IM199-60 Installation Manual with IPL for Conversion Kit Part No. 199-60

NOTE: Service bulletins, service letters and similar documentation issued by the airframe manufacturer can affect the installation of Conversion Kit No. 199-60. Contact the airframe manufacturer for documentation applicable to your model aircraft before installing Conversion Kit No. 199-60. The equipment supplied as Kit No. 199-60 is applicable to the following aircraft under the listed STC. TABLE 1, APPLICABILITY STC MAKE MODELS SA62GL Cessna 180, 180A, 180B, 180C, 180D, 180E, 180F, 180H, 180J, 185, 185A, 185B, A185E, A185F, 206E, 206F, TU206E, TU206F SA52GL Cessna 210, 210A, 210B, 210C, 210K, 210L, 210M, T210K, T210L, T210M 4.1 KIT EQUIPMENT Refer to paragraph 14.0 for the kit parts list. The following hardware is not included in the 199-60 Conversion Kit: - Brake hydraulic fittings. - Brake / axle attachment bolts, washers and nuts. - Axle nut cotter pins. Different brake hydraulic fittings, brake hydraulic supply lines and brake/axle attachment hardware configurations are used on the Cessna aircraft models listed in Table 1. The installer must consult with the appropriate aircraft parts catalog to identify the required hardware to complete the installation of the conversion kit. Refer to paragraph 9.2 for more hardware configuration information. 5.0 SAFETY Follow proper safety precautions when servicing aircraft braking systems. • A “SAFETY WARNING” flagged by this symbol , calls attention to possible serious or life threatening situations if procedures are not followed. • A “WARNING” calls attention to use of materials, processes, methods, procedures, or limits which must be followed precisely to avoid injury to persons. • A “CAUTION” calls attention to methods and procedures which must be followed to avoid damage to equipment. • A “NOTE” calls attention to an essential operating or maintenance procedure, condition, or statement, which must be highlighted. Page 2 October 01, 2003 IM199-60 INSTALLATION MANUAL WITH IPL FOR CONVERSION KIT PART NO. 199-60 6.0 ORDER INFORMATION To order spare parts, contact the nearest Parker Hannifin, Aircraft Wheel and Brake distributor in your area, or contact Aircraft Wheel and Brake at the following address or numbers: Parker Hannifin Corporation Website: www.parker.com/cleveland Aircraft Wheel & Brake Division E-mail: techhelp@parker.com 1160 Center Road Fax: (440) 937-5409 Avon, Ohio 44011 U.S.A. Tel: 1-800-BRAKING (1-800-272-5464) Attn: Technical Services/Hotline (440) 937-1315 7.0 EQUIPMENT DESCRIPTION 7.1 BRAKE ASSEMBLY Refer to Figure 3 for identification of brake assembly components. The brake is a single caliper, two piston external disc design, with non asbestos organic lining. It is suitable for use with brake fluid conforming to MIL-H-5606. The cylinder (3-2) contains the brake fluid which operates the pistons (3-4) and pressure plate (3-7). Back plates (3-11) are secured to the cylinder with bolts and washers (3-15 and 3-16) on the opposite side of the brake disc. The back plates and pressure plate each hold brake linings (3-9). Two anchor bolts (3-12), attached to the cylinder with nuts and washers (3-14 and 3-13), slide or float in torque plate bushings. The torque plate assembly (3-20) is mounted to the landing gear axle. 7.2 WHEEL ASSEMBLY Refer to Figure 2 for identification of wheel assembly components. The wheel is cast magnesium and conforms to all tire and rim association standards for a 6.00-6 divided type wheel. It is a tube-type design only. The wheel has inboard and outboard wheel half assemblies (2-2 and 2-4) which are fastened together with bolts (2-6), washers (2-7), and nuts (2-8). The brake disc (2-5) is attached to the wheel with the bolts. The wheel rotates on two tapered roller bearing cones (2-9), which seat in the bearing cups (2-3). Felt grease seals (2-11 and 2-13) provide protection and lubricant retention for the bearing. 