Cleveland Wheels & Brakes Conversion Kit Installation Manual

SECTION SUBJECT PAGE 1. Introduction 1 2. TSO Notice 1 3. Applicability 2 4. Order Information 2 5. Description 2 6. Operation 2 7. Installation 3 - 10 8. Weight and Balance 10 9. Flight Manual Inserts 10 10. Metallic Brake Lining Procedure 10 11. Warranty Registration 10 12. Kit Parts List 11 INSTALLATION INSTRUCTIONS Cleveland Wheels & Brakes Conversion Kit 199-220A Jan. 25, 2002 Page 1 1. INTRODUCTION 1.1 This manual is published for the guidance of personnel responsible for the installation of Cleveland Conversion Kit 199-220A. It is permissible to use Flight Manual Supplement P/N 129-590000-31, Revision No. 4 or latest revision, in conjunction with Parker Hannifin Aircraft Wheel and Brake Division Main Wheel and Brake Conversion Kit 199-220A (Ref. USA DOT FAA STC No. SA1789GL). 1.2 Brake De-ice: Unless the aircraft has the optional brake de-icing equipment, the 199-220A kit contains all materials and instructions needed to replace existing equipment with Cleveland Wheels and Brakes. If the aircraft has the Beech brake de-icing equipment, then either two 199-212 or 199- 213 Kits are required. These kits must be purchased separately. The Cleveland 199-213 Kit contains all materials and instructions needed to replace one Beech P/N 114-81088-5 Brake De-ice Manifold with one Cleveland P/N 139-29900 Brake De-ice Manifold. Please refer to figure 1 of this manual for illustrations of Beech P/N 114-810088-5. Kit 199-212 is designed to replace two Beech P/N 101-810072-1 Brake De-ice Manifold Support Assemblies which fasten to Beech P/N 101-810071-1 Brake De-ice Manifold. The 199-212 Kit is designed to retrofit one strut equipped with Beech P/N 101-810071-1. Please refer to figure 1 of this manual for illustrations of Beech P/N 101-810071-1 Brake De-ice Manifold. 2. TSO NOTICE 2.1 The wheel and brakes used in this conversion kit carry a “TSO” marking which identifies them as having been fully laboratory tested and qualified to meet the applicable Federal Aviation Agency (FAA) specifications and requirements. 2.2 After final certification, substitution of critical parts or changes of processes or materials are not permitted without requalification of the assemblies and resubmittal of the test data to the FAA for approval. 2.3 FAA regulations subject both Parker Hannifin, Aircraft Wheel and Brake Division and the user to constant surveillance to assure that uncompromising Quality Assurance materials and processing controls are maintained in order to provide replacement parts that are the same as the parts originally certified in the assembly. INSTALLATION INSTRUCTIONS Cleveland Wheels & Brakes Conversion Kit 199-220A Aug. 31, 2001 Page 2 3. APPLICABILITY 3.1 “KIT 199-220A” MAKE MODELS Beech *1900D *only models equipped with Hydro-Aire Mark III Anti-Skid system 4. ORDER INFORMATION 4.1 To order spare parts, contact the nearest Parker Hannifin, Aircraft Wheel & Brake distributor in your area, or call Parker Hannifin, Aircraft Wheel & Brake Division, Customer Service for assistance at: 1-800-272-5464 or (440) 937-9211 Fax: (440) 937-5409 5. DESCRIPTION 5.1 The brake is a single fixed cylinder, 5 piston, hydraulically operated, and internal dual floating disc design. The brake is designed for use with MIL-H-5606 hydraulic fluid and to withstand 1,000 psi operation pressure with zero psi back pressure. The 30-204A brake assembly is composed of the parts listed in the 30-204A Brake Assembly Component Maintenance Manual. 5.2 The wheel is forged aluminum and conforms to all Tire and Rim Association Standards for a 22 x 6.75-10 divided type wheel. The wheel can be used in either a tubeless or tube-type application. It incorporates an O-ring seal. The inner wheel half flange will drive the dual free floating discs. Rubber lip seals on both wheel halves protect the bearings. The wheel is also equipped with an anti- skid compatible hubcap. The 40-273B wheel assembly is composed of the parts listed in the 40- 273B Wheel Assembly Component Maintenance Manual. 6. OPERATION 6.1 Braking action begins to occur when hydraulic pressure is applied to the brake. As the hydraulic pressure builds it will overcome the spring force in the retract assemblies and cause the piston insulators to force the pressure plate assembly, rotating discs, stationary discs and back plate assembly together. The normal force and friction between the rotating and stationary components is responsible for generating brake torque. The brake torque is transmitted to the wheel drive keys by the rotating discs tabs. INSTALLATION INSTRUCTIONS Cleveland Wheels & Brakes Conversion Kit 199-220A Aug. 31, 2001 Page 3 7. INSTALLATION 7.1 Jack aircraft per Beech Service Manual. 7.2 Deflate Main Wheels completely. 7.3 Remove the screws securing the hubcap to the wheel and remove hubcap. Cut the safety wire and remove the screws and washers that retain the lock ring. Remove the lock ring. Discard the safety wire, screws, washers, and lock ring.. 7.4 Remove the wheel-retaining nut (Beech P/N 114-810062-1). Keep the retaining nut. Remove the key washer and any washers between the key washer and the bearing cone. Discard key washer and additional washers 7.5 Remove existing main gear wheels. 7.6 If the aircraft is equipped with the optional Beech Brake De-ice system, disconnect brake de-ice hose assembly using a 1 in. open end wrench. If the aircraft is equipped with the Beech P/N 101- 810071-1 Brake De-icing Manifold, remove and retain the sixteen (16) Beech P/N 130909814 bolts and AN960-10L washers which fasten the brake de-icing manifold to the brake support bracket. Retain also the brake de-icing manifold P/N 101-810071-1. The sixteen (16) MS21042L3 nuts may be discarded. 7.7 Disconnect lower hydraulic line from swivel kit using a 9/16 in. open end wrench, and cap hydraulic line tightly. See view A-A of installation drawing 50-156. Figure 1 INSTALLATION INSTRUCTIONS Cleveland Wheels & Brakes Conversion Kit 199-220A Aug. 31, 2001 Page 4 7.8 Remove and discard the two (2) brake tie bolts (analogous to Item #3 on 50-156 drawing). 7.9 Remove both brake assemblies from strut. 7.10 Disassemble swivel kit and remove O-ring seals. Clean all metal swivel kit parts. - NOTE - The brake inlet fittings (Beech P/N 9535088) must be removed from the old brake assemblies and installed into the new brake assemblies. 7.11 Reassemble Beech Swivel Kit with O-rings, items #6 and #7 on the 50-156 installation drawing. Figure 2 7.12 If the aircraft is not equipped with Beech Brake De-ice, mount the cylinders on opposite sides of the strut making sure that the cylinder bottoms on the strut and the torque ring engages the gear lug. 7.13 If the aircraft is equipped with Beech brake de-ice, refer to the brake de-ice installation manual before proceeding further. INSTALLATION INSTRUCTIONS Cleveland Wheels & Brakes Conversion Kit 199-220A Aug. 31, 2001 Page 5 Figure 3 7.14 Install the swivel fitting (hydraulic “T” fitting) between the two brake assemblies. - NOTE - The brake is nonhanded. The plug and inlet fitting may be moved to the opposite ports if needed. INSTALLATION INSTRUCTIONS Cleveland Wheels & Brakes Conversion Kit 199-220A Aug. 31, 2001 Page 6 7.15 Draw the two cylinder assemblies together using the two brake tie bolts, two nuts, and four washers shown as items 3, 4 and 5 on the 50-156 installation drawing. Using MIL-T-5544 anti-seize, lubtork these bolts to 175-190 in-lbs. - NOTE - The countersunk side of the washer (P/N 095-02800) must interface with the bolt head (P/N 103-24400). Figure 4 INSTALLATION INSTRUCTIONS Cleveland Wheels & Brakes Conversion Kit 199-220A Aug. 31, 2001 Page 7 7.16 Unplug the lower hydraulic line and re- attach this line to the swivel fitting. 7.17 If the aircraft has brake de-ice, wait until the aircraft is lowered off of the jacks before beginning to re-attach the brake de-ice hose assembly. 7.18 Check the master cylinder fluid reservoir and add fluid as required. 7.19 Bleed the brakes per Raytheon Aircraft Beech 1900D Airliner Maintenance Manual instructions (ref. 32-41-01). - NOTE - Brake assembly 30-204A has two bleeder fittings. Bleed both fittings. Figure 5 - CAUTION - DO NOT ALLOW THE RESERVOIR TO BECOME EMPTY DURING BLEEDING. 7.20 The wheel assemblies are shipped from the factory as a complete assembly. The bearings are packed with grease and installed in the wheel halves. - NOTE - Extended storage of lubricated bearings may require relubrication. 7.21 Remove grease seals and bearing cones from the wheel assembly and place on a clean surface to avoid contamination. 7.22 To separate wheel halves remove nuts, countersunk washers, plain washers, and tie bolts which hold the wheel halves together for shipment. 7.23 Position outer wheel half on a flat surface with the register side facing up. 7.24 Place serviceable tire over outer wheel half and install tube in tire if applicable. 7.25 Next, lubricate O-ring seal with Dow Corning Molykote 55M grease or equivalent and position on register portion of inner wheel half. INSTALLATION INSTRUCTIONS Cleveland Wheels & Brakes Conversion Kit 199-220A Aug. 31, 2001 Page 8 - CAUTION - SEAL SHOULD NOT BE TWISTED, BUT FULLY ALIGNED IN THE GROOVE. 7.26 Place inner wheel half in tire making sure to properly align inner and outer registers on wheel as well as valve stem on tube if applicable. 7.27 Coat both surfaces on the countersunk washers and under the bolt head of the 8 (eight) wheel tie bolts with MIL-T-5544 Anti-Seize compound, then slide the tie bolts through wheel assembly. - CAUTION - THE COUNTERSUNK SIDE OF COUNTERSUNK WASHER MUST BE TOWARD THE BOLT HEAD. Coat both surfaces of the plain washers and the treaded portion of the bolt shank with MIL-T-5544 Compound. Install plain washers and nuts on the outer wheel half and torque to 300 in-lbs. When all nuts have been torqued, retorque a second time to make sure that the required torque value has been achieved. The wheel may now be inflated to proper pressure in a safety cage. 7.28 Inspect bearing cone for contamination and/or solidification at every periodic inspection. If required, repack wheel bearings with grease per MIL-G-81322 (Aeroshell 22) or equivalent. 7.29 Check for burrs or rough threads on axle and axle nut. Install bearing cone and grease seal into the inner wheel half. 7.30 Mount the wheel and tire assembly on the axle. Make sure that the wheel drive keys engage the brake disc lugs. If the wheel fails to engage both discs, simultaneously lift up on the inboard disc and push the wheel towards the center of the strut. 7.31 Install bearing cone and grease seal into outer wheel half assembly. Install retaining ring in outboard wheel half subassembly (optional). -NOTE- Retaining ring installation is not required. The retaining ring is provided to prevent the grease seal and bearing cone from falling out of the wheel assembly when the wheel assembly is not installed on the axle. Apply a thin coat of bearing grease to both sides of tang washer (Parker P/N 095-75200). Install tang washer (Parker P/N 095-75200) onto axle. INSTALLATION INSTRUCTIONS Cleveland Wheels & Brakes Conversion Kit 199-220A August 15, 2002 Page 9 - CAUTION - BE SURE TO USE ONLY THE PARKER P/N 095-75200 TANG WASHER, PARKER P/N 139- 34900 LOCK RING, PARKER P/N 102-33600 SCREWS AND PARKER P/N 095-13800 WASHERS. THESE COMPONENTS ARE DESIGNED TO INSURE THAT THE AXLE NUT CASTELLATIONS WILL ALIGN WITH THE LOCKING HOLES IN THE AXLE AT THE PROPER TORQUE. Apply a thin coat of bearing grease to the axle nut threads (Beech P/N 114-810062-1). Install axle nut. Tighten axle nut to 150 to 200 in.