMBLY

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WARNING: USE EYE PROTECTION WHEN YOU CUT THE LOCKWIRE. WHEN YOU CUT THE LOCKWIRE, PIECES THAT BREAK OFF CAN HIT YOUR EYES AND CAUSE INJURY.

D. Cut the lock wire (5) and remove the screw (25), washer (30) bleeder valve (35), bleeder fitting (40) from the bleeder adapter (50). The screw and bleeder valve can contain cadmium.

E. Remove the preformed packing (45) from the bleeder fitting (40) and discard.

F. Cut the lock wire (5) and remove bolts (10) and washers (15) from the bleeder adapter (50). The bolts and washers can contain cadmium.

G. Remove the bleeder adapter (50) from the piston housing assembly (280).

H. Remove the preformed packing (55) from bleeder adapter and discard. Remove the packing retainer (60) when it is damaged and discard.

I. Remove the adapters (70) from the shuttle valve assembly (75). The adapters can contain cadmium.

J. Remove the preformed packing (45) from each adapter (70) and discard.

K. Cut the lock wire (5) and remove the bolts (65) and washers (15) from the shuttle valve assembly (75). The bolts and washers can contain cadmium.

L. Remove the shuttle valve assembly (75) from the piston housing assembly (280).

M. Remove the preformed packing (55) from the shuttle valve assembly (75) and discard. Remove the packing retainer (60) when it is damaged and discard.

N. Remove nut (85), spring (100) and wear indicator pin (95) from the piston housing assembly (280). The nut can contain cadmium.

O. Remove the bushing (90) from the piston housing assembly (280).

P. Remove the piston insulator (195) and retaining ring (190) from each piston (240).

Q. Cut the lock wire (5) and remove each adjuster assembly (200) from the piston housing assembly (280).

R. Remove the preformed packing (185) from each adjuster assembly (200) and discard.

NOTE: No more disassembly is necessary to replace the adjuster tube (230) (refer to paragraph 6. this section).



DISASSEMBLY

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S. Do not remove the Heli-Coil inserts (290, 295) or Lee Plugs (285) unless they are damaged (refer to the REPAIR section).

6. Adjuster Disassembly

NOTE: The disassembly of all four adjuster assemblies is the same. Therefore, only one procedure is given.

A. Disengage the pin retainer (210) from the adjuster pin (235) and remove the pin retainer from the adjuster assembly (200).

B. Push the piston assembly (215) out from the bottom of the sleeve assembly (255).

CAUTION: DO NOT USE SHARP, HARD TOOLS TO REMOVE PREFORMED PACKINGS AND PACKING RETAINERS. THESE TOOLS CAN CAUSE DAMAGE TO ALUMINUM PARTS.

C. Remove the packing assembly (T-seal) (245) from the outside diameter of the piston assembly (215) and discard.

D. Piston Assembly Disassembly

(1) Remove the retaining ring (220), tube retainer (225), adjuster tube (230), and adjuster pin (235) from the inner diameter of the piston (240) (refer to Figure 302).

(2) Discard the adjuster tubes.

Figure 302. Piston Assembly



DISASSEMBLY

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CAUTION: DO NOT USE SHARP, HARD TOOLS TO REMOVE PREFORMED PACKINGS AND PACKING RETAINERS. THESE TOOLS CAN CAUSE DAMAGE TO ALUMINUM PARTS.

E. Remove a damaged backup packing (190) from the outer diameter of the adjuster sleeve (275) and discard (refer to Figure 303).

F. Remove the scraper ring assembly (250) from the inner diameter of the adjuster sleeve (275).

Figure 303. Sleeve Assembly

G. Sleeve Assembly Disassembly

WARNING: OBEY THE INSTRUCTIONS TO REMOVE THE SPRING IN EACH ADJUSTER ASSEMBLY. THE SPRING IS COMPRESSED UNDER HIGH LOAD. IF YOU DO NOT REMOVE THE SPRING WITH CORRECT EQUIPMENT OR DO NOT OBEY THE INSTRUCTIONS, PARTS CAN BE EJECTED AND CAUSE INJURY TO PERSONNEL.

(1) Put the sleeve assembly (255) and the spring removal tool (Figure 902) in a drill press or arbor press (refer to Figure 304).