7.3 OPERATION Actuation of the toe pedals engages the master cylinder and delivers hydraulic pressure to the brake cylinder. The pressure flows through the cylinder and forces the pistons outward against the pressure plate. The anchor bolts slide freely in the torque plate assembly bushings and allows the pressure plate and back plate linings to squeeze the brake disc at the same time. Page 3 October 01, 2003 IM199-60 INSTALLATION MANUAL WITH IPL FOR CONVERSION KIT PART NO. 199-60 8.0 GENERAL INFORMATION a. The brakes are shipped from the factory as a complete assembly. b. The wheels are shipped from the factory as a complete assembly. The bearing cones are packed with grease and installed in the wheel halves. NOTE: Extended storage (longer than two years) of lubricated bearings will require re- lubrication. Refer to paragraph 8.1 for bearing cone grease packing procedure. 8.1 BEARING CONE GREASE PACKING PROCEDURE The proper application of grease to the tapered roller bearing will reduce friction, dissipate heat and maintain a rust and corrosion proof coating on the operating surfaces of the roller bearings. CAUTION: USE A MULTI-PURPOSE GREASE CONFORMING TO MIL-G-81322. DO NOT MIX WITH OTHER GREASES. GREASE INCOMPATIBILITY COULD RESULT IN CONTAMINATION AND LOSS OF GREASE PERFORMANCE. NOTE: To prevent possible foreign matter contamination, pack bearing cones just prior to installing. NOTE: Packing bearing cones with grease is best performed by mechanical means such as a bearing greaser. a. Ensure bearings are completely dry before packing them with lubricant. b. Pack the bearing cone from the wide (outer) side. c. Force the grease up between rollers, cone and cage, making sure that all voids inside the cone are filled (see Figure 1). Also, make sure that a generous amount of grease is applied to the roller surfaces on the outside of the cone. NOTE: Shaded area indicates the recommended amount of grease. Figure 1, Packing Bearing Cones Page 4 October 01, 2003 IM199-60 INSTALLATION MANUAL WITH IPL FOR CONVERSION KIT PART NO. 199-60 9.0 KIT INSTALLATION Read this installation manual and look at the installation drawings before removing and installing components. SAFETY WARNING: INSURE AIRCRAFT IS SECURE AND STABLE BEFORE BEGINNING ANY WORK. WORKING UNDER AN IMPROPERLY STABILIZED AIRCRAFT COULD CAUSE INJURY OR DEATH. SAFETY WARNING: COMPLETELY DEFLATE THE TIRE BEFORE REMOVING THE VALVE CORE. VALVE CORES UNDER PRESSURE CAN BE EJECTED LIKE A BULLET. 9.1 REMOVE ORIGINAL EQUIPMENT CAUTION: ALWAYS CHECK THE CONDITION OF ORIGINAL EQUIPMENT HARDWARE THAT WILL BE RETAINED SUCH AS FITTINGS, AXLE NUTS, ETC. REPLACE THESE ITEMS AS NEEDED. a. Properly raise and support the aircraft off the ground following the airframe manufacturer’s instructions. b. Remove the cap from the tire inflation valve and slowly deflate the tire. c. Confirm that the tire is completely deflated. d. When all the tire pressure has been released, remove the valve core from the inside of the valve stem. NOTE: The cotter pin is not supplied as part of 199-60 kit and must be obtained separately. Refer to the airframe parts catalog for the part number and the quantity. e. Remove and keep the axle hardware. Discard the cotter pin. f. Remove the original equipment main landing gear wheels from the axle. g. Disconnect the hydraulic line (original equipment flexible inlet hose or