-lbs. of torque while rotating the wheel to insure proper seating of the bearings. -NOTE- Do not allow the wheel to rotate while backing off the axle nut. Back the axle nut off to zero in.-lbs. of torque, then torque the axle nut until the grease seal does not rotate when rotating the wheel. Tighten the axle nut (Beech P/N 114-0810062-1) so that the next available castellation is aligned with a through hole in the axle threads. Do not exceed 200 in.-lbs. of torque or 30° of rotation of the axle nut. -NOTE- IF MORE THAN 200 IN-LBS OF TORQUE ARE REQUIRED TO ALIGN THE HOLE WITH THE NEXT AVAILABLE CASTELLATION THEN REMOVE THE AXLE NUT AND INSTALL ONE SPACER (PARKER P/N 095-75400); TORQUE THE AXLE NUT UNTIL THE GREASE SEAL DOES NOT ROTATE WHEN ROTATING THE WHEEL. TIGHTEN THE AXLE NUT (BEECH P/N 114-0810062-1) SO THAT THE NEXT AVAILABLE CASTELLATION IS ALIGNED WITH A HOLE IN THE AXLE THREADS. DO NOT EXCEED 200 IN-LBS OF TORQUE OR 30° OF ROTATION OF THE AXLE NUT. Install lock ring (Parker P/N 139-34900), lock ring retaining screws (Parker P/N 102-33600), and washers (Parker P/N 095-13800). Torque lock ring retaining screws to 8 to 15 in.-lbs. Safety wire retaining screws per NASM33540. It is permissible to use either MS20995C20 OR MS20995C32 safety wire. -NOTE- Final axle nut torque must not exceed 200 in-lbs. 7.32 Refer to Figure 6 and fasten hubcap assembly to wheel assembly making sure that the hubcap drive coupling engages the wheel speed transducer. Lubricate the hubcap attachment fastener threads with MIL-T-5544 anti-seize compound. Secure hubcap with washers and screws. Torque the hubcap attachment fasteners to 20 - 25 in-lbs. Figure 6 INSTALLATION INSTRUCTIONS Cleveland Wheels & Brakes Conversion Kit 199-220A May, 2001 Page 10 7.33 Repeat the procedure to install the second wheel and tire on the opposite side of the strut. 7.34 Repeat this procedure for both struts. 7.35 After lowering aircraft off of the jacks, re-attach both brake de-ice hose assemblies (if applicable). 8. WEIGHT AND BALANCE COMPUTATIONS Weight: 39.0 lbs. per wheel and brake assembly. The weight does not include a tire. Complete Form 337 and make appropriate log book entries. 9. AIRCRAFT FLIGHT MANUAL AND EQUIPMENT LIST ENTRIES 9.1 Update the “Weight and Balance” Section of the Aircraft Flight Manual as well as the Aircraft Equipment List for the change in both weight and moment created by the installation of this conversion kit. 10. METALLIC BRAKE LINING CONDITIONING PROCEDURE 10.1 The brake lining material used in this brake assembly is a copper based metallic composition. This material must be properly conditioned (glazed) in order to provide optimum service life. 10.2 Dynamometer tests have shown that at low braking energies, unglazed linings experience greater wear and the brake discs become severely scored. 10.3 Conditioning may be accomplished as follows: 10.3.1 Perform two (2) full stop braking applications from 30 to 35 knots, allowing the brake disc to cool between each stop. 10.3.2 This conditioning procedure will wear off high spots and generate sufficient heat to glaze the lining. Once the lining is glazed, the brake system will provide many hours of maintenance free service. 10.3.3 If the brakes are used exclusively for low speed (below 25 kts) applications, then periodic conditioning is recommended to optimize service life. 11. WARRANTY REGISTRATION 11.1 Completely fill out enclosed warranty card and return promptly. Postage is prepaid. INSTALLATION INSTRUCTIONS Cleveland Wheels & Brakes Conversion Kit 199-220A Jan. 11, 2002 Page 11 12. KIT PARTS LIST AIRCRAFT WHEEL AND BRAKE DIVISION PARKER HANNIFIN CORPORATION AVON, OHIO PARTS LIST 199-220A CONVERSION KIT BEECH 1900D PART NO. CODE NO. DESCRIPTION QUANTITY 30-204A 030-20401 Brake Assembly 4 40-273B 040-27302 Wheel Assembly 4 MS21250-05040 103-24400 Bolt MS21250-05040 4 095-02800 095-02800 Washer MS20002C5 8 NAS1804-5N 094-16400 Nut 4 MS28775-112 101-50337 O-Ring 4 MS28778-4 101-20400 O-Ring 4 095-75200 095-75200 Washer 4 139-34900 139-34900 Lock Ring 4 102-33600 102-33600 Screw 8 095-13800 095-13800 Washer, AN960-8 8 095-75400 095-75400 Washer 4 * 199-212 Brake De-ice Manifold Support Kit 2 or * 199-213 Brake De-ice Manifold Kit 2 199-220A Manual Installation Manual 1 50-156 Drawing 1 THIS KIT WILL CONVERT ONE AIRCRAFT TO CLEVELAND WHEELS & BRAKES NOTE: For use with MIL-H-5606 (Red Fluid) * Optional - Two 199-212 or two 199-213 Kits are required if aircraft is equipped with Beech Brake De-ice system. These Kits must be purchased separately. CLEVELAND WHEELS AND BRAKES COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST BRAKE ASSEMBLY PART NO. 30-204A Aerospace Aircraft Wheel & Brake Division Parker Hannifin Corporation 1160 Center Road Avon, OH 44011 Aerospace CLEVELAND WHEELS & BRAKES CM30-204A COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST FOR BRAKE ASSEMBLY PART NUMBER 30-204A REVISION D DATED 17 MARCH 2004 Aircraft Wheel & Brake Division Parker Hannifin Corporation 1160 Center Road U.S.A. Avon, Ohio 44011 March, 2004 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A RECORD OF REVISIONS REV NO. ISSUE DATE DATE INSERTED BY REV NO. ISSUE DATE DATE INSERTED BY A 9-15-94 9-15-94 PH B 3-28-96 3-28-96 PH C 9-19-03 9-19-03 PH D 3-17-04 3-17-04 PH Record of Revisions Page 1/1 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A LIST OF REVISIONS INITIAL RELEASE DATED 4 APRIL 1994 REVISION _DATE_ PAGE __________DESCRIPTION OF CHANGE__________ Rev. A 9-15-94 Table of 5. Repair of Base Plates 505 -Added- Contents(p.2) 6. Repair of Adjuster Assembly 507 -Added- Description & “26.1 lbs.” -was- “23.8 lbs.” Operation(p.2) 102 K. “The two Bleeder Seats (Item #22) and Bleeder Screws (Item #23) must also be removed from the cylinder along with the Bleeder Plug(Item #25). When these items are” - was - K. “The two Bleeder Seats (Item #22) and Bleeder Screws (Item #23) can also be removed from the cylinder (if necessary).along with the Bleeder Plug (Item #25). If these items are” 303 A. “.525 - .570” -was- “.537 - .570” 502 D. “The Pressure Plate (Item #7) or Center Stator (Item #11) may be straightened by either Cold Straightening or Draw Flattening. Draw Flattening is the preferred method. Refer to the Repair of Base Plates for details.” - was - D. “The Pressure Plate may be ground within the flatness requiremetns provided that the thickness of the Pressure Plate (Item #7) exceeds .125 in. after grinding. Similarly, the Center Stator (Item #11) and Back Plate (Item #16) may be ground flat provided the finished thicknesses exceed .130 in. and .115 in. respectively. (All thickness measurements must be taken at the bolt circle diameter of the outer rivet holes.” Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A REVISION _DATE_ PAGE __________DESCRIPTION OF CHANGE__________ Rev. A 503 G. “If not, repair” -was- “If not, grind flat” (Cont’d) 505 - ADDED - New page with Section 5, A and B 506 - ADDED - New page with Figure 502 507 - ADDED - New page with Section 6, A thru F, and Figure 503 1003 139-30200 Subass’y Brake De-ice Manifold -ADDED- or 139-30300 Subass’y Brake De-ice Manifold all pages “CM 30-204A COMPONENT MAINTENANCE “ -WAS- “OVERHAUL” Rev. B 3-28-96 Description “Primer: Columbia Paint Corporation 11-347Z Primer” & Operation -was- Page 2 “Primer: Sherwin Williams P60G2 Primer” “Topcoat: Columbia Paint Corporation 11-358A Gloss White Enamel” -was- “Topcoat: Sherwin Williams F63W13 White Polyurethane 302 Section J. “.....that measure .405 inches or less in height.” -was- “ ....that measure .375 inches or less in height (.032 inches above piston when installed).” 303 Sections S., T., and U. “.....repair or replace...” -was- “.....replace....” 501 “Columbia Paint Corporation 11-347Z Primer” “Columbia Paint Corporation Huntington W. VA. -was- “Epoxy Polyamide Primer Specification Mil-P-23377” “Commercially Available” Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A REVISION _DATE_ PAGE __________DESCRIPTION OF CHANGE__________ Rev. B 501 “Columbia Paint Corporation 11-358A Gloss (Cont’d) White Enamel” “Columbia Paint Corporation Huntington W. VA. -was- “White Polyurethane Topcoat Specification MIL-C-83286” “Sherwin Williams Commercial Products Division 761 Beta Drive Mayfield Village, Ohio 44143” ADD: “Galvilite Galvanizing Compound (MIL-P-26915A)” “ZRC Products Quincy, Mass.” “XXX Thinner” “ZRC Products Quincy, Mass.” 504 “CAUTION: DO NOT TOPCOAT OR .....” -was- “CAUTION: DO NOT PAINT OR .....” 3.D. “The outside of the housing should be primed (.0002 to .0005 dry film thickness) and topcoated (.0008 to .0014 inch dry film thickness including primer).” -was- “The outside of the housing should be primed with epoxy polyamide primer per MIL-P-23377, and painted with one coat of White Polyurethane topcoat per MIL-C-83288.” 505 ADD Section 5.C., Painting base plates... 601 Section 2.C. “....to 65-70 in.-lbs.” -was- “....to 180-200 in.-lbs.” Sections 2.D. & 2.E. “....to 65-70 in.-lbs.” -was- “....to 160-180 in.-lbs.” 603 Section 2.L. “Torque snug to preclude leakage.” -was- “Torque to 30-35 in.lbs.” Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A REVISION _DATE_ PAGE __________DESCRIPTION OF CHANGE__________ Rev. B 604 Section 2.Z. “Pressurize to 360 psi ± 50 psi to set (Cont’d) retracts and check for leaks. It is permissible to perform this test off-aircraft on an individual brake assembly.” -was- “Pressurize to approximately 360 psi to set retracts and check for leaks.” Rev. C 9-19-03 SB List Add Service Bulletin “SB7079” Rev. No. “NC” (DCN 0357-83) 1002 Add Item 19A Call-out 1003 Item 19: Add Notation “SUPSD BY Item 19A, (refer to Parker Hannifin Service Bulletin SB7079)” Add Item 19A: “P/N 065-15401, Torque Ring, SUPSDS Item 19, Qty 1” Add Item 38: “P/N 139-29900, Assembly, Brake De-ice Manifold, Item 19, Qty 1” Remove Line item for: “P/N 139-30200, Subassy, Brake De-ice Manifold, Qty 1.” Remove Line item for: “P/N 139-30300, Subassy, Brake De-ice Manifold, Qty 1.” Add Flagnotes: “1: Optional Equipment. Refer to Parker Hannifin Conversion Kit, P/N 199-212.” “2: Optional Equipment. Refer to Parker Hannifin Conversion Kit, P/N 199-213.” Add definitions for abbreviations used: “- Item is not illustrated.” “SUPSD BY The part in the part number column is replaced by and is not interchangeable with interchangeable with the item number shown in the notation.” “SUPSD The part in the part number column replaces and is not interchangeable with interchangeable with the item number shown in the notation.” Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A REVISION _DATE_ PAGE __________DESCRIPTION OF CHANGE__________ Rev. D 3-17-04 301 (DCN 0360-24) (Now) Zyglo ZL-60D Zyglo ZP-4B, ZP-9F, ZP-5B, or SKD-S2 Fluorescent Zyglo ZL-2C, with emulsifier/rem over ZE-4B Zyglo ZP-4B, ZP-9F, ZP-5B, ZP-14A or SKD-S2 Magnaflux Corp. 3624 West Lake Ave. Glenview, IL 60025 www.magnaflux.com Ph. 847-657-5300 Fax. 847-657-5388 e-mail: info@magnaflux.com (Was) Fluorescent Zyglo ZL-16 Zyglo ZP-13 (wet) optional Penetrex ZL- 2A with emulsifier ZE- 4 Penetrex ZP-4 (dry) or ZP-13 optional Magnaflux Corp. 7300 West Lawrence St. Chicago, IL 60656 303 (Add (ref. paragraph N)) Check the five torque ring stationary disc engagement lugs for battering. If the drive lug width is less than .650 inches, replace the Torque Ring (Item #19). Record of Revisions Updated to reflect Rev. D Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A SERVICE BULLETIN LIST SERVICE BULLETIN NO. REV. NO. DATE INCORPORATED SERVICE BULLETIN NO. REV. NO. DATE INCORPORATED SB7079 NC Service Bulletin List Page1/1 Rev. C September 19, 2003 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A Table of Contents Subject Page INTRODUCTION 1 DESCRIPTION AND OPERATION 1 1. Description and Operation 1 2. Leading Particulars 2 DISASSEMBLY 101 1. General 101 2. Disassembly Procedures 101 CLEANING 201 1. Cleaning Materials 201 2. Cleaning Procedures 201 3. Paint Removal Procedures 202 CHECK 301 1. Check Materials 301 2. General 301 3. Detailed Check 301 Table of Contents Page 1 April 4, 1994 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A Table of Contents Subject Page REPAIR 501 1. General 501 2. Replacing Wear Pads 502 3. Repair of Cylinders 503 4. Repair of Pistons 503 5. Repair of Base Plates 505 6. Repair of Adjuster Assembly 507 ASSEMBLY 601 1. Assembly Materials 601 2. Assembly Procedures 601 TROUBLE SHOOTING 701 WEAR LIMITS 801 1. General 801 2. Wear Pads 802 3. Discs 803 ILLUSTRATED PARTS LIST 1001 1. Introduction 1001 2. Exploded View 1002 3. Parts List 1003 Table of Contents Page 2 April 4, 1994 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A INTRODUCTION This manual is published for the guidance of personnel responsible for the overhaul and/or maintenance of the Parker Hannifin 30-204A Brake Assembly covered in this publication. The procedures outlined in this manual may be altered if better and/or more economical methods can be employed by the individual facilities. However, alternative procedures must not reduce the efficiency of operation of the assembly. NOTE: All torque values and specified limits or values set by Parker Hannifin Engineering and contained herein must be strictly observed and not deviated from. While Parker Hannifin Corporation represents that the information contained in this manual was current at the time of publication, it is recommended that the user inquire as to the latest revision level in existence before proceeding with overhaul or maintenance operations. This can be accomplished by contacting the Product Support Department of the Aircraft Wheel & Brake Division at the following address or numbers: Parker Hannifin Corporation Aircraft Wheel & Brake Division Attn: Product Support Dept. 1160 Center Road Avon, Ohio 44011 Phone: (216) 937-6211 1-800-272-5464 Fax: (216) 937-5409 Introduction Page 1 April 4, 1994 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A TSO NOTICE This assembly carries a “TSO C26c” marking for FAR Part 23 usage, which identifies it as having been fully tested in the laboratory and qualified to applicable FAA (Federal Aviation Administration) requirements and specifications. After final certification, substitutions of critical parts or changes of processes or materials are not permitted without requalification of the assembly and resubmittal of the test data to the FAA for approval. FAA regulations subject both Parker Hannifin, Aircraft Wheel & Brake Division and the user to constant surveillance to assure that uncompromising quality assurance material and processing controls are maintained in order to provide replacement parts that are the same as the parts originally certified in the assembly. DATA RIGHTS The unit charge for this manual covers reproduction and handling costs only and does not constitute purchase of the data or design contained herein, nor does it convey to the purchaser any rights, patent or otherwise, to reproduce or manufacture from said data. Introduction Page 2 April 4, 1994 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A DESCRIPTION AND OPERATION 1. Description and Operation A. The Parker Hannifin 30-204A Brake Assembly is a piston actuated, hydraulically operated dual rotor unit that is designed to be compatible with MIL-H-5606 and MIL-H-83282 hydraulic fluids. The brake assembly is a nonhanded unit and can be used on the opposite side of the strut by simply switching the fittings on top of the housing to the opposite port. The 30-204A Brake Assembly is designed to be used with the 40-273A Wheel Assembly. B. Each Brake Assembly is composed of the following: One Cylinder Sub- assembly, one Pressure Plate Sub-assembly utilizing replaceable steel wear pads, two Rotating Discs with sintered friction material on the core, one Cast Steel Torque Tube, one Backplate Subassembly with replaceable steel wear pads, five high strength Bolts and Washers, one Center Stator Assembly with replaceable steel wear pads, and four pressure plate retraction mechanisms. C. Each of the five pistons contains an O-Ring groove to prevent leakage of hydraulic fluid past the pistons. D. An Insulator slides into the pocket of each piston in order to shield the brake fluid from the heat generated during braking. E. This manual specifies minimum wear dimensions that must be checked when the brake is off of the aircraft for periodic servicing intervals. F. The 30-204A Brake Assembly is designed in such a way that there is a built in running clearance on the wear components that prevents excessive drag from occurring. G. The brake also utilizes four pressure plate retraction mechanisms to minimize brake drag and maximize lining life. Description & Operation Page 1 April 4, 1994 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A H. Braking action begins to occur when hydraulic pressure is applied to the brake, via the pilot’s or copilot’s master cylinders. As the hydraulic pressure reaches the brake it forces the pistons in the cylinder housing outward against the pressure plate which contacts the inboard disc, center stator, outboard disc and backplate. The frictional force of the wear components generates torque in the brake which is transmitted into the wheel/tire and slows the aircraft. 2. Leading Particulars Hydraulic fluid...................................................................... MIL-H-5606 or MIL-H-83282 Normal Operating Pressure ................................................ 275-325 psi. Running Clearance in Brake ............................................... .015 in. nominal Weight of Brake Assembly ................................................... 26.1 Lbs. Cylinder Housing Material .................................................... C355 T6 Cast Aluminum O-Ring Compound ............................................................... Parker N304-75 (Nitrile) Cylinder Coatings ................................................................ Anodize: MIL-A-8625, Type I, Class 1 Primer: Columbia Paint Corporation 11-347Z Primer Topcoat: Columbia Paint Corporation 11-358A Gloss White Enamel Description & Operation Page 2 April 4, 1994 Rev. B, March 28, 1996 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A DISASSEMBLY 1. General Disassemble the brake assembly in accordance with the following instructions (Ref. IPL Fig. 1). 2. Disassembly Procedures A. After the main wheel and tire have been removed, disconnect hydraulic lines and cap open lines and ports. B. Disconnect Beech Swivel Kit (99-80003-27) and remove the bolts, nuts, and washers which fasten the two brake assemblies together. C. Unfasten the deicing tubes from the mounting bracket (if the plane has this optional equipment). D. Slide the assembly off of the axle and place it on a clean flat surface. E. Remove the five Bolts and Washers (Item #20 and #21) which fasten the assembly. F. Remove the Back Plate Assembly (Item #15), the Torque Ring (Item #19), the two Rotors (Item #10), and Center Stator (Item #11). G. Unscrew the four Internal Wrenching Adjuster Assemblies (Item #26). H. Remove the Pressure Plate Assembly (Item #6) with the four Retraction Base Assemblies (Item #34) still in the pressure plate pockets. Page 101 April 4, 1994 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A Ι. The four retraction base assemblies can then be removed from the pressure plate assembly. J. Remove the five Piston Insulators (Item #5), O-rings (Item #4), and Pistons (Item #3) by threading an AN4 (or any other Ø .250-28 UNF-3B bolt) into the pistons and pulling them from the cylinder. K. The two Bleeder Seats (Item #22) and Bleeder Screws (Item #23) must be removed from the cylinder along with the Bleeder Plug (Item #25). When these items are removed, the three O- Rings (Item #24) must be replaced upon reassembly. L. The remainder of the four Adjuster Assemblies (Item #26 less Item #34 which is in the pressure plate assembly) can be removed from the cylinder (if necessary) by removing the four Snap Rings (Item #32). M. Drain hydraulic fluid from housing. Page 102 April 4, 1994 Rev. A, Sept. 15, 1994 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A CLEANING 1. Cleaning Materials NOTE: EQUIVALENT SUBSTITUTES MAY BE USED FOR ITEMS LISTED BELOW. Dry Cleaning Solution Specification P-D-680 Stoddard Solvent Commercially Available Isopropyl Alcohol Specification TT-I-735 Commercially Available Soft Bristle Brush Commercially Available Clean Wiping Cloth Commercially Available 2. Cleaning Procedures WARNING: CLEANING SOLUTIONS SHOULD BE USED IN A WELL VENTILATED AREA. AVOID PROLONGED INHALATION OF FUMES. A. Clean all metal parts, except Discs (Item #10), by immersing in dry cleaning solution conforming to specification P-D-680. Use a soft bristle brush to remove hardened grease, dust, and dirt. B. Clean rotating Discs (Item #10) with compressed air and a stiff bristle or wire brush. C. Dry all metal parts thoroughly after cleaning, using filtered and dried compressed air. D. Clean Piston Insulators (Item #5) in isopropyl alcohol and dry with a clean, soft cloth. E. All O-Rings must be replaced at each overhaul. Page 201 April 4, 1994 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A 3. Paint Removal Procedures A. Remove paint from the cylinder using chemical paint removal solvents or plastic media stripping in accordance with the following instructions. WARNING: DUE TO THE TOXICITY OF CHEMICAL PAINT REMOVAL SOLVENTS, IT IS HIGHLY RECOMMENDED THAT PAINT REMOVAL BY THIS METHOD BE ACCOMPLISHED BY A COMMERCIAL FACILITY WITH THE PROPER EQUIPMENT AND CHEMICAL DISPOSAL CAPABILITIES. CAUTION: REFER TO THE APPLICABLE MANUFACTURERS INSTRUCTIONS WHEN UTILIZING CHEMICAL PAINT REMOVAL SOLVENTS OR PLASTIC MEDIA STRIPPING EQUIPMENT. B. Completely disassemble the brake prior to paint removal. NOTE: REFER TO “REPAIR” FOR RETREATING AND REPAINTING CYLINDER. Page 202 April 4, 1994 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A CHECK 1. Check Materials NOTE: EQUIVALENT SUBSTITUTES MAY BE USED FOR ITEMS LISTED BELOW: Type Penetrant Developer Supplier Zyglo ZL-60D Zyglo ZP-4B. ZP-9F, ZP-5B, or SKD-S2 Fluorescent Zyglo ZL-2C with emulsifier/remover ZE-4B Zyglo ZP-4B, ZP-9F, ZP-5B, ZP-14A, or SKD-S2 Red Dye Spot Check Spot Check Magnaflux Corp. 3624 West Lake Ave. Glenview, IL 60025 www.magnaflux.com Ph. 847-657-5300 Fax. 847-657-5388 e-mail: info@magnaflux.com Dy-Chek Dy-Chek Turco Products Division of Purex Corp. P.O. Box 6200 Carson, CA 90749 Met-L-Chek Met-L-Chek Met-L-Chek Company 1639 Euclid Street Santa Monica, CA 90404 2. General (Ref. IPL Fig. 1) A. Check all components of the brake assembly for cracks, nicks, corrosion, and other damage. Replace any cracked, severely corroded, or badly damaged parts. B. Perform the specific checks listed below and refer to REPAIR for the appropriate repair procedures. 