DISASSEMBLY

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(2) Lower the spring removal tool onto the spring retainer (265).

(3) Push the spring retainer (265) down until the retaining ring (260) can be removed.

(4) Lock the press and remove the retaining ring (260).

(5) Unlock the press and slowly release the pressure on the spring retainer (265) until all the spring pressure is released.

(6) Remove the spring retainers (265) and spring (270) from the adjuster sleeve (275).

Figure 304. Adjuster Sleeve Disassembly



CLEANING

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- Abrasive blast equipment- Chemical conversion coating (MIL-C-5541, Class 1A)- Goggles- Low pressure, compressed air source- Paint remover (SAE-AMS-1375)- Plastic media (MIL-P-85891 Type II)- Soft plastic-bristle brushes (solvent resistant)- Solvent, butyl alcohol- Solvent, degreasing (MIL-PRF-680 Type II or III)- Walnut hulls (A-A-1722 Type II)

NOTE: Refer to the SPECIAL TOOLS, FIXTURES, EQUIPMENT, AND CONSUMABLES section for the sources of materials. The list of consumables gives recommended concentrations and temperatures of aqueous cleaners.

CAUTION: DAMAGE TO PARTS OR UNSATISFACTORY CLEANING CAN BE THE RESULT IF THE PARTS ARE NOT CORRECTLY CLEANED WITH AQUEOUS CLEANING PRODUCTS. CAREFULLY OBEY THE MANUFACTURERS INSTRUCTIONS.

WARNING: BEFORE YOU USE BUTYL ALCOHOL, READ, UNDERSTAND, AND OBEY ALL SAFETY INSTRUCTIONS FOR THE ALCOHOL. THESE INCLUDE MANUFACTURERS INSTRUCTIONS, THE MATERIAL SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS. BUTYL ALCOHOL MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED. THE MSDS GIVES INSTRUCTIONS ON HOW TO SAFELY USE, KEEP, AND DISCARD BUTYL ALCOHOL. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW TO SAFELY USE, KEEP, AND DISCARD BUTYL ALCOHOL.

WARNING: BEFORE YOU USE DRYCLEANING SOLVENT (MIL-PRF-680 TYPE II OR III), READ, UNDERSTAND, AND OBEY ALL SAFETY INSTRUCTIONS FOR THE DRYCLEANING SOLVENT. THESE INCLUDE MANUFACTURERS INSTRUCTIONS, THE MATERIAL SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS. DRYCLEANING SOLVENT MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW TO SAFELY USE, KEEP, AND DISCARD DRYCLEANING SOLVENT. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW TO SAFELY USE, KEEP, AND DISCARD DRYCLEANING SOLVENT.



CLEANING

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1. Cleaning Metal Parts





CAUTION: DO NOT USE A WIRE BRUSH TO CLEAN ALUMINUM PARTS. A WIRE BRUSH CAUSES DAMAGE TO THE ANODIZE LAYER ON THESE PARTS.

CAUTION: MAKE SURE THAT CONTAMINATION IS FULLY REMOVED FROM THE BOLTS AND NUTS THAT HOLD THE WHEEL HALF ASSEMBLIES TOGETHER. CONTAMINATION CAN PREVENT FULL INSPECTION OF THE BOLTS AND NUTS. CONTAMINATION CAN CAUSE INCORRECT BOLT TENSION WHEN THE NUTS ARE TORQUED.

CAUTION: CAREFULLY OBEY THE MANUFACTURERS INSTRUCTIONS FOR USE OF AQUEOUS CLEANING PRODUCTS. INCORRECT PROCEDURES CAN CAUSE DAMAGE TO PARTS OR UNSATISFACTORY CLEANING.

A. Clean metal parts with MIL-PRF-680 Type II or III solvent or aqueous cleaning products. Refer to paragraph 2 to clean metal parts that have attached rubber (for example: seals). Make sure that bolt and nut threads are fully clean. Adjuster sleeves can be cleaned with this solvent with backup packings (205) installed. Some of these parts can contain cadmium (refer to the ILLUSTRATED PARTS LIST to identify these parts).

CAUTION: DO NOT DIP THE SHUTTLE VALVE INTO SOLVENT BASED CLEANING PRODUCTS. CLEANING PRODUCTS CAN GET INSIDE THE SHUTTLE VALVE AND CAUSE DAMAGE TO THE PACKINGS INSIDE THE SHUTTLE VALVE.