rigid inlet line) at the brake inlet fitting and seal the hydraulic line. h. Remove and keep the inlet fitting from the original equipment brake assemblies. i. Remove the original equipment brake assemblies from the axle. Page 5 October 01, 2003 IM199-60 INSTALLATION MANUAL WITH IPL FOR CONVERSION KIT PART NO. 199-60 9.2 INSTALL CLEVELAND EQUIPMENT Refer to IPL Figure 2 and IPL Figure 3 for identification of wheel and brake assembly components. The installation procedures are applicable to the aircraft models listed in Section 3.0 Applicability. • Installation drawing 50-34 is applicable to Cessna model series 210 aircraft: - Sheet 1 covers tubular landing gear configuration. - Sheet 2 covers flat spring landing gear configuration. • Installation drawing 50-35 is applicable to Cessna model series 180, 185, and 206 aircraft equipped with rigid tube or flexible hose brake lines. 9.2.1 Mount Tube-Type Tire a. Remove the following items from both the inboard and outboard side of wheel assembly: snap rings (2-15), grease seal rings (2-10, 2-12, 2-14) and grease seal felts (2-11, 2-13). Place the removed items on a clean surface to prevent contamination NOTE: Be careful with the bearing cones to prevent contamination or damage. b. Next, remove the bearing cones (2-9). Place bearing cones on a clean surface to prevent contamination. c. Inspect the bearing cones to make sure they are filled with grease. If they need grease, refer to paragraph 8.1, Bearing Cone Grease Packing Procedure to add grease to the bearing cones. CAUTION: DO NOT USE AN IMPACT WRENCH OR A POWER WRENCH TO REMOVE OR INSTALL THE WHEEL NUTS AND BOLTS. THESE TOOLS CAN DAMAGE THE EXTERNAL FEATURES OF THE NUTS AND BOLTS. THESE TOOLS CAN CREATE TOO MUCH FORCE AND CAN DAMAGE THE MATING COMPONENTS. d. Remove all three nuts (2-8), washers (2-7) and bolts (2-6) to separate wheel halves and place brake disc (2-5) to the side. NOTE: Tire slippage may occur with new tires and tubes. Wipe the tire and tube with denatured alcohol, followed by soap and water. e. Make sure the inside of the tire is clean and dry. Inspect the bead seat area and wipe it clean with denatured alcohol, followed by soap and water, then dry thoroughly. f. Inflate the inner tube just enough to round it out. Page 6 October 01, 2003 IM199-60 INSTALLATION MANUAL WITH IPL FOR CONVERSION KIT PART NO. 199-60 NOTE: Refer to the airframe service manual for additional guidance on balancing the wheel and tire unit. g. The inner tube heavy spot is indicated by a painted yellow stripe. Align the stripe on the tube with the tire red balance dot. If the tube has no balance mark, align the tube valve with the tire red balance dot. NOTE: This procedure is usually sufficient to prevent vibration during high speed taxi. If excess vibration is encountered, check all fasteners for looseness and make sure that the components are correctly attached. h. Install the tire and inner tube on the outer wheel half, inserting the valve stem through the valve hole in the wheel. Place the inner wheel half inside the tire and align the bolt holes. i. Install the disc in inner wheel half and align bolt holes with wheel half. CAUTION: FAILURE TO PROPERLY TORQUE THE WHEEL ASSEMBLY BOLTS MAY RESULT IN PREMATURE FAILURE OF THE MATING COMPONENTS OR HARDWARE. NOTE: Install bolts with the bolt head against the brake disc. j. Install the bolts through the brake disc bolt holes. Install the washers and nuts on the bolts. While using the dry torque procedure, observe the torque required to turn the nut (free running torque). This torque value must be added to the torque value stated on the wheel assembly nameplate to obtain