3. Detailed Check (Requires stripping topcoat and primer) A. Check the Brake Cylinder and Torque Ring (Items #2 and 19) for cracks and structural damage. NOTE: Parker recommends that the Brake Cylinder and Torque Ring (Items #2 and #19) be penetrant inspected at every brake overhaul (due to lining being worn below minimum limits). Page 301 April 4, 1994 Rev. D March 17, 2004 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A NOTE: CHECK BRAKE BY ZYGLO OR OTHER DYE-PENETRANT METHODS. REPLACE ALL CRACKED CYLINDERS AND TORQUE RINGS. B. Check the Backplate Assembly (Item #15), Center Stator (Item #11), and Pressure Plate Assembly (Item #6) for loose, cracked, or worn wear pads; replace all wear pads if three or more wear pads are worn below .080 in. in thickness. Replace all loose or cracked wear pads. C. Check discs for cracks. Replace any cracked Discs (Item #10). D. Check disc thickness. Replace any disc whose thickness is .205 in. or less, or if there is less than .010 in. of mix at any unchipped point on the entire face of the Disc (Item #10). E. Check Disc (Item #10) drive tangs for wear and battering. Replace discs if one or more tangs are bent, battered, severely corroded or cracked. F. Check Center Stator (Item #12) for cracks and corrosion. Replace any cracked or severely corroded center stators. G. Check corners of the center stator key slots (the slots which engage the torque tube) for both cracks and wear. If the width of any key slot is .802 inches or greater, replace the center stator; if any of the key slots contain cracks, replace the center stator. H. Check Pressure Plate (Item #7) for cracks (especially in the key slot area) and wear. If the width of any key slot is .802 inches or greater, replace the pressure plate; if any of the key slots contain cracks, replace the pressure plate. I. Check all Pistons (Item #3) for nicks, scratches, burrs, and wear. Measure the outside diameter of the piston at three places. Replace all pistons whose outside diameter measures 1.485 inches or less at any location. Replace all pistons with a nick or scratch .003 inch deep or more. Pistons with defects of a depth less than .003 inch can be repaired per the section of this manual entitled REPAIR. J. Check the Piston Insulators (Item #5) for deterioration. Replace all piston insulators that show signs of deterioration or that measure .405 inches or less in height. K. Install new insulators per REPAIR. Page 302 April 4, 1994 Rev. B March 28, 1996 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A L. Check the condition of the threads in the inlet and bleeder ports of the Cylinder (Item #2). Replace all housings that have badly damaged threads in any port. M. Check the five piston bores for nicks, scratches, and wear. Any nicks or scratches deeper than .003 inch necessitates replacement of the Cylinder (Item #2). Measure the inside diameter of each piston bore in three places; if any measurement exceeds 1.496 inches, then replace the cylinder. Blend any nicks or scratches less than .003 inches deep per REPAIR. N. Check the torque ring strut engagement area for battering. If the width between flats exceeds 3.370 inches, replace the Torque Ring (Item #19). Check the five torque ring stationary disc engagement lugs for battering. If the drive lug width is less than .650 inches, replace the Torque Ring (Item #19). O. Check the torque ring bolt holes for elongation; replace the Torque Ring (Item #19) if any of the bolt holes becomes elongated into an ellipse with a major diameter exceeding ∅ .350 inches. P. Check the Bolts (Item #20) for thread damage. Replace thread damaged bolts. Q. Check the bolts for cracks using magnetic particle inspection methods or penetrant inspection methods. If any of the bolts are cracked, replace all of the bolts. R. Visually inspect the Retraction Assembly Parts (Items #26 through #36) for wear and damage. Replace Studs (Item #27) if threads are damaged or if the surface on the shaft contains elevated nicks. Replace the Snap Ring (Item #32) if it becomes bent or twisted during removal. Check Springs (Item 333) for load at installed height of .525-.570; the pre- load should be 21 - 23 pounds. S. Inspect the Pressure Plate Assembly (Item #6) for flatness. If the flatness exceeds .020 in. repair or replace the assembly. T. Inspect the Center Stator Assembly (Item #11) for flatness on both sides. If the flatness exceeds .015 in., repair or replace the assembly. U. Inspect the rubbed surface of the backplate assembly for flatness. If the flatness exceeds .020 in., repair or replace the assembly. Page 303 April 4, 1994 Rev. B March 28, 1996 Rev. D March 17, 2004 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A REPAIR 1. General Repair Procedures: Repair of the brake is limited to the replacement of worn or damaged parts and to the specific repairs listed in this section. The following is a list of the required repair equipment and materials and its source. (NOTE: Equivalent substitutes may be used for the items listed below): Equipment/Materials Source Columbia Paint Corporation 11-347Z Primer Columbia Paint Corporation Huntington, W. VA. Columbia Paint Corporation 11-358A Gloss White Enamel Columbia Paint Corporation Huntington, W. VA. Dry-Cleaning Solvent Specification P-D-680 (Stoddard Solvent) Commercially Available Aluminum, Oxide Cloth 400 Grit Wet-or-Dry Commercially Available Grease Dow Molykote 55M Grease Dow Corning Corp. Box 1767 Midland, MI. 48640 Sulfuric-acid Anodize Specification MIL-A-8625 Type II, Class 1 Commercially Available Chemical Conversion Coating Specification MIL-C-5541, Class 1A (Alodine) Commercially Available Galvilite Galvanizing Compound (MIL-P-26915A) ZRC Products Quincy, Mass. XXX Thinner ZRC Products Quincy, Mass. Page 501 April 4, 1994 Rev. B March 28, 1996 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A 2. Replacing Wear Pads A. Using a 3/16 (∅ .187) in. drill bit, drill out the shop head of the rivets and punch the rivets from the assembly. CAUTION: Do not enlarge the rivet holes in the base plate. If the rivet hole is enlarged to ∅ .205 in. or larger, the base plate must be replaced. B. Check the base plates for cracks using Zyglo or magnaflux methods. Replace cracked base plates. C. Check the base plates for flatness. If the flatness of any base plate exceeds .020 in., repair or replace that Base Plate (Item #7, Item #12 and Item #16). Failure to do so could result in a dragging brake. D. The Pressure Plate (Item #7) or Center Stator (Item #11), may be straightened by either Cold Straightening or Draw Flattening. Draw Flattening is the preferred method. Refer to Repair of Base Plates for details. E. Install the proper Rivet [i.e. a 105-06700 (Items #9 and #18) are used in the Pressure Plate (Item #6) and Back Plate (Item #15) Assemblies while a 105-06800 (Item #14) is used in the Center Stator Assembly (Item #11)] as shown in Figure 501. Page 502 April 4, 1994 Rev. A, Sept. 15, 1994 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A Figure 501 F. Form the shop head of the rivet using a compression rivetor. NOTE: Check the seating of the wear pads by attempting to insert a .0015 inch feeler gage must between the pad and the base plate. The gage must not pass the centerline of the wear pads between the rivets, nor should the corners of the wear pads be dished up after riveting. Loose pads, or pads whose corners dish by more than .010 TIR must be replaced. CAUTION: The Wear-padded subassemblies (Items #6, #11, and #15) are designed to maintain the rivet heads flush with or recessed below the wear pad surface. If the rivet head protrudes above the wear pad surface, it must be ground flush with the wear pad. Failure to do so could result in brake failure. NOTE: No more than two cracks are permitted in the shop head of the rivet, and no cracks are permitted to extend into the rivet shank. If the rivet has more than two cracks or has at least one crack which extends into the rivet shank, replace the rivet. G. Check to insure that the newly padded subassemblies (Items #6, #11, and #15) are flat within .020 inch. If not, repair. Page 503 April 4, 1994 Revision A, Sept. 15, 1994 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A 3. Repair of Cylinder A. Polish scratches not exceeding .003 inch deep in piston cavities with fine (400 grit) aluminum- oxide paper. WARNING: DO NOT USE ABRASIVES CONTAINING IRON SUCH AS STEEL WOOL, IRON OXIDE, OR STEEL WIRE; IRON PARTICLES WHICH BECOME EMBEDDED IN THE ALUMINUM CYLINDER WILL ACCELERATE CORROSION. B. Blend out burrs, nicks, and scratches less than .030 inch deep on the outside of the housing with 280 grit aluminum oxide paper. C. Treat reworked areas with sulfuric-acid anodize per MIL-A-8625 Type II, Class 1, or “Alodine” per MIL-C-5541 Class 1A. CAUTION: DO NOT TOPCOAT OR PRIME PISTON BORES. D. The outside of the housing should be primed (.0002 to .0005 inch dry film thickness) and topcoated (.0008 to .0014 inch dry film thickness including the primer). 4. Repair of Pistons A. Polish scratches, nicks, and burrs of up to .003 inches deep. Replace all pistons that are damaged deeper than .003 inches. B. Treat reworked areas with sulfuric-acid anodize per MIL-8625 Type II, Class 1, or “Alodine” per MIL-C-5541, Class 1A. CAUTION: DO NOT PAINT PISTONS. 