CLEANING

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B. Clean the shuttle valve MIL-PRF-680 Type II or III solvent or aqueous cleaning products.

2. Clean Non-Metal Parts

WARNING: BEFORE YOU USE BUTYL ALCOHOL, READ, UNDERSTAND, AND OBEY ALL SAFETY INSTRUCTIONS FOR THE ALCOHOL. THESE INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS. BUTYL ALCOHOL MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS TELLS HOW YOU MUST SAFELY USE, KEEP, AND DISCARD BUTYL ALCOHOL. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD BUTYL ALCOHOL.

CAUTION: USE ONLY SPECIFIED CLEANING PRODUCTS TO CLEANNON-METALLIC PARTS. SOME OTHER CLEANING PRODUCTS(FOR EXAMPLE: MIL-PRF-680) CAN CAUSE DAMAGE TO THESE PARTS.

Clean non-metallic parts with butyl alcohol or aqueous cleaning products.

3. Remove Paint

NOTE: Remove paint before penetrant inspection of the wheel halves. Do not remove paint for eddy current inspection.

A. Abrasive Blast Piston Housing

WARNING: OBEY GOVERNMENT REGULATIONS AND INSTRUCTIONS FROM YOUR EMPLOYER WHEN YOU TOUCH, KEEP, AND DISCARD PAINT THAT IS REMOVED. PAINT THAT IS REMOVED CAN BE DANGEROUS TO THE SKIN, EYES, AND LUNGS.

CAUTION: DO NOT USE A WIRE BRUSH OR USE SAND OR GLASS BEADS IN THE ABRASIVE-BLAST PROCEDURE TO CLEAN ALUMINUM PARTS. A WIRE BRUSH, SAND, OR GLASS BEADS CAUSE DAMAGE TO THE ANODIZE LAYER ON ALUMINUM PARTS.

(1) Apply mask material to threaded ports.

(2) Blast the parts by the procedures in MIL-STD-1504. Use media that does not cause damage to the anodize layer - for example:

(a) Plastic media (MIL-P-85891 Type II) (maximum media hardness of3.5 MOH).



CLEANING

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(b) Walnut hulls (A-A-1722 Type II) (grain-soft abrasive walnut hulls,Grade 20/30).

B. Abrasive Blast Torque Plate, Pressure Plate, and Stator Disk

(1) Seal or mask all threaded holes.

(2) Lightly abrasive blast to remove the paint and corrosion. Use 40 - 80 gauge abrasive media. For example, steel grit, sand, plastic media, or aluminum oxide. Steel particles (not shot) abrasive media is recommended.

C. Chemical Removal

WARNING: BEFORE YOU USE PAINT REMOVER, READ, UNDERSTAND, AND OBEY ALL SAFETY INSTRUCTIONS FOR THE PAINT REMOVER. THESE INSTRUCTIONS INCLUDE MANUFACTURERS INSTRUCTIONS, THE MATERIAL SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS. PAINT REMOVER MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES THE INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD PAINT REMOVER. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD PAINT REMOVER.

WARNING: OBEY GOVERNMENT REGULATIONS AND INSTRUCTIONS FROM YOUR EMPLOYER WHEN YOU TOUCH, KEEP, AND DISCARD PAINT THAT IS REMOVED. PAINT THAT IS REMOVED CAN BE DANGEROUS TO THE SKIN, EYES, AND LUNGS.

CAUTION: DO NOT USE A WIRE BRUSH TO REMOVE PAINT ON ALUMINUM PARTS. A WIRE BRUSH CAUSES DAMAGE TO THE ANODIZE LAYER ON THESE PARTS.

(1) Apply paint remover (SAE-AMS-1375) that can remove urethane paint and epoxy primer and does not cause damage to aluminum or steel parts. Refer to instructions from the manufacturer of the paint remover.

(2) Fully remove the paint remover.



CHECK

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- Hardness tester equipment- Magnetic particle inspection equipment (ASTM E1444)- Micrometer- Penetrant inspection equipment (ASTM E1417 Type 1, Method A, Level 2)- Torque wrench (accurate to 4% or better)

WARNING: DO AN NDT INSPECTION ON A BRAKE ASSEMBLY THAT CAUSED A THERMAL RELIEF PLUG (IN THE WHEEL) TO RELEASE THE TIRE PRESSURE.