a true torque value. NOTE: Wheel assembly bolt torque values can also be referenced from Parker Hannifin publications, AWBCMM0001, Maintenance Manual and PRM64, Technician’s Service Guide. k. Lightly coat or dampen the grease seal felts with SAE 10 engine oil. NOTE: Be careful with the bearing cones to prevent contamination or damage. l. Place the bearing cones (2-9) in the bearing cups (2-3). m. Re-assemble the grease seals (rings and felts) and snap rings. Page 7 October 01, 2003 IM199-60 INSTALLATION MANUAL WITH IPL FOR CONVERSION KIT PART NO. 199-60 SAFETY WARNING: INFLATION OF TIRE CAN BE EXTREMELY DANGEROUS AND IT IS RECOMMENDED THAT INFLATION BE PERFORMED IN AN INFLATION CAGE TO PREVENT INJURY TO PERSONNEL FROM POSSIBLE EXPLOSION. TIRES AND WHEEL ASSEMBLIES MUST BE SERVICED WITH INFLATION EQUIPMENT THAT HAS BEEN SPECIFICALLY DESIGNED FOR THIS OPERATION. m. Inflate tire per tire manufacturer’s specifications to seat beads on wheel. Complete inflation to operating pressure per the airframe service manual. Set wheel/tire unit aside. 9.2.2 Mount Torque Plate The brake and axle attachment hardware is not included in the 199-60 Conversion Kit. Refer to the applicable Parker Hannifin installation drawing for information on brake/axle attachment hardware. a. Use one bushing (3-21) each in the upper torque plate/axle hole locations for the 0.3125 inch (5/16) dia. bolts. b. Refer to the applicable installation drawing for torque plate mounting orientation. Attach the torque plate assembly (3-20) to the axle using the axle mounting hardware (bolts, washers, and nuts). Torque nuts to value specified in the airframe service manual. 9.2.3 Mount Wheel/Tire Assembly a. Check the tire inflation pressure and adjust if necessary. b. Carefully slide the wheel/tire unit onto axle. c. Apply a thin coat of bearing grease to the axle nut and threads. d. Refer to the airframe service manual and install the axle nut. 9.2.4 Mount Brake Assembly NOTE: The bolts (3-15) and washers (3-16) can remain in the cylinder bolt holes. a. Loosen the four back plate attachment bolts (3-15) and remove the two back plate assemblies (3-10). Page 8 October 01, 2003 IM199-60 INSTALLATION MANUAL WITH IPL FOR CONVERSION KIT PART NO. 199-60 CAUTION: DO NOT FORCE THE CYLINDER ANCHOR BOLTS INTO THE TORQUE PLATE ENGAGEMENT HOLES. NOTE: A dry film lubricant, such as Dri-Slide (molybdenum disulfide) or silicon spray, can be applied to the anchor bolts and the torque plate engagement holes. This will help installation and give easier operation. A liquid type lubricant should not be used because it will allow dirt and moisture to collect and increase the risk of corrosion, binding and wear. b. Engage the cylinder assembly (3-1) into the torque plate by sliding the anchor bolts (3-12) into the torque plate engagement holes (noted by the welded bushings on torque plate). c. Position the back plate assemblies (3-10) between the brake disc (2-5) and the inner wheel flange. Align the back plate assemblies with the brake cylinder bolt holes and thread the bolts (3-15) [with installed washers (3-16)] into the back plate assemblies. Dry torque the bolts between 85 to 95 in-lb. 9.2.5 Connect Brake Assembly a. Install the inlet fitting (the fitting retained when original equipment was removed) into the Cleveland brake assembly. b. Follow the applicable installation drawing to route the hydraulic lines and connect the hydraulic lines to the brake assembly. c. Upon completion of the installation, bleed the system per the airframe service manual. d. Follow paragraph 9.3 System Checks prior to removing aircraft from jacks. 