5. Repair of Base Plates A. Cold Straightening (1) Pressure Plate Assemblies (Item #7) or Stator Assemblies (Item #11) which do not meet the flatness requirements of this manual may be straightened in accordance with the following instructions: (a) Remove wear pads from base plate. Page 504 April 4, 1994 Rev. B March 28, 1996 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A 5. Repair of Base Plates (Cont’d) (b) Fabricate upper and lower register plates (Ref. Fig. 501). (c) Mount upper and lower register plates in an arbor press. (d) Place dished plate or disk in lower register plate with domed side up. (e) Apply sufficient pressure with arbor press to straighten plate or disk. Base plates must be flat within .010 inch. B. Draw Flattening (1) Pressure Plate Assemblies (Item #7) or Stator Assemblies (Item #11) which do not meet the flatness requirements of this manual may be straightened in accordance with the following instructions: (a) Remove wear pads from base plate. (b) Stack base plates back-to-back between two-inch thick boiler plates with long bolts through center of stack and boiler plates. (c) Place in an oven and heat slowly to a temperature range of 1100° F (593° C) to 1150° F (621° C) and hold that temperature range for one hour. (d) Remove from oven and retighten bolts. (e) Place in an oven and heat slowly to a temperature range of 1100° F (593° C) to 1150° F (621° C) and hold that temperature range for three hours. (f) Remove from oven and air cool at room temperature; then remove bolts and separate parts. C. Painting (1) The Pressure Plate (Item #7), Center Stator (Item #12), and Back Plate (Item #16) may be stripped and repainted. Paint with Galvilite Galvanizing Compound. The dry film thickness shall be .0015 to .0030 inch. Page 505 April 4, 1994 Rev. B March 28, 1996 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A Figure 502 Page 506 Rev. A, Sept. 15, 1994 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A 6. Repair of Adjuster Assembly A. During the Overhaul Procedure, the four adjuster assemblies (Item #26) must be repaired before returning the brake to service. B. Discard any severely corroded parts. WARNING: DO NOT ATTEMPT TO REMOVE CORROSION FROM THE SPACER (ITEM #30) OR THE FRICTION SLEEVE (ITEM #29) BY SANDING. THESE PARTS HAVE BEEN CADMIUM PLATED, AND INHALATION OF CADMIUM DUST CAN BE HAZARDOUS TO YOUR HEALTH. C. If the friction sleeve (Item #28) can be moved on the stud (Item #27) by a force of thirty pounds or less, replace the friction sleeve. D. If the friction sleeve (Item #28) is not flush with the sleeve retainer (Item #29), use a vice or an arbor press to install the friction sleeve flush into the sleeve retainer. E. Use a vice or an arbor press to reset the spacer (Item #30), friction sleeve (Item #28), and sleeve retainer (Item #29) onto the stud (Item #27) as shown in figure 502. F. The adjuster assembly (Item #26) may now be returned to service. Figure 503 Page 507 Rev. A, Sept. 15, 1994 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A ASSEMBLY 1. Assembly Materials NOTE: EQUIVALENT SUBSTITUTES MAY BE USED FOR ITEMS LISTED BELOW. Hydraulic Fluid Specification MIL-H-5606 or MIL-H-83282 Commercially Available Antiseize Thread Compound Specification MIL-T-5544 W.J. Ruscoe & Company 479 Kenmore Boulevard Akron, Ohio 44301 2. Assembly Procedures It is strongly recommended that all O-Ring packings (removed during disassembly) be replaced with new O-Ring packings during assembly. A. Lubricate a new O-Ring (Item #24) with a thin film of MIL-H-5606 or MIL-H-83282 hydraulic fluid and place it on the Plug (Item #25). B. Lubricate two new O-Rings (Item #24) with a thin film of hydraulic fluid (MIL-H-5606 or MIL-H- 83282) and place one on each of the two bleeder seats (Item #22). C. Thread the two bleeder seats (with new packings) into their respective ports and torque to 65- 70 in.-lbs. D. Similarly thread the plug from Step A into its respective port (to make either a right or left hand brake). Torque to 65-70 in.-lbs. E. Next, place a new O-Ring with a thin layer of hydraulic film onto the hydraulic fitting (Beech supplied part), and thread the hydraulic fitting into the appropriate port torquing to 65-70 in.- lbs. F. Next, lubricate a new O-Ring (Item #4) and place the O-Ring into the appropriate groove in the piston for each of the five Pistons (Item #3). Lubricate the piston bore with hydraulic fluid also. Page 601 April 4, 1994 Rev. B March 28, 1996 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A G. Install each of the five pistons (as shown in Figure 1) into the Cylinder (Item #2), and each of the five piston Insulators (Item #5) into the Pistons (Item #3). Push and rotate the pistons (do not cock) until they seat in the bottom of the bore. H. Install each of the five Retraction Springs (Item #33) into the appropriate cylinder cavities. I. Place one Washer (Item #31) over each Spring (Item #33), place one Snap Ring (Item #32) over each washer, compress the spring, and position the snap ring into the snap ring groove in the Cylinder (Item #2). See Figure 601. Figure 601 Page 602 April 4, 1994 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A J. Next, slide the four Retraction Base Assemblies (Item #34) into the corresponding pockets in the Pressure Plate Assembly (Item #6). K. Slide each of the four Adjuster Studs (Item #27) through the retraction housing and thread the stud into the Retraction Base Assembly (Item #34) as shown in Figure 601. Torque to 40-50 in.-lbs. NOTE: Be sure to position the pressure plate assembly carved out section at the top of the cylinder as shown in Figure 1. L. Thread one of the two Bleeder Screws (Item #23) into each of the two Bleeder Seats (Item #22). Torque snug to preclude leakage. M. Coat each of the five Washers (Item #21) with antiseize compound (per MIL-T-5544) and slide one washer onto each of the five Bolts (Item #20); make sure that the countersunk side of the washer faces the bolt head. * N. Slide one of the five Bolts/Washers (Item #20 and Item #21) through each of the five bolt holes in the Cylinder (Item #2). O. Slide the Torque Ring (Item #19), positioned as shown in Figure 1, onto the five Bolts (Item #20) and up against the Cylinder (Item #2). P. Slide a Disc (Item #10) over the Torque Ring (Item #19) and up against the Pressure Plate Assembly (Item #6). * If the aircraft is equipped with the optional brake de-icing equipment, the Bolts (Item #20) pass through the Mounting Bracket (Item #37), then the Washers (Item #21), then through the Cylinder (Item #2). See Figure 1. Page 603 April 4, 1994 Rev. B March 28, 1996 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A Q. Slide the Center Stator Assembly (Item #11) onto the Torque Ring (Item #19) and up against the Disc (Item #10). R. Slide the remaining Disc (Item #10) over the Torque Ring (Item #19) and up against the center stator. S. Position the Back Plate Assembly (Item #15) against the Torque Ring (Item #19), align the bolt holes and torque the five Tie Bolts (Item #20) to 175-190 in.-lbs., in a crisscross pattern. Torque again to 175-190 in.-lbs. T. Check to verify that the pressure plate assembly is fully retracted up against the Piston Insulators (Item #5). If it is not, check for obstructions. If no obstructions can be found, it may be necessary to replace the Retraction Springs (Item #33). U. Verify that the two bleeder fittings, the plug, and the hydraulic fitting have been installed. V. Install the brake assembly on the axle. W. Install another brake assembly on the opposite side of the axle, and fasten together per Parker P/N 199-220 Conversion Kit Installation Instructions. X. Reconnect hydraulic pressure source. Y. Bleed brakes per Aircraft Manual. Z. Pressurize to 360 psi ± 50 psi to set retracts and check for leaks. It is permissible to perform this test off-aircraft on an individual brake assembly. Page 604 April 4, 1994 Rev. B March 28, 1996 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A TROUBLE SHOOTING Trouble Cause Correction Hydraulic fluid leaking from brake assembly Defective hydraulic Connection Tighten connection or replace fitting. Defective O-Ring packing Replace O-Ring packing. Piston or cylinder worn or damaged Replace piston and/or housing. Brake not engaging correctly Air in brake Bleed brake. Obstruction in hydraulic line or fluid passage Remove obstruction. Pistons sticking Replace piston O-Ring packings and wiper rings. Pistons damaged Replace pistons. Cylinder damaged Replacing housing. Torque tube damaged Replace torque tube. Pressure plate, rotating disk, not moving freely on torque tube. Repair or replace defective plate or disk. Brake not releasing correctly. Obstruction in hydraulic line or fluid passage Remove obstruction. Pistons sticking Replace piston O-Ring packings and wiper rings. Defective Retraction Mechanisms Replace Retracts. Page 701 April 4, 1994 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A TROUBLE SHOOTING Trouble Cause Correction Brake not releasing correctly (Cont’d.) Pistons damaged Replace Pistons. Cylinder damaged Replacing housing. Torque ring damaged Replace torque ring. Pressure plate, rotating disk, or stationary disk not moving freely on torque ring. Repair or replace defective plate or disk. Rotating or stationary disk excessively dished Replace disk or Pressure Plate Sub-Assy. Loss or ineffective Braking Friction material worn from Brake Disc Replace Brake Disc and Wear Pads if worn. Excessive glaze on surface of Friction Material resulting in decreased friction coefficient Perform several hard braking. applications to brake or reduce glaze on friction surface. Worn seals in Master Cylinders Repair Master Cylinder. Stone or foreign object jammed in brake stack Remove foreign object. Page 702 April 4, 1994 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A WEAR LIMITS 1. General A brake wear check can be accomplished by parking the brake and checking the indicator pins (Item #26 111-10300 Adjuster Assemblies on page 1003); if the pin is flush or recessed below the friction sleeve, then the brake should be disassembled and further inspection of the individual wear components should be performed per Sections 3.3 and 8.2. Figure 801 Page 801 April 4, 1994 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A NOTE: When a wear component of the 30-204A BRAKE ASSEMBLY fails to meet the min. dimensions noted in this section, the Brake Assembly should be rebuilt by replacing that wear component. 2. Wear Pads The wear limits for the wear pads used on the Pressure Plate Assembly (Item #6), Center Stator Assembly (Item #11), and Backplate Assembly (Item #15) are identical. The minimum dimensions for wear are shown in Figures 802 and 803. Figure 802 Page 802 April 4, 1994 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A Figure 803 Page 803 April 4, 1994 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A Figure 804 3. Discs Figure 804 shows the minimum amounts of friction material that are allowed before Discs (Item #10) have to be replaced. NOTES: 1. Cracks at slots (as shown above) are acceptable if in the lining material only. Cracks extending from the thermal relief slot to the I.D. of the Disc in the steel material necessitates replacement. 2. Pitting is acceptable if area of pitting does not exceed .250 in. max. diameter. 3. Crumbling of lining material is acceptable in I.D., O.D. and slot areas (as shown above), if loss from edges does not exceed .125 inch. Page 804 April 4, 1994 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A ILLUSTRATED PARTS LIST 1. Introduction A. The Illustrated Parts List (IPL) section lists and illustrates the procurable parts of the Parker Hannifin assembly covered in this publication. B. The Figure item column provides the cross reference between the parts list and IPL Figure 1. C. The Part Number column gives the part number of the item, which is stamped on the part when practical. This number should be used when ordering parts. D. The description column gives the basic name of each part, together with any specifications required to identify the part listed. The descriptions are indented under the column heading to show the relationship of the parts to their subassemblies and to the assembly. E. The Units Per Assembly column gives the number of parts required for each assembly or subassembly. Page 1001 April 4, 1994 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A FIGURE 1 EXPLODED VIEW WITH ILLUSTRATED PARTS LIST Page 1002 Rev. C September 19, 2003 Aerospace CM30-204A COMPONENT MAINTENANCE MANUAL WITH IPL BRAKE ASSEMBLY 30-204A KEY TO FIGURE 1 ITEM PART NUMBER DESCRIPTION QTY 1 30-204A Brake Assembly 1 2 061-14000 Cylinder 1 3 062-08900 Piston 5 4 101-02300 O-Ring MS28775-218 5 5 088-01500 Insulator 5 6 073-07101 Pressure Plate Assembly 1 7 063-05501 Pressure Plate 1 8 109-00201 Wear Pad 16 9 105-06700 Rivet 32 10 159-05900 Disc 2 11 242-01200 Stator Assembly 1 12 232-01201 Stator 1 13 109-00201 Wear Pad 36 14 105-06800 Rivet 36 15 074-07000 Backplate Assembly 1 16 064-04303 Backplate 1 17 109-00201 Wear Pad 18 18 105-06700 Rivet 36 19 065-15400 Torque Ring, SUPSD BY Item 19A (refer to Parker Hannifin Service Bulletin SB 7079) 1 19A 065-15401 Torque Ring, SUPSDS Item 19 1 20 103-25100 Bolt MS21250-05034 5 21 095-02800 Washer MS20002C5 5 22 081-00200 Bleeder Seat 2 23 079-00300 Bleeder Screw 2 24 101-00700 O-Ring MS28775-012 3 25 104-05000 Plug AN814-4 1 26 111-10300 Adjuster Assembly 4 27 139-21500 Stud 4 28 139-12000 Friction Sleeve 4 29 139-11900 Sleeve Retainer 4 30 067-13200 Spacer 4 31 095-13600 Washer MS20002-5 4 32 155-07800 Snap Ring 4 33 082-10400 Spring 4 34 111-08301 Retract Base Assembly 4 35 230-03300 Insert 4 36 139-22101 Retract Base 4 1 37 139-19101 Assembly, Bracket Manifold 1 − 2 139-29900 Assembly, Brake De-ice Manifold 1 1 Optional Equipment. Refer to Parker Hannifin Conversion Kit, P/N 199-212. 