1. General Inspection

NOTE: The heat sink is designed to last until it is fully worn. Inspection of the heat sink parts is not necessary until they are fully worn (wear indicator pin nut is touching the bushing as shown in Figure 301). If the brake is removed before an overhaul is scheduled, use the heat sink parts again unless the manual tells you to replace the parts.





A. Examine all metal parts for corrosion, cracks, nicks, scratches, gouges, distortion, damaged threads, and other faults. Discard or repair the damaged parts. Some of the parts can contain cadmium.



CHECK

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2. Rotor Carrier Inspection

WARNING: BEFORE YOU USE MAGNETIC PARTICLE (ASTM E1444) OR PENETRANT FLUID (ASTM E1417 TYPE I, METHOD A), READ, UNDERSTAND, AND OBEY ALL SAFETY INSTRUCTIONS FOR THE FLUID. THESE INCLUDE MANUFACTURERS INSTRUCTIONS, THE MATERIAL SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS. THESE FLUIDS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED. THE MSDS GIVES INSTRUCTIONS ON HOW TO SAFELY USE, KEEP, AND DISCARD THESE FLUIDS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW TO SAFELY USE, KEEP, AND DISCARD THESE FLUIDS.

A. Examine each rotor carrier (140) for wear, cracks, and flatness (refer to Figure 501). Magnetic particle (ASTM E1444) or penetrant (ASTM E1417 Type I, Method A, Level 2) for cracks.

B. A crack is permitted in the lining material only (refer to Figure 501). Discard the rotor carrier if a crack is found in the steel carrier.

C. Surface damage (pits) is permitted if the area of damage is not more than a maximum diameter of 0.500 inch (12,70 mm) and covers no more than 20% of the lining area on each side.

D. Surface damage (crumbling) of lining material is permitted on the inside diameter, outside diameter, and slot areas if the loss is not more than 0.50 inch (12,7 mm) wide (in from the edge).

E. Examine each rotor carrier to make sure it is flat to 0.020 inch (0.51 mm) or less (refer to the REPAIR section). Magnetic particle or penetrant inspect for cracks after the rotor carrier is made flat. Discard the rotor carrier with a crack in the steel carrier.

F. Discard a rotor carrier that is damaged to more than the limits.



CHECK

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Figure 501. Rotor Carrier Inspection

3. Stator Carrier Inspection

A. If the brake assembly was overheated, measure the hardness of the stator carrier (160). Measure the hardness on three torque lugs and calculate the average. Discard the stator carrier if the hardness value is less than 332 BHN (Rockwell C 36) (refer to Figure 502).

NOTE: Hardness measurement is only necessary if the thermal relief plugs (in the wheel assembly) released the tire pressure.

B. At each wear plate change, visually examine the stator carrier (160) for cracks.



CHECK

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C. At each third wear plate change, magnetic particle (ASTM E1444) or penetrant (ASTM E1417 Type I, Method A, Level 2) inspect the stator carrier (160) for cracks.

NOTE: It is recommended to let the penetrant fluid remain on the part for 30 minutes before inspection.

D. A crack that starts from the outer diameter and moves to the inner diameter is permitted if the crack it is not more than 0.250 inch (6,35 mm) long.

E. A crack that goes from one slot to another slot is not permitted. If a crack is found at a thermal expansion hole, or at the junction of the carrier inner diameter and the drive lug, discard the carrier (refer to Figure 502).

F. Examine each stator carrier to make sure it is flat to 0.020 inch (0.51 mm) or less (refer to the REPAIR section). Magnetic particle or penetrant inspect for cracks after the stator carrier is made flat. Discard the stator carrier with a crack, except for the area given in paragraph 3.D.

G. Measure the diameter of each rivet hole. Discard the stator carrier (160) if a rivet hole has a diameter more than 0.220 inch (5,59 mm).



CHECK

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.

Figure 502. Stator Carrier Inspection

4. Torque Plate Inspection

A. If the brake assembly was overheated, measure the torque plate hardness between the mounting bolt holes (refer to Figure 503). Measure hardness at four equally spaced locations and calculate the average. Discard the torque plate if the hardness value is less than 321 BHN (Rockwell C 35).