9.3 SYSTEM CHECKS 9.3.1 All Applicable Aircraft Models a. After bleeding the brakes, the wheel assemblies should rotate freely. There should be no evidence of binding or excessive brake drag. b. Check for possible interference peculiar to individual aircraft. 9.3.2 Cessna Series 210 With Flat Spring Landing Gear Refer to installation drawing 50-34 a. While the aircraft is on jacks, slowly cycle both landing gears to make sure the hydraulic line does not interfere with the uplatch mechanism or bumper pad before returning the aircraft to service. Page 9 October 01, 2003 IM199-60 INSTALLATION MANUAL WITH IPL FOR CONVERSION KIT PART NO. 199-60 9.4 BRAKE LINING CONDITIONING When new linings are installed, it is important to condition them properly to obtain the service life designed into them. Condition linings per attached product reference memo PRM 13A. 10.0 WEIGHT AND BALANCE COMPUTATIONS Weigh the original equipment wheels and brakes. Subtract from the new weights to derive weight increase created by the kit installation. Multiply the weight increase by the applicable aircraft moment and revise the weight and balance information in the log book. 10.1 WEIGHT AND BALANCE DATA New installed (per gear leg) Wheel assy........ 6.75 lbs. Brake assy ........ 3.00 lbs. Total ...........…... 9.75 lbs. Complete form 337 and make appropriate log book entries. 11.0 PILOT OPERATING MANUAL INSERTS Inserts are located in front with conversion kit documentation. Attach the label in the pilot operating manual as close as possible to the original section labeled Main Wheel Assembly. Enter the correct arm and moment in the blocks provided. Zero the items out for the original main wheel and brake assemblies that have been removed. Inserts are reprinted below for reference: x Two dual piston, single disc Brake Assemblies, Cleveland P/N 30-52 3.00 ea. x Two 6.00-6 Type III Wheel Assemblies, Cleveland P/N 40-75B 6.75 ea. Cleveland Brake Assembly P/N 30-52 is a single caliper, single fixed disc design, using two pistons per caliper which respond to fluid pressure from the master cylinders for brake application. Page 10 October 01, 2003 IM199-60 INSTALLATION MANUAL WITH IPL FOR CONVERSION KIT PART NO. 199-60 12.0 WHEEL ASSEMBLY ILLUSTRATED PARTS LIST Figure 2, 40-75B Wheel Assembly Exploded View FIG PART NUMBER DESCRIPTION QTY 40-75B Wheel Assembly (standard) 40-75B CHROME Wheel Assembly 2-1 40-75B GOLD Wheel Assembly RF 2 161-03000 Inboard Wheel Half Assembly 1 3 214-00100 Cup-Bearing 1 4 162-02700 Outboard Wheel Half Assembly 1 3 214-00100 Cup-Bearing 1 164-01501 Brake Disc (standard) 164-11501 Brake Disc (chrome) 5 164-41501 Brake Disc (gold) 1 6 103-20400 Bolt (AN5-35A) 3 7 095-10500 Washer (AN960-516) 3 8 094-10400 Nut (MS21044-N5) 3 9 214-00200 Cone-Bearing 2 10 153-00400 Ring-Grease Seal 2 11 154-00300 Felt-Grease Seal 1 12 153-00300 Ring-Grease Seal 1 LEGEND: 13 154-01300 Felt-Grease Seal 1 – Item Not Illustrated 14 153-01500 Ring-Grease Seal 1 15 155-00100 Snap Ring 2 − 16 166-19700 Nameplate 1 − 17 166-20000 Nameplate 1 Page 11 October 01, 2003 IM199-60 INSTALLATION MANUAL WITH IPL FOR CONVERSION KIT PART NO. 199-60 13.0 BRAKE ASSEMBLY ILLUSTRATED PARTS LIST Figure 3, 30-52 Brake Assembly Exploded View FIG PART NUMBER DESCRIPTION QTY 3-1 30-52 Brake Assembly RF − 1 091-02100 Cylinder Assembly 1 2 061-01800 Cylinder 1 − 3 092-01600 Piston Assembly 2 4 062-01500 Piston 2 5 101-02700 O-Ring (MS28775-222) 2 − 6 073-01000 Pressure Plate Assembly 1 7 063-01100 Pressure Plate 1 8 105-00200 Rivet 4 9 066-10500 Lining 2 −10 074-01000 Back Plate Assembly 2 11 064-01500 Back Plate 2 8 105-00200 Rivet 4 9 066-10500 Lining 2 12 069-00400 Anchor Bolt 2 13 095-10200 