2 Optional Equipment. Refer to Parker Hannifin Conversion Kit, P/N 199-213. − Item is not illustrated SUPSD BY The part in the part number column is replaced by and is not interchangeable with the item number shown in the notation. SUPSDS The part in the part number column replaces and is not interchangeable with the item number shown in the notation. Page 1003 Rev. C September 19, 2003 CLEVELAND WHEELS AND BRAKES COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST WHEEL ASSEMBLY PART NO. 40-273B Aerospace Aircraft Wheel & Brake Division Parker Hannifin Corporation 1160 Center Road Avon, Ohio 44011 U.S.A. Aerospace CLEVELAND WHEELS & BRAKES CM40-273B COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST FOR WHEEL ASSEMBLY PART NUMBER 40-273B Aircraft Wheel & Brake Parker Hannifin Corporation 1160 Center Road U.S.A. Avon, Ohio 44011 Initial Release May 15, 2001 Rev. G August 31, 2006 Aerospace CM40-273B COMPONENT MAINTENANCE MANUAL WITH IPL WHEEL ASSEMBLY 40-273B TO: HOLDERS OF CM40-273B COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST FOR MAIN WHEEL ASSEMBLY PART NO. 40-273B. Attached to this transmittal letter is Revision NC of CM40-273B (dated May 15, 2001) Revision NC, Dated May 15, 2001 REVISION NC CONTAINS ALL PAGES OF THE MANUAL. Pages that have been added or revised are outlined below together with the highlights of the revision. Please retain all REVISION HIGHLIGHTS pages, inserting them into the manual for future reference. REVISION HIGHLIGHTS Section/Page No. Description Of Change All Sections/All Pages Initial Release (DCN 0344-84) Revision Highlights Page 1/1 May 15, 2001 Aerospace CM40-273B COMPONENT MAINTENANCE MANUAL WITH IPL WHEEL ASSEMBLY 40-273B TO: HOLDERS OF CM40-273B COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST FOR MAIN WHEEL ASSEMBLY PART NO. 40-273B. Attached to this transmittal letter is Revision A of CM40-273B (dated August 28, 2001) Revision A, Dated August 28, 2001 REVISION A CONTAINS ALL PAGES OF THE MANUAL. Pages that have been added or revised are outlined below together with the highlights of the revision. Please retain all REVISION HIGHLIGHTS pages, inserting them into the manual for future reference. REVISION HIGHLIGHTS Section/Page No. Description Of Change As Follows: Rev A (DCN 0347-40): Record of Rev./RR-1 Update page to reflect Rev. A Disassembly/Pg. 201 Para. 2.B. (add) “….and washers (26).” Pg. 201 Para. 2.C. (add) “If installed, ….” Pg. 201 Para. 2.D. (add) “Cut safety wire and loosen lock ring retaining screws, and washers. Remove lock ring from axle.” (now) “Remove axle nut...” (was) “Remove and retain axle nut…” Check/Pg. 402 Para. 3.E. (now) “…Figure 401.” (was) “…Figure 40.” Pg. 403 Para. 3.J. (now) “Replaced drive coupling if…” (was) “Replaced drive coupling is…” Repair/Pg. 501 Repair Material Table (add) “www.dowcorning.com” Pg. 504 Para. 2. (add) “NOTE: EQUIVALENT PRIMERS AND TOPCOATS MAY BE USED IN LIEU OF THE PRODUCTS SPECIFIED HEREIN, PROVIDED THAT THE PRIMERS AND TOPCOATS ARE COMPATIBLE AND PROVIDED THAT THE THICKNESS SPECIFICATIONS AND MASKING INSTRUCTIONS CONTAINED HEREIN ARE OBEYED.” Pg. 507 Para. 5. (now) “WARNING: DURING CUP INSTALLATION OR REMOVAL…” (was) “WARNING: DURING CUP REMOVAL…” Pg. 507 Para. 5. (add) “CAUTION: USE PROTECTIVE GLOVES WHEN HANDLING HEATED OR CHILLED PARTS.” Revision Highlights Page 1/3 Aug. 28, 2001 Aerospace CM40-273B COMPONENT MAINTENANCE MANUAL WITH IPL WHEEL ASSEMBLY 40-273B Section/Page No. Description Of Change Repair/Pg. 507 Para. 5. (add) “NOTE: WORK SWIFTLY SINCE THERMAL EXPANSION OF THE CUP AND CONTRACTION OF THE WHEEL WILL INCREASE THE DIFFICULTY OF INSTALLATION.” Pg. 507 Para. 5. A. (now) “…to 200° ± 15° F (93.3° ± 8.3° C) for 30 to 60 minutes.” (was) “…not exceeding 212° F for 15 minutes.” Pg. 507 Para. 5. B. (add) “Remove wheel half from heat source and place wheel half on a support block…” Pg. 507 Para. 5. B. (now) “Remove cup from bore by tapping the cup out…” (was) “Remove cup from bore by tapping it out…” Pg. 507 Para. 5. B. (now) “…(See Figure 503) and use by hand…” (was) “…(See Figure 503) and utilize by hand…” Pg. 507 Para. 5. D. (now) “…chill the new bearing cup to between -30° to -60° F (-34° to -51° C) for a minimum of 30 minutes.” (was) “…chill the new bearing cup with dry ice for a minimum of 15 minutes.” Pg. 507 Para. 5. E. (now) “…to 200° ± 15° F (93.3° ± 8.3° C) for 30 to 60 minutes.” (was) “…not exceeding 212° F for 15 minutes.” Pg. 507 Para. 5. F. (now) “Remove…the bearing cup from refrigeration.” (was) “…remove the bearing cup from the dry ice.” Pg. 507 Para. 5. G. (now) “Brush a wet coat of primer...” (was) “Brush a wet coat (generous but not dripping) of primer..” Pg. 507 (add) Para. 5. J. “Try inserting a 0.002 in. (051mm) feeler gage between the cup and the base of the bearing bore in three equally spaced locations. If the gage can be inserted, the cup is not seated, and this procedure must be repeated.” Pg. 509 Para. 6. A. (now) “…may be repaired per 40-273B wheel assembly.” (was) “…may be repaired per 40-273A wheel assembly.” Assembly/Pg. 601 Para. 2.E. (now) “…use NASM33540...” (was) “…use MS33540…” Pg. 601 Para. 2.H. (now) “…10 Ply…” (was) “…8 Ply or 10 Ply…” Pg. 602 Para. 2.S. (now) “Install…ring (21) in …subassembly (7) (optional).” (was) “Install…ring (21) in …subassembly (7).” Pg. 602 Following Para. 2.S. (add) “NOTE: RETAINING RING (21) INSTALLATION IS NOT REQUIRED. THE RETAINING RING IS PROVIDED TO PREVENT THE GREASE SEAL AND BEARING CONE FROM FALLING OUT OF THE WHEEL ASSEMBLY WHEN THE WHEEL ASSEMBLY IS NOT INSTALLED ON THE AXLE.” Revision Highlights Page 2/3 Aug. 28, 2001 Aerospace CM40-273B COMPONENT MAINTENANCE MANUAL WITH IPL WHEEL ASSEMBLY 40-273B Section/Page No. Description Of Change Assembly/Pg. 603 Before Para. 2.T. (add) “CAUTION: BE SURE TO USE ONLY THE PARKER P/N 095-75200 WASHER. THE PARKER P/N 095-75200 IS DESIGNED TO INSURE THAT THE AXLE NUT CASTELLATIONS WILL ALIGN WITH THE LOCKING HOLES IN THE AXLE AT THE PROPER TORQUE.” Pg. 603 (add) Para. 2.T. “Apply a thin coat of bearing grease to both sides of tang washer (Parker P/N 095-75200) and install tang washer on axle.” Pg. 603 (add) Para. 2.U. “Apply a thin coat of bearing grease on axle nut (Beech P/N 114-810062-1) threads. Tighten axle nut to 150 to 200 in.-lbs. of torque while rotating the wheel to insure proper seating of the bearings.” ______________________________________ Note: verbage previously identified as para. 2.U. is now identified as para. 2.W. Pg. 603 Before Para. 2.V (add). “NOTE: DO NOT ALLOW THE WHEEL TO ROTATE WHILE BACKING OFF THE AXLE NUT.” Pg. 603 (add) Para. 2.V. “Back-off axle nut to zero in.-lbs. of torque, then torque axle nut to 40 in.-lbs. while rotating wheel. Tighten axle nut so that the next available castellation is aligned with a through hole in the axle threads. Do not exceed 160 in.-lbs. of torque or 30° of rotation of the axle nut. Install lock ring (Parker P/N 139-34900), lock ring retaining screws (Parker P/N 102-33600), and washers (Parker P/N 095-13800). Torque ring retaining screws to 8 to 15 in.-lbs. Safety wire axle nut retaining screws per NASM33540. It is permissible to use either MS20995C20 or MS20995C32 safety wire.” Pg. 603 (now) Para. 2.W. “Lubricate screw threads with antiseize…” (was) previously identified as para. 2.U. Revision Highlights Page 3/3 Aug. 28, 2001 Aerospace CM40-273B COMPONENT MAINTENANCE MANUAL WITH IPL WHEEL ASSEMBLY 40-273B TO: HOLDERS OF CM40-273B COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST FOR MAIN WHEEL ASSEMBLY PART NO. 40-273B. Attached to this transmittal letter is Revision B of CM40-273B (dated November. 30, 2001) Revision B, Dated Nov. 30, 2001 REVISION B CONTAINS ALL PAGES OF THE MANUAL. Pages that have been added or revised are outlined below together with the highlights of the revision. Please retain all REVISION HIGHLIGHTS pages, inserting them into the manual for future reference. REVISION HIGHLIGHTS Section/Page No. Description Of Change As Follows: Rev B (DCN 0348-71): Record of Rev./RR-1 Update page to reflect Rev. B Assembly/Pg. 602 Following Para. 2.O. (ADD) “NOTE: RE-PACK THE WHEEL BEARINGS WITH GREASE AT EVERY TIRE CHANGE OR 200 HOURS, WHICHEVER COMES FIRST.” Assembly/Pg. 603 Para. 2.V.: (NOW) “Back-off axle nut to zero in.-lbs. of torque, then torque axle nut until the grease seal does not rotate when rotating the wheel.” (WAS) “Back-off axle nut to zero in-lbs of torque, then torque axle nut to 40 in-lbs while rotating wheel.” (NOW) Do not exceed 200 in.-lbs. of torque or 30° of rotation of the axle nut.” (WAS) Do not exceed 160 in.-lbs. of torque or 30° of rotation of the axle nut.” Assembly/Pg. 603 Following Para. 2.V. (ADD) “NOTE: IF MORE THAN 200 IN-LBS OF TORQUE ARE REQUIRED TO ALIGN THE HOLE WITH THE NEXT AVAILABLE CASTELLATION THEN REMOVE THE AXLE NUT AND INSTALL ONE SPACER (PARKER P/N 095-75400); TORQUE THE AXLE NUT UNTIL THE GREASE SEAL DOES NOT ROTATE WHEN ROTATING THE WHEEL. TIGHTEN THE AXLE NUT SO THAT THE NEXT AVAILABLE CASTELLATION IS ALIGNED WITH A HOLE IN THE AXLE THREADS. DO NOT EXCEED 200 IN-LBS OF TORQUE OR 30° OF ROTATION OF THE AXLE NUT.” Revision Highlights Page 1/1 Nov. 30, 2001 Aerospace CM40-273B COMPONENT MAINTENANCE MANUAL WITH IPL WHEEL ASSEMBLY 40-273B TO: HOLDERS OF CM40-273B COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST FOR MAIN WHEEL ASSEMBLY PART NO. 40-273B. Attached to this transmittal letter is Revision C of CM40-273B (dated June 20, 2002) Revision C, Dated June 20, 2002 REVISION C CONTAINS ALL PAGES OF THE MANUAL. Pages that have been added or revised are outlined below together with the highlights of the revision. Please retain all REVISION HIGHLIGHTS pages, inserting them into the manual for future reference. REVISION HIGHLIGHTS Section/Page No. Description Of Change As Follows: Rev C (DCN 0351-11): Record of Rev./RR-1 Update page to reflect Rev. C Assembly/Pg. 603 (NOW) W. Lubricate screw threads with antiseize compound specification MIL-T-5544. Install hubcap assembly (22) on outboard wheel half subassembly (7) and secure with washers (26) and screws (27). Torque screws to 20-25 in.-lbs. (WAS) W. Lubricate screw threads with antiseize compound specification MIL-T-5544. Install hubcap assembly (22) on outboard wheel half subassembly (7) and secure with washers (26) and screws (27). Torque screws 30 to 40 in.