CHECK

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B. At each wear plate change, visually examine the torque plate (135) for cracks.

C. At each third wear plate change, magnetic particle (ASTM E1444) or penetrant (ASTM E1417 Type I, Method A, Level 2) inspect the torque plate (135) for cracks. Surface cracks can be removed (refer to the REPAIR section).


D. Examine the side surfaces of the torque lug slots for wear or damage. Repair rough torque lug slots (refer to the REPAIR section). Discard the torque plate if a slot width is more than 0.410 inch (10,41 mm) (refer to Figure 503).

E. Examine the Heil-Coil inserts (130) for thread damage and internal thread-locking element. Install a new, clean, and dry bolt into the Heli-Coil insert. Replace the Heli-Coil insert if the bolt is turned through the locking element with hand force or if the back-off torque is less than 9.5 pound-inches (1,1 Nm)

F. Measure for thermal set yield. Measure for 4.155 inches (105,54 mm) maximum distance from the mounting flange to the backleg (refer to Figure 503). The total difference of measured dimensions must not be more than 0.015 inch(0,38 mm).

G. Measure the diameter of each rivet hole. Discard the torque plate (135) if a rivet hole has a diameter is more than 0.220 inch (5,59 mm).



CHECK

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Figure 503. Torque Plate Inspection

5. Pressure Plate Inspection

A. If the brake assembly was overheated, measure the hardness of the pressure plate (180). Measure the hardness on three torque lugs and calculate the average. Discard the stator carrier if the hardness value is less than 332 BHN (Rockwell C 36) (refer to Figure 504).


B. At each wear plate change, visually examine the pressure plate (180) for cracks.



CHECK

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C. At each third wear plate change, magnetic particle (ASTM E1444) or penetrant (ASTM E1417 Type I, Method A, Level 2) inspect the pressure plate (180) for cracks.


D. A crack that starts from the outer diameter and moves to the inner diameter is permitted if the crack it is not more than 0.250 inch (6,35 mm) long.

E. A crack that goes from one slot to the another slot is not permitted. If a crack is found at a thermal expansion hole, or at the junction of the pressure plate inner diameter and the drive lug, discard the carrier (refer to Figure 504).

F. Examine each pressure plate to make sure it is flat to 0.020 inch (0.51 mm) or less (refer to the REPAIR section). Magnetic particle or penetrant inspect for cracks after the pressure plate is made flat. Discard the pressure plate with a crack, except for the area stated in paragraph 5.C.

G. Measure the diameter of each rivet hole. Discard the pressure plate (180) if a rivet hole has a diameter of more than 0.220 inch (5,59 mm).



CHECK

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Figure 504. Pressure Plate Inspection

6. Wear Plate Inspection

A. Examine each wear plate (125, 155, 175) (refer to Figure 505). Discard a defective wear plate. Replace the wear plates in sets. Do not use a mix of new and used wear plates unless new wear plates are ground down to the thickness of the used wear plates.

B. Examine each wear plate for loose rivets. Replace each loose rivet. Do not hit a rivet again to tighten.

C. Examine each wear plate for a crack. No more than one crack is permitted in each rivet hole.

D. Examine each wear plate for edge curl. Edge curl is permitted when the wear plates are attached to the pressure plate assembly (165) stator carrier assembly (145), or torque plate assembly (115) (refer to Figure 505).

NOTE: Edge curl and wear that is not even between the wear plates is usual.



CHECK

Page 510Nov 1/0432-48-10

Figure 505. Wear Plate Inspection

7. Adjuster Assembly Parts Inspection

A. Replace all adjuster tubes (230) and adjuster pins (235) at each lining change.

B. Examine the retaining rings (220, 260) for cracks, distortion and wear. Replace a retaining ring that is cracked, distorted, or worn.

C. Spring Inspection

WARNING: PUT A PROTECTIVE SHIELD AROUND THE SPRING. A SPRING THAT IS NOT PUT IN THE CORRECT POSITION CAN EJECT FROM THE TEST EQUIPMENT WITH MUCH FORCE.

Examine each spring (270) for load limit (refer to Figure 506) at each heat sink change. Put the dial indicator to read zero at the spring height dimension shown (refer to Figure 506). Put the spring in the center of the platform, below the ram. Compress the spring until the dial indicator shows zero. Discard a spring if not in the spring load range.