Washer (AN960-416L) 2 14 094-10300 Nut (MS21044-N4) 2 15 103-11800 Bolt (ABP4-21AM) 4 16 095-10400 Washer (AN960-416) 4 LEGEND: 17 081-00100 Seat-Bleeder 1 – Item Not Illustrated 18 079-00300 Screw-Bleeder 1 19 183-00100 Cap-Bleeder 1 20 075-05401 Torque Plate Assembly 1 21 145-01000 Bushing 2 − 22 166-20100 Nameplate 1 − 23 215-00200 Cap, Shipping 1 Page 12 October 01, 2003 IM199-60 INSTALLATION MANUAL WITH IPL FOR CONVERSION KIT PART NO. 199-60 14.0 KIT PARTS LIST 199-60 KIT (3) (4) SEE NOTE PART NUMBER DESCRIPTION QUANTITY (1) 40-75B Wheel Assembly 2 (2) 30-52 Brake Assembly 2 IM199-60 Installation Manual for Conversion Kit 199-60 1 50-34 Installation Drawing 1 50-35 Installation Drawing 1 SA52GL Supplemental Type Certificate (210 Series) 1 SA62GL Supplemental Type Certificate (180, 185, 206 Series) 1 PRM13A Conditioning Procedure for Non Asbestos Organic Brake Lining 1 ------- Pilot Operating Manual Inserts 1 ------- Product Registration Card 1 (1) For Subassembly and Parts identification: See Figure 2; 40-75B IPL (2) For Subassembly and Parts identification: See Figure 3; 30-52 IPL (3) 199-60 CHROME is identical to 199-60 except for chrome plated brake disc: see Figure 2; 40-75B IPL (4) 199-60 GOLD is identical to 199-60 except for performance gold brake disc: see Figure 2; 40-75B IPL Page 13 October 01, 2003 ClevelandWheels & Brakes Parker Hannifin Corporation Aircraft Wheel & Brake 1160 Center Road Avon, Ohio 44011 USA 1-800-BRAKING (272-5464) 216-937-1272 l FAX 216-937-5409 PRODUCT REFERENCE MEMO Initial Release November 4, 1987 Rev A July 1, 1995 PRM13A Page 1 of 1 CONDITIONING PROCEDURE FOR NON ASBESTOS ORGANIC BRAKE LINING The brake lining material used in this brake assembly is a non asbestos organic composition. This material must be properly conditioned in order to provide maximum performance and service life. Conditioning may be accomplished as follows: 1. Taxi aircraft for 1500 feet with engine at 1700 rpm applying brake pedal force as needed to develop a 5 - 10 mph taxi speed. 2. Allow brakes to cool for 10 - 15 minutes. 3. Apply brakes and check to see if a high throttle static run up may be held with normal pedal force. If so, conditioning is completed. 4. If static run up cannot be held, repeat steps 1 through 3 as needed to successfully hold. This conditioning procedure will generate sufficient heat to create a thin layer of glazed material at the lining friction surface. Normal brake usage should generate enough heat to maintain the glaze throughout the life of the lining. Light brake usage can cause the glaze to wear off, resulting in reduced brake performance. In such cases, the lining may be conditioned again following the instructions set forth in this PRM. 1 Parker Hannifin Corporation Aerospace/Aircraft Wheel & Brake 1160 Center Road Avon, OH 44011 Date: _ _/_ _/20_ _ Subject: Letter of Authorization for Installation of STC’d Conversion Kits To whom it may concern: Parker Hannifin Corporation, Aircraft Wheel & Brake Division, hereby states that the following item(s): KIT NUMBER: 199-___________ FAA APPROVAL: 1) STC # ________________________ NO OTHER APPROVALS NECESSARY AUTHORIZATION TO INSTALL: With the sale of this STC KIT, OWNER of the Supplemental Type Certificate agrees to permit the buyer or buyer’s agent or agency to use the certificate to alter the product under the terms and conditions of this STC. A/C MAKE: ______________________ A/C MODEL______________________ TAIL # __________________________ Regards, Technical Support Team Technical Hotline (800) 272-5464 Clevelandwbhelp@parker.com Web-site: www.clevelandwheelandbrake.com Manufacturer of Cleveland Wheels & Brakes