-lbs. Revision Highlights Page 1/1 June 20, 2002 Aerospace CM40-273B COMPONENT MAINTENANCE MANUAL WITH IPL WHEEL ASSEMBLY 40-273B Revision Highlights Page 1/2 December 18, 2003 TO: HOLDERS OF CM40-273B COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST FOR MAIN WHEEL ASSEMBLY PART NO. 40-273B. Attached to this transmittal letter is Revision D of CM40-273B (dated December 18, 2003) Revision D, Dated December 18, 2003 REVISION D CONTAINS ALL PAGES OF THE MANUAL. Pages that have been added or revised are outlined below together with the highlights of the revision. Please retain all REVISION HIGHLIGHTS pages, inserting them into the manual for future reference. REVISION HIGHLIGHTS Section/Page No. Description Of Change As Follows: Rev D (DCN 0359-07): Record of Rev./RR-1 Update page to reflect Rev. D Description and (Now) Bearing Lubricant: MIL-G-81322, Grade A, Mobil Aviation Grease SHC Operation/2 100 or equivalent. (Was) Bearing Lubricant: MIL-G-81322, Grade A or equivalent. Cleaning/301 (Now) C. Dry bearing cones thoroughly, using filtered and dried compressed air. Immediately after visually inspecting per CHECK, repack bearing cones with clean bearing grease, specification MIL-G-81322 Grade A, Mobil Aviation Grease SHC 100, or equivalent. (Was) C. Dry bearing cones thoroughly, using filtered and dried compressed air. Repack bearing cones with clean bearing grease, specification MIL-G-81322 or equivalent, immediately after visually inspecting per CHECK. Assembly/601 (Now) Mobil Aviation Grease SHC 100 ExxonMobil Corp. Beaumont, TX 77704 www.exxonmobil.com Aeroshell Grease 22 Shell Oil Company, Lubricant Div. One Shell Plaza Houston, TX 77002 www.shell.com (Was) Aeroshell Grease 22 Shell Oil Company, Lubricant Div. One Shell Plaza Houston, TX 77002 www.shell.com Aerospace CM40-273B COMPONENT MAINTENANCE MANUAL WITH IPL WHEEL ASSEMBLY 40-273B Revision Highlights Page 2/2 March 17, 2004 Section/Page No. Description Of Change Assembly/602 Now) O. Pack bearing cones (13) with clean bearing grease, specification MIL-G-81322 Grade A, Mobil Aviation Grease SHC 100, or equivalent. (Was) O. Pack bearing cones (13) with clean bearing grease, specification MIL-G-81322 or equivalent. (Add) CAUTION: AVIATION BEARING GREASES SHOULD NOT BE INTERMIXED WITH EACH OTHER. PRECAUTIONS SHOULD BE TAKEN TO INSURE THAT THE BEARING GREASES ARE BEING USED IN ACCORDANCE WITH THE MANUFACTURER’S GUIDELINES. TECHNICAL DATA AND MSDS SHEETS ARE AVAILABLE ON THE MANUFACTURER’S WEBSITES. (Now) NOTE: IF USING MOBIL AVIATION GREASE SHC 100, REPACK THE WHEEL BEARINGS WITH GREASE AT EVERY TIRE CHANGE OR 350 HOURS, WHICHEVER COMES FIRST. IF USING MIL-G-81322 GREASE OR EQUIVALENT, REPACK THE WHEEL BEARINGS WITH GREASE AT EVERY TIRE CHANGE OR 200 HOURS, WHICHEVER COMES FIRST. (Was) NOTE: RE-PACK THE WHEEL BEARINGS WITH GREASE AT EVERY TIRE CHANGE OR 200 HOURS, WHICHEVER COMES FIRST. Aerospace CM40-273B COMPONENT MAINTENANCE MANUAL WITH IPL WHEEL ASSEMBLY 40-273B Revision Highlights Page 1/2 March 17, 2004 TO: HOLDERS OF CM40-273B COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST FOR MAIN WHEEL ASSEMBLY PART NO. 40-273B. Attached to this transmittal letter is Revision E of CM40-273B (dated March 17, 2004) Revision E, Dated March 17, 2004 REVISION E CONTAINS ALL PAGES OF THE MANUAL. Pages that have been added or revised are outlined below together with the highlights of the revision. Please retain all REVISION HIGHLIGHTS pages, inserting them into the manual for future reference. REVISION HIGHLIGHTS Section/Page No. Description Of Change As Follows: Rev E (DCN 0360-24): Title Page (Now) Revision E Dated March 17, 2004 (Was) Initial Issue May 15, 2001 (Added) Rev. E March 17, 2004 Record of Revisions (Added) E 3-17-04 3-17-04 PH 401 (Now) Zyglo ZL-60D Zyglo ZP-4B, ZP-9F, ZP-5B, or SKD-S2 Fluorescen t Zyglo ZL-2C, with emulsifier/remover ZE-4B Zyglo ZP-4B, ZP-9F, ZP-5B, ZP-14A or SKD-S2 Magnaflux Corp. 3624 West Lake Ave. Glenview, IL 60025 www.magnaflux.com Ph. 847-657-5300 Fax. 847-657-5388 e-mail: INFO@magnaflux.com (Was) Fluorescen t Zyglo ZL-60D Zyglo ZP-4B (wet) optional Magnaflux Corp. 7300 West Lawrence St. Chicago, IL 60656 www.magnaflux.com Aerospace CM40-273B COMPONENT MAINTENANCE MANUAL WITH IPL WHEEL ASSEMBLY 40-273B Revision Highlights Page 2/2 March 17, 2004 Section/Page No. Description Of Change 603 (When page 602 Dec. 18, 2003 was created, data was moved to page 603. The data transfer was not documented. Therefore, Rev. E hereby documents the transfer of the following data from page 602 (dated Nov. 30, 2001) to page 603 (dated March 17, 2004).) R. Install outboard bearing cone and outboard grease seal in the wheel assembly. S. Install retaining ring (21) in outboard wheel half subassembly (7) (optional). N NO OTTE E:: R RE ETTA AIIN NIIN NG G R RIIN NG G ((2211)) IIN NS STTA ALLLLA ATTIIO ON N IIS S N NO OTT R RE EQ QU UIIR RE ED D.. TTH HE E R RE ETTA AIIN NIIN NG G R RIIN NG G IIS S P PR RO OV VIID DE ED D TTO O P PR RE EV VE EN NTT TTH HE E G GR RE EA AS SE E S SE EA ALL A AN ND D B BE EA AR RIIN NG G C CO ON NE E FFR RO OM M FFA ALLLLIIN NG G O OU UTT O OFF TTH HE E W WH HE EE ELL A AS SS SE EM MB BLLY Y W WH HE EN N TTH HE E W WH HE EE ELL A AS SS SE EM MB BLLY Y IIS S N NO OTT IIN NS STTA ALLLLE ED D O ON N TTH HE E A AX XLLE E.. Aerospace CM40-273B COMPONENT MAINTENANCE MANUAL WITH IPL WHEEL ASSEMBLY 40-273B Revision Highlights Page 1/1 June 01, 2005 TO: HOLDERS OF CM40-273B COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST FOR MAIN WHEEL ASSEMBLY PART NO. 40-273B. Attached to this transmittal letter is Revision F of CM40-273B (dated June 01, 2005) Revision F, Dated June 01, 2005 REVISION F CONTAINS ALL PAGES OF THE MANUAL. Pages that have been added or revised are outlined below together with the highlights of the revision. Please retain all REVISION HIGHLIGHTS pages, inserting them into the manual for future reference. REVISION HIGHLIGHTS Section/Page No. Description Of Change As Follows: Rev F (DCN 0365-89): Title Page (Now) Revision F Dated June 01, 2005 Record of Revisions Update page to reflect Revision F Description and (Add) “…or AMS2518” Operation / pg. 2 Assembly / pg. 601 Assembly Material Table: (Add) “…or AMS2518” to antiseize callout pg. 602 Paragraph J: (Add) “…or AMS2518” to antiseize reference pg. 603 Paragraph W: (Add) “…or AMS2518” to antiseize reference Illustrated Parts Parts List for 102-07700 screw: List / pg. 1003 (Now) MS35266-59 (Was) AN501A10-4 Aerospace CM40-273B COMPONENT MAINTENANCE MANUAL WITH IPL WHEEL ASSEMBLY 40-273B Revision Highlights Page 1/1 August 31, 2006 TO: HOLDERS OF CM40-273B COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST FOR MAIN WHEEL ASSEMBLY PART NO. 40-273B. Attached to this transmittal letter is Revision G of CM40-273B (dated August 31, 2006) Revision G, Dated August 31, 2006 REVISION G CONTAINS ALL PAGES OF THE MANUAL. Pages that have been added or revised are outlined below together with the highlights of the revision. Please retain all REVISION HIGHLIGHTS pages, inserting them into the manual for future reference. REVISION HIGHLIGHTS Section/Page No. Description Of Change As Follows: Rev G (DCN 0371-03) Title Page (Now) Revision G Dated August 31, 2006 Record of Revisions Update page to reflect Revision G Assembly / pg. 602 Paragraph 2.O. NOTE: (NOW ) “…REPACK THE WHEEL BEARINGS WITH GREASE AT EVERY TIRE CHANGE OR 400 HOURS,…” (WAS) “…REPACK THE WHEEL BEARINGS WITH GREASE AT EVERY TIRE CHANGE OR 350 HOURS,…” Aerospace CM40-273B COMPONENT MAINTENANCE MANUAL WITH IPL WHEEL ASSEMBLY 40-273B Record of Revisions Page 1/1 August 31, 2006 RECORD OF REVISIONS REV NO. ISSUE DATE DATE INSERTED BY REV NO. ISSUE DATE DATE INSERTED BY NC 5-15-01 5-15-01 PHC A 8-28-01 8-28-01 PHC B 11-30-01 11-30-01 PHC C 06-20-02 06-20-02 PHC D 12-18-03 12-18-03 PHC E 3-17-04 3-17-04 PHC F 6-01-05 6-01-05 PHC G 08-31-06 08-31-06 PHC Aerospace CM40-273B COMPONENT MAINTENANCE MANUAL WITH IPL WHEEL ASSEMBLY 40-273B Record of Revisions Page 1/1 June 01, 2005 SERVICE BULLETIN LIST SERVICE BULLETIN NO. REV NO. DATE INCORPORATED SERVICE BULLETIN NO REV NO. DATE INCORPORATED Aerospace CM40-273B COMPONENT MAINTENANCE MANUAL WITH IPL WHEEL ASSEMBLY 40-273B Table of Contents Page 1 May 15, 2001 T Ta ab blle e o off C Co on ntte en nttss Subject Page INTRODUCTION 1 DESCRIPTION AND OPERATION 1 1. Description and Operation 1 2. Handling Procedures 1 3. Leading Particulars 2 TESTING 101 1. General 101 2. Testing Procedures 101 DISASSEMBLY 201 1. General 201 2. Disassembly Procedures 201 CLEANING 301 1. Cleaning Materials 301 2. Cleaning Procedures 301 3. Paint Removal Procedures 302 CHECK 401 1. Check Materials 401 2. General 401 3. Detailed Check 401 Aerospace CM40-273B COMPONENT MAINTENANCE MANUAL WITH IPL WHEEL ASSEMBLY 40-273B Table of Contents Page 2 May 15, 2001 T Ta ab blle e o off C Co on ntte en nttss Subject Page REPAIR 501 1. Repair Materials 501 2. General 501 3. Repair of Wheel Halves 502 4. Repainting 504 5. Replacing Defective Bearing Cups 507 6. Repair of Inboard Wheel Half Drive Key 509 Attachment Screw Tapped Holes 7. Replacing Hubcap Drive Coupling 509 8. Insert Repair 511 ASSEMBLY 601 1. Assembly Materials 601 2. Assembly Procedures 601 STORAGE INSTRUCTIONS 701 ILLUSTRATED PARTS LIST 1001 1. Introduction 1001 2. Parts List 1003 Aerospace CM40-273B COMPONENT MAINTENANCE MANUAL WITH IPL WHEEL ASSEMBLY 40-273B Introduction Page 1 May 15, 2001 IIN NT TR RO OD DU UC CT TIIO ON N This manual is published for the guidance of personnel responsible for the overhaul and/or maintenance of the Parker Hannifin 40-273B Wheel Assembly covered in this publication. The procedures outlined in this manual may be altered if better and/or more economical methods can be employed by the individual facilities. However, alternative procedures must not reduce the efficiency of operation of the assembly. N NO OT TE E:: A Allll ttoorrqquuee vvaalluueess aanndd ssppeecciiffiieedd lliim miittss oorr vvaalluueess sseett bbyy P Paarrkkeerr H Haannnniiffiinn E Ennggiinneeeerriinngg aanndd ccoonnttaaiinneedd hheerreeiinn m muusstt bbee ssttrriiccttllyy oobbsseerrvveedd aanndd nnoott ddeevviiaatteedd ffrroom m.. While Parker Hannifin Corporation represents that the information contained in this manual was current at the time of publication, it is recommended that the user inquire as to the latest revision level in existence before proceeding with overhaul or maintenance operations. This can be accomplished by contacting the Product Support Department of the Aircraft Wheel & Brake Division at the following address or numbers: Parker Hannifin Corporation Aircraft Wheel & Brake Division Attn: Product Support Dept. 1160 Center Road Avon, Ohio 44011 Phone: (216) 937-6211 1-800-272-5464 Fax: (216) 937-6416 TSO NOTICE This assembly carries a "TSO C26c" marking for FAR Part 23 usage, which identifies it as having been fully tested in the laboratory and qualified to applicable FAA (Federal Aviation Administration) requirements and specifications. After final certification, substitutions of critical parts or changes of processes or materials are not permitted without requalification of the assembly and resubmittal of the test data to the FAA for approval. FAA regulations subject both Parker Hannifin, Aircraft Wheel & Brake Division and the user to constant surveillance to assure