CHECK

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Figure 506. Spring Load Inspection

TEST HEIGHT SPRING LOAD RANGE

0.923 - 0.943 inch(23,44 - 23,95 mm) 122 - 146 lb. (55,34 - 66,2Kg)



CHECK

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D. Piston Inspection

Examine each piston (240) for surface damage and for wear (refer to Figure 507). Local repair of damage to a seal surface is permitted (refer to the REPAIR section). Small surface scratches on the seal surface that cannot be felt with a sharp plastic pick or a single-edged razor blade are permitted. Measure dimensions only if wear indications appear on the surface of the piston.

Local repair of damage to a non-seal surface of 0.005 (0.13 mm) maximum depth is permitted, but not more than the minimum and maximum diameter given (refer to paragraph 7 in the REPAIR section).

Figure 507. Piston Inspection



CHECK

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E. Adjuster Sleeve Inspection

Examine each adjuster sleeve (275) for surface damage and for wear (refer to Figure 508). Local repair of damage to a seal surface is permitted. (refer to the REPAIR section). Small surface scratches that cannot be felt with a sharp plastic pick or single-edged razor blade are permitted. Measure dimensions only if wear indications appear in the sleeve bore.

Local repair of damage to a non-seal surface is permitted, but not more than the minimum and maximum diameter is given (refer to paragraph 8 in the REPAIR section).

Figure 508. Adjuster Sleeve Inspection



CHECK

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8. Piston Housing Inspection

A. If the brake assembly was overheated, measure the hardness of the piston housing assembly (280). Measure the hardness on the mating face between the mounting bolt holes (refer to Figure 509). Measure the hardness at four equally spaced locations and calculate the average. Discard the piston housing assembly if the average hardness is less than 120 BHN (Rockwell B 76) or if the conductivity value is more than 40.5% IACS.

NOTE: Hardness measurement is only necessary on brakes that have caused thermal relief plugs (in the wheel assembly) to release tire pressure.

B. Visually examine the piston housing assembly (280) at each wear plate change for surface damage and crack (refer to the REPAIR section Figure 602).

WARNING: BEFORE YOU USE PENETRANT FLUID (ASTM E1417 TYPE I, METHOD A), READ, UNDERSTAND, AND OBEY ALL SAFETY INSTRUCTIONS FOR THE FLUID. THESE INCLUDE MANUFACTURERS INSTRUCTIONS, THE MATERIAL SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS. THIS FLUID MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED. THE MSDS GIVES INSTRUCTIONS ON HOW TO SAFELY USE, KEEP, AND DISCARD THIS FLUID. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW TO SAFELY USE, KEEP, AND DISCARD THIS FLUID.

C. Penetrant inspect (ASTM E1417 Type I, Method A, Level 2) the full piston housing at each third wear plate change. Let the fluid stay on the piston housing for a minimum of 30 minutes before the inspection is done. Discard the piston housing if a crack is found.

NOTE: Remove the paint and primer from the piston housing before penetrant inspection (refer to the CLEANING section).

D. Do an inspection for corrosion. Repair areas with corrosion (refer to the REPAIR section). Discard the piston housing if the repair is more that the limits specified.



CHECK

Page 515Nov 1/0432-48-10

Figure 509. Piston Housing Examination

E. Heli-Coil Inserts Inspection

Examine each Heil-Coil insert (290, 295) for thread damage and internal thread-locking element. Install a new, clean, and dry bolt into the Heli-Coil insert. Replace the Heli-Coil insert if the bolt can be turned with hand force past the locking element or if the back-off torque is less than referenced in Figure 510. Replace the Heli-Coil insert (refer to the REPAIR section).

Figure 510. Heli-Coil Minimum Back-Off Torque

ITEM NO.

HELI-COIL INSERTPART NUMBER

HELI-COIL THREAD SIZE

MINIMUM BACK-OFF TORQUE

290 3591-4CN250 1/4-28 3.5 pound-inches (0,40 Nm)

295 3591-6CN375 3/8-24 9.5 pound-inches (1,10 Nm)



CHECK

Page 516Nov 1/0432-48-10

9. Miscellaneous Inspections





A. Bolt (10, 65, 105) Inspection

Do an inspection for corrosion, cracks, and damage in the threads or on the radius below the bolt head. The bolts can contain cadmium. Discard a damaged bolt.