that uncompromising quality assurance material and processing controls are maintained in order to provide replacement parts that are the same as the parts originally certified in the assembly. Aerospace CM40-273B COMPONENT MAINTENANCE MANUAL WITH IPL WHEEL ASSEMBLY 40-273B Introduction Page 2 May 15, 2001 DATA RIGHTS The unit charge for this manual covers reproduction and handling costs only and does not constitute purchase of the data or design contained herein, nor does it convey to the purchaser any rights, patent or otherwise, to reproduce or manufacture from said data. Aerospace CM40-273B COMPONENT MAINTENANCE MANUAL WITH IPL WHEEL ASSEMBLY 40-273B Description & Operation Page 1 May 15, 2001 D DE ES SC CR RIIP PT TIIO ON N A AN ND D O OP PE ER RA AT TIIO ON N 1. Description and Operation A. The Main wheel assembly is a 6.50-10, Type III wheel designed for use with a 22 x 6.75- 10, 8 ply or 10 ply tube type or tubeless tire. B. The divided type main wheel facilitates tire installation and removal. C. The two wheel halves are fastened together with high strength bolts, washers and self- locking nuts. The wheel halves are machined from aluminum alloy forgings. D. An O-ring is installed on the inner wheel half to provide an air seal at the juncture of the wheel halves. An inflation valve assembly is installed in the outer wheel half to inflate and deflate a tubeless tire. This valve must be removed to utilize a tube type tire. E. The wheel assembly rotates on two tapered roller bearings. The bearings are protected by a molded type lip seal in each hub. The bearing cups are shrink-fitted into the hubs of each wheel half. F. The inner wheel half flange is slotted in nine (9) places to engage the brake discs and transmit torque to the brake. G. The inner wheel half flange slots are lined with steel drive keys (which are held in place by a single screw and lockwire) to prevent the aluminum wheel flange from being battered by the steel brake discs. H. The wheel assembly is equipped with an anti-skid compatible hubcap 2. Handling Procedures A. Strictly observe the deflation and inflation procedures, as well as the torque and lubtork values specified in this manual. Do not overtighten any bolt, nut, or fitting. Aerospace CM40-273B COMPONENT MAINTENANCE MANUAL WITH IPL WHEEL ASSEMBLY 40-273B Description & Operation Page 2 June 01, 2005 B. Handle the wheel bearing cones with extreme care. Many bearing failures can be traced to dropping or mishandling the bearings during maintenance. C. Handle and maintain the wheel halves properly to protect the paint and surface finishes. 3. Leading Particulars Wheel Size and Type: 6.50-10, Type III Tubeless or Tubetype Material: Aluminum Alloy Forging. Approximate Wheel Weight : 12.7 Lbs. Wheel Bolt Nut Torque: 290-300 in.-lbs. Lubtork. (Use MIL-T-5544 or AMS2518 antiseize compound) Bearing Lubricant: MIL-G-81322, Grade A, Mobil Aviation Grease SHC 100, or equivalent Paint Requirements: (Recommended) Primer: Columbia Paint Corporation Alternate: Sherwin Williams Company P/N 11-347Z P/N P60G2 Topcoat: Columbia Paint Corporation Alternate: Sherwin Williams Company 11-358A Gloss White Enamel P/N F63W13 Aerospace CM40-273B COMPONENT MAINTENANCE MANUAL WITH IPL WHEEL ASSEMBLY 40-273B Page 101 May 15, 2001 T TE ES ST TIIN NG G 1. General Test the wheel assembly in accordance with the following procedure. (Ref. IPL Fig. 1) 2. Testing Procedures A. Clean bearing cones (13) in dry cleaning solution, specification P-D-680, and visually check roller contacting surfaces for nicks, scratches, rust, corrosion, spalling, flat spots, pitting, heat discoloration and wear. Check bearing cage for dents or distortion and for wear of sides, corners and at ends of roller pockets. Replace bearing cones having any defects. B. Wipe bearing cups (6) free of grease and visually check cup face for scratches, pitting, brinelling, spalling, heat discoloration, rust, corrosion and wear. Remove defective cups and install new cups per R RE EP PA AIIR R. C. Visually check grease seals (14) for cuts and wear on rubber sealing lip and bent or distorted reinforcing washer. Replace damaged grease seals. D. Cover hub openings of wheel halves to prevent contamination of bearing lubricant. E. Place wheel/tire assembly in an inflation cage and inflate to recommended operating pressure. Aerospace CM40-273B COMPONENT MAINTENANCE MANUAL WITH IPL WHEEL ASSEMBLY 40-273B Page 102 May 15, 2001 F. Coat juncture around inflation valve (15) and tire beads with soap solution. Check carefully for air leaks in the form of soap bubbles. If air leaks occur around valve, check torque on leaking part. If air leaks occur around tire bead seat, completely deflate tire and remove assembly from inflation cage. Remove tire from wheel and examine wheel bead seat and tire for damage. If wheel bead seat is scratched, nicked or pitted, repair in accordance with R RE EP PA AIIR R. G. Place wheel/tire assembly in an inflation cage and inflate to recommended operating pressure, after the initial 24 hours (growth stabilization) reinflate to recommended operating pressure. Check pressure after an additional 24 hours. If the reduction in pressure exceeds five percent of inflation pressure, replace wheel O-Ring (16) and retest wheel/tire assembly in accordance with step F. Aerospace CM40-273B COMPONENT MAINTENANCE MANUAL WITH IPL WHEEL ASSEMBLY 40-273B Page 201 Aug. 28, 2001 D DIIS SA AS SS SE EM MB BLLY Y 1. General Disassemble the main wheel assembly in accordance with the following instructions (Ref. IPL Fig. 1). W WA AR RN NIIN NG G:: D DO O N NO OT T A AT TT TE EM MP PT T T TO O D DIIS SA AS SS SE EM MB BL LE E W WH HE EE EL L U UN NT TIIL L T TIIR RE E H HA AS S B BE EE EN N C CO OM MP PL LE ET TE EL LY Y D DE EF FL LA AT TE ED D;; O OT TH HE ER RW WIIS SE E,, S SE ER RIIO OU US S IIN NJJU UR RY Y T TO O P PE ER RS SO ON NN NE EL L O OR R D DA AM MA AG GE E T TO O E EQ QU UIIP PM ME EN NT T C CA AN N R RE ES SU UL LT T.. 2. Disassembly Procedures A. Jack aircraft per aircraft maintenance manual until tire is clear of ground. It is strongly recommended that the tire be deflated at this time. W WA AR RN NIIN NG G:: F FA AIIL LU UR RE E T TO O D DE EF FL LA AT TE E T TIIR RE E B BE EF FO OR RE E R RE EM MO OV VIIN NG G A AX XL LE E N NU UT T C CA AN N R RE ES SU UL LT T IIN N S SE ER RIIO OU US S IIN NJJU UR RY Y O OR R D DE EA AT TH H B. Remove hubcap assembly (22) by removing the three installation screws (27) and washers (26). C. If installed, remove retaining ring (21). D. Cut safety wire and loosen lock ring retaining screws and washers. Remove lock ring from axle. Remove axle nut, tang washer, grease seal (14), and outer bearing cone (13). E. Remove wheel assembly from axle and place on a clean flat surface. F. Remove remaining grease seal (14) and inner bearing cone (13). G. Break tire beads away from both wheel flanges by applying pressure in even increments around entire sidewall as close to tire beads as possible. CAUTION: THE USE OF POWER OR IMPACT WRENCHES IS NOT A RECOMMENDED PRACTICE. IF USING POWER OR IMPACT WRENCHES, OBSERVE TORQUING SPECIFICATIONS. IN THE EVENT A BOLT/NUT COMBINATION IS OVER TORQUED, THE BOLT/NUT COMBINATION SHALL BE DISCARDED.. Aerospace CM40-273B COMPONENT MAINTENANCE MANUAL WITH IPL WHEEL ASSEMBLY 40-273B Page 202 May 15, 2001 H. Remove nuts (12), washers (11), bolts (9) and countersunk washers (10). G. Separate the wheel halves and remove tire. H. Remove O-Ring (16) from wheel register groove of inner wheel half (3). I. Remove lockwire (18), screws (5), and drive keys (4) from inner wheel half (3). N NO OT TE E:: IIT T IIS S R RE EC CO OM MM ME EN ND DE ED D T TH HA AT T A A N NE EW W O O--R RIIN NG G B BE E IIN NS ST TA AL LL LE ED D A AT T E EA AC CH H O OV VE ER RH HA AU UL L.. J. Bearing cups (6) should not be removed from the wheel halves unless replacement is required. Refer to R RE EP PA AIIR R for removal and installation procedures. N NO OT TE E:: T TH HE E IIN NF FL LA AT TIIO ON N V VA AL LV VE E ((1155)) M MU US ST T B BE E R RE EM MO OV VE ED D IIF F P PA AIIN NT T IIS S T TO O B BE E S ST TR RIIP PP PE ED D F FR RO OM M T TH HE E W WH HE EE EL L H HA AL LV VE ES S B BY Y P PL LA AS ST TIIC C M ME ED DIIA A S ST TR RIIP PP PIIN NG G;; T TH HE E B BE EA AR RIIN NG G C CU UP PS S M MA AY Y R RE EM MA AIIN N IIN N T TH HE E W WH HE EE EL L H HA AL LV VE ES S P PR RO OV VIID DE ED D T TH HA AT T T TH HE EY Y A AR RE E N NO OT T D DA AM MA AG GE ED D B BY Y T TH HE E S ST TR RIIP PP PIIN NG G P PR RO OC CE ES SS S.. B BO OT TH H T TH HE E IIN NF FL LA AT TIIO ON N V VA AL LV VE E A AN ND D T TH HE E B BE EA AR RIIN NG G C CU UP PS S M MU US ST T B BE E R RE EM MO OV VE ED D IIF F P PA AIIN NT T IIS S T TO O B BE E S ST TR RIIP PP PE ED D F FR RO OM M T TH HE E W WH HE EE EL L H HA AL LV VE ES S B BY Y C CH HE EM MIIC CA AL L P PA AIIN NT T R RE EM MO OV VA AL L S SO OL LV VE EN NT TS S.. Aerospace CM40-273B COMPONENT MAINTENANCE MANUAL WITH IPL WHEEL ASSEMBLY 40-273B Page 301 December 18, 2003 C CLLE EA AN NIIN NG G 1. Cleaning Materials NOTE: EQUIVALENT SUBSTITUTES MAY BE USED FOR ITEMS LISTED BELOW. Dry Cleaning Solution Specification P-D-680 Stoddard Solvent Commercially Available Cleaner/Degreaser per AMS 1526 Commercially Available Isopropyl Alcohol Commercially Available Soft Bristle Brush Commercially Available Clean Wiping Cloth Commercially Available 2. Cleaning Procedures W WA AR RN NIIN NG G:: C CL LE EA AN NIIN NG G S SO OL LU UT TIIO ON NS S S SH HO OU UL LD D B BE E U US SE ED D IIN N A A W WE EL LL L V VE EN NT TIIL LA AT TE ED D A AR RE EA A.. A AV VO OIID D P PR RO OL LO ON NG GE ED D IIN NH HA AL LA AT TIIO ON N O OF F F FU UM ME ES S.. CAUTION: THE WHEEL HALVES MAY HAVE A WATER REDUCIBLE FINISH (COLUMBIA PAINT CORP.) AND THE USE OF SOLVENTS SUCH AS MINERAL SPIRITS WILL REMOVE THE FINISH AND ARE NOT RECOMMENDED. A. Clean all metal parts by immersing in dry cleaning solution conforming to specification P- D-680. Use a soft bristle brush to remove hardened grease, dust, and dirt. C CA AU UT TIIO ON N:: C CL LE EA AN N B BE EA AR RIIN NG G C CO ON NE ES S ((1133)) C CA AR RE EF FU UL LL LY Y IIN N A A S SE EP PA AR RA AT TE E C CO ON NT TA AIIN NE ER R O OF F C CL LE EA AN N S SO OL LV VE EN NT T T TO O A AV VO OIID D C CO ON NT TA AM MIIN NA AT TIIO ON N.. B. Dry all metal parts thoroughly after cleaning, using filtered and dried compressed air. C. Dry bearing cones thoroughly, using filtered and dried compressed air. Immediately after visually inspecting per CHECK, repack bearing cones with clean bearing grease, specification MIL-G-81322 Grade A, Mobil Aviation Grease SHC 100, or equivalent. C CA AU UT TIIO ON N:: D DO O N NO OT T S SP PIIN N B BE EA AR RIIN NG G C CO ON NE ES S W WIIT TH H C CO OM MP PR RE ES SS SE ED D A AIIR R.. D. Clean rubber parts in isopropyl alcohol and dry with a clean, soft cloth. Aerospace CM40-273B COMPONENT MAINTENANCE MANUAL WITH IPL WHEEL ASSEMBLY 40-273B Page 302 May 15, 2001 E. Inner and outer wheel half subassemblies (2) and (7) can be degreased with a water based cleaner/degreaser that meets or exceeds AMS1526. Use a non-metallic soft bristled brush to remove stubborn deposits. F. Rinse parts thoroughly with a mild soap and water solution at ambient temperature. G. Final rinse parts thoroughly with water he