B. Nut (85) Inspection

(1) Visual Inspection - Do an inspection for corrosion, cracks, and damage in the threads or on the chamfer where the threads start. The nuts can contain cadmium. Discard a damaged nut.

(2) Locking Function Inspection

Do this inspection when the nut is installed (refer to the ASSEMBLY section).

C. Washer (15, 30, 110) Inspection

Do an inspection of each washer for corrosion and damage. The washers can contain cadmium. Discard a damaged washer.

D. Visually examine each piston insulator (195) for damaged. Discard an insulator that is less than 0.320 inch (8,31 mm) thick or damaged.



CHECK

Page 517Nov 1/0432-48-10

E. Replace each preformed packing (45, 55, 185) at each wear plate change. Replace the packing retainers (60) and backup rings (190) when damaged.

F. Visually examine the wear indicator bushing (90) for damage. Discard a wear indicator bushing that is damaged.



REPAIR

Page 601Nov 1/0432-48-10

NOTE: The repairs shown in this section will extend the life of the parts, but willnot put the parts back to a new condition. Replace all parts that are cracked, worn, twisted, or damaged too much to be economically repaired.



- Grinding/burring equipment- Chemical that removes corrosion, SAE-AMS-1640- Conversion coat, MIL-C-5541 Class 1A- Pin punch and drill press- Penetrant inspection equipment (ASTM E1417 Type I, Method A, Level 2- Magnetic particle inspection equipment (ASTM E1444)- Micrometers or vernier calipers- Spray paint equipment and materials- Solvent, degreasing, MIL-PRF-680 Type II or III- Rust Veto Spray

1. Rotor Carrier Repair

Make a rotor carrier (140) flat to less than 0.020 inch (0,51 mm). Use furnace-flatten or cold-flatten procedures (refer to Figure 601). Examine the rotor carrier after it is flat (refer to the CHECK section, paragraph 2).

2. Stator Carrier Assembly Repair

A. Remove worn or damaged wear plates (155).

(1) Use a 1/8 inch (3 mm) diameter drill bit to remove the rivet (150) head (non-upset side). Use a mallet and a punch to push out the rivet.

(2) Discard the wear plates (155).

B. Examine each stator carrier (160) (refer to CHECK section paragraph 3).

C. Make a stator carrier (140) flat to less than 0.020 inch (0,51 mm). Use furnace-flatten or cold-flatten procedures (refer to Figure 601). Examine the stator carrier after it is flat (refer to the CHECK section, paragraph 3).

D. Lightly abrasive blast the stator carrier to remove the corrosion (refer to the CLEANING section).

E. Examine the stator carrier for minimum thickness after abrasive blast (refer to Figure 502).



REPAIR

Page 602Nov 1/0432-48-10

Figure 601. Furnace Flatten Procedures

F. Clean the stator carrier to remove the contamination (refer to the CLEANING section).

G. Apply a thin layer of Rust Veto Spray (or equivalent) to the stator carrier for corrosion protection.

H. Put new wear plates (155) on the two sides the stator carrier. Align the rivet holes in the wear plate with the rivet holes in the stator carrier.

Procedure

1. Put the disk(s) in the fixture. Tighten the nut until the parts are held fully flat.

2. Put the fixture with parts in the furnace for 4 1/2 hours at a temperature of 1150 F (621 C), then air cool to an ambient temperature.

3. Examine the parts for cracks after the part is made flat (refer to the CHECK section).



REPAIR

Page 603Nov 1/0432-48-10

I. Put new rivets (150) through the two wear plates.

NOTE: Do not use a mixture of new and used wear plates unless new wear plates are ground down to the thickness of the used wear plates.

J. Make the rivet heads on one side of the stator carrier. Use the peen and anvil tools shown in Figure 904. The rivet head diameter must be more than 0.262 (6,65 mm).

3. Torque Plate Assembly Repair

A. Remove worn or damaged wear plates (125).

(1) Use a 1/8 inch (3 mm) diameter drill bit to remove the rivet (120) head (non-upset side). Use a mallet and a punch to push out the rivet.

(2) Discard the wear plates (125).


B. Examine the torque plate (135) (refer to CHECK section paragraph 4. and Figure 503).

C. Lightly abrasive blast the torque plate (135) to remove the corrosion (refer to the CLEANING section).

D. Examine the torque plate for minimum thickness after abrasive blast (refer to Figure 503).

E. Discard the torque plate if a rivet hole diameter is larger than 0.220 inch (5,59 mm).

F. Locally blend to remove damage to 0.030 inch (0.76 mm) maximum depth, but not in the area shown in Figure 503.

NOTE: A blend repair is done with hand tools to remove the damaged material. The repair is done with a very small change in contour from the repaired surface to the adjacent initial surface(s).

G. Polish the rough areas on the sides of the torque plate slots to make sure the movement of the stator is smooth. Do not increase the width to more than 0.410 inch (10,4 mm).

H. Make the backleg straight, if the measurement is more than 4.155 inches (105,54 mm) (refer to Figure 503). The total difference of measured dimensions must not be more than 0.015 inch (0,38 mm).



REPAIR

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I. Magnetic particle or penetrant inspect for cracks after the torque plate is made straight. If a crack is found, and can not be removed by locally blend, discard the torque plate.

J. Torque Plate Heli-Coil Insert Repair

(1) Repair Heli-Coil Insert (130) with initial-size Heli-Coil Insert

NOTE: If the hole is not damaged, install a new Heli-Coil insert (130) as follows:

(a) Remove the damaged insert with a Heli-Coil extraction tool, P/N 1227-6, or needle-nose pliers.

(b) Clean the hole threads with a Heli-Coil tap, P/N 6FBB.

(c) Clean the tapped hole.

(d) Install the new insert with a Heli-Coil installation tool, P/N 7552-6.

(e) Install the new insert 2 1/2 - 3 1/2 turns below the top surface.

(f) Remove the tang from the insert with a Heli-Coil tang break-off tool, P/N 3692-6.

(2) Repair Heli-Coil Insert with oversize Heli-Coil insert, P/N 3891-6CN562.

NOTE: If the hole has damage, install an oversize Heli-Coil insert (130A) as follows:

(a) Remove the insert with a Heli-Coil extraction tool P/N 1227-6, or needle-nose pliers

(b) Tap the damaged hole with a Heli-Coil tap, P/N 56193-6-2.

(c) Clean the hole.



REPAIR

Page 605Nov 1/0432-48-10

(d) Install the oversized insert with Heli-Coil installation tool, P/N 7552-6.

(e) Install the oversized insert 2 1/2 - 3 1/2 turns below the top surface.

(f) Remove the tang from the insert with a Heli-Coil tang break-off tool, P/N 3692-6.

K. Torque Plate Paint

NOTE: Refer to the CLEANING section for paint removal instructions.

WARNING: DO NOT DISCARD WASTE FROM WATER-BORNE PAINT IN THE SAME WASTE CONTAINER AS WASTE FROM SOLVENT-BORNE PAINTS THAT CONTAIN ALUMINUM POWDER (SUCH AS METALLIC PAINT). DISCARD THESE DIFFERENT TYPES OF WASTE PRODUCTS IN SEPARATE, FIRE-PROOF CONTAINERS. WHEN WATER TOUCHES ALUMINUM POWDER (WHICH MAKES HYDROGEN GAS), A FIRE OR EXPLOSION IS POSSIBLE.

WARNING: BEFORE YOU USE PAINT MATERIALS, READ, UNDERSTAND, AND OBEY ALL SAFETY INSTRUCTIONS FOR THESE MATERIALS. THESE INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS. THESE MATERIALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD THESE MATERIALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD THESE MATERIALS.

(1) Clean the surfaces to be painted, with a cloth that has no lint and is soaked with thinner.

(2) Apply two layers of aluminum, heat resistant paint (TT-P-28). Refer to the instructions from the manufacturer for data to mix, thin, apply, and dry the paint.

NOTE: Do not bake a touch-up layer paint.

L. Put new wear plates (125) on the torque plate. Align the rivet holes in the wear plate with the rivet holes in the torque plate.

M. Put the new rivets (120) through the wear plates and torque plate.


Brake Assembly 32-48-10

Documents

piston inspection

torque plate inspection

pressure plate inspection

washer inspection

checkgeneral inspection

spring inspection

bolt inspection

nut inspection