EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.

br>
COMPONENT MAINTENANCE MANUAL
with
ILLUSTRATED PARTS LIST

BRAKE ASSEMBLY

PART NUMBER
5003096, 5003096-1, 5003096-3, 5003096-4,
5003096-5, 5003096-6 and 5003096-7

0B9R9

BRASIL VIDA TAXI AEREO

All Rights Reserved

Copyright © 2013
Meggitt Aircraft Braking Systems
Proprietary Notice
This document is the property of Meggitt Aircraft Braking Systems and shall not be copied or used, either in whole or part, for any purpose other
than that for which it is supplied, without the express written authority of Meggitt Aircraft Braking Systems.
These commodities, technology or software were exported from the United States in accordance with the Export Administration Regulations.
Diversion contrary to US law is prohibited.

PUB. NO. AP-455

32-43-32
CO: 8462

Basic Issue Aug 01/1975

Revision 9 Aug 12/2013
SEE EXPORT COMPLIANCE PARAGRAPH REVERSE SIDE.
 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
EXPORT COMPLIANCE
These commodities, technology or software were exported from the United States in accordance with the
Export Administration Regulations. Diversion contrary to U.S. law is prohibited.

BRASIL VIDA TAXI AEREO

CO: 8462
 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

TO: HOLDERS OF AP-455 (32-43-32) COMPONENT MAINTENANCE MANUAL WITH

ILLUSTRATED PARTS LIST FOR BRAKE ASSEMBLIES 5003096, 5003096-1,
5003096-3, 5003096-4, 5003096-5, 5003096-6 AND 5003096-7 USED ON THE
LEARJET 25, 31A, 35, 35A, 36, 36A, LEARJET 55, "LONG AXLE" LEARJET 55
AIRCRAFT (STARTING WITH AIRCRAFT TAIL NO. 101, 107 AND SUBSEQUENT) AND
LEARJET 60 SERIES AIRCRAFT.

Attached to this transmittal letter is Revision No. 9 of AP-455 (basic issue dated 01
August 1975).

REVISION NO. 9 DATED 12 AUGUST 2013

REVISION NO. 9 CONTAINS ALL PAGES OF THE MANUAL. Pages which have been added or
revised are outlined below, together with the Highlights of the revision.

The purpose of Revision No. 9 is to add temporary revision and to do a general update to the
manual. All changes are highlighted in the Description of Change that follows.

Please retain all previous HIGHLIGHTS pages inserting them into this manual for future reference.

CHAPTER/SECTION/PAGE NO. DESCRIPTION OF CHANGE

Title Page Updated to Meggitt Aircraft Braking Systems format and
revised to Revision “9”. Changed the date to current revision
date.
Record of Revisions Added Revision 9 and date.
Record of Temporary Revisions Added TR32-10 thru TR32-15 revisions and date.
List of Effective Pages,
Pages 1 and 2 Updated pages and revised date to latest revision date.
Table of Contents,
Pages 1 thru 4 Updated table of contents page numbers.
All Pages as applies Updated unit from "psi" to "psig" entire manual.
Updated WARNINGS notes as required.
Updated MIL-Specification entire manual.
Added item 110B and 152A.
Introduction,

BRASIL VIDA TAXI AEREO

Pages 1 and 4 Updated introduction with publication website and E-mail ID.
Updated MABS customer support location.
Description and Operation,
Page 2 Added NOTE for installation of brake bolt (20).
Page 4 Added NOTE about installation of brake bolt (20A).
Page 6 Added item 110B and 152A.

Highlights
32-43-32 Page 1 of 4
CO: 8462

Aug 12/13
 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

CHAPTER/SECTION/PAGE NO. DESCRIPTION OF CHANGE

Cleaning,
Page 401 Updated blue gold industrial cleaner.
Pages 404 and 405 Added procedure for blue gold industrial cleaner.
Check,
Page 502 Updated Para 4.A and 5.A.
Updated maximum value of keyslot width.
Page 503 Updated Para 6.A.
Updated maximum value of keyslot width.
Page 506 Added NOTE for bolt inspection procedure.
Page 507 Updated tube damage check by magnetic particle method in
torque tube procedure.
Repair,
Page 602 Updated grit value of aluminum oxide cloth.
Added Gas Tungsten Arc Weld or Gas Metal Arc Weld in
material table.
Page 607 Replaced item 180A by item 180.
Page 609 Updated the temperature for pre and post heating after
welding rivet hole.
Page 612 Deleted "disk with holes/elongation more than these diameters
must be discarded" in para 8.E.(1).
Updated the temperature for post heating after welding rivet
hole.
Page 614 Deleted "disk with holes/elongation more than these diameters
must be discarded" in para 9.C.(1).
Page 622 Updated grit value of aluminum oxide cloth.
Repair No.1,
Page 601 Updated metal stamping "R1-1" procedure.
Repair No 2,
Page 601 Deleted metal stamping "R" procedure.
Assembly and Storage,

BRASIL VIDA TAXI AEREO

Page 703 Added paragraph 3.D.(3) which describes applying bearing
grease to the insulator.
Page 710 Updated paragraph 4.M.(4) to indicate correct Long Brake Bolt
(20A) installation.
Fixture and Clearances
Page 802 Updated maximum value of keyslot width.

Highlights
32-43-32 Page 2 of 4
CO: 8462

Aug 12/13
 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

CHAPTER/SECTION/PAGE NO. DESCRIPTION OF CHANGE

Special Tools, Fixture and
Equipment,
Page 901 Added drilling Tool in tools and fixture table.
Page 902 Updated MABS technical support contact address.
Illustrated Parts List
Pages 1001 and 1002 Updated IPL introduction
Page 1003 Updated CAGE codes and address.
Page 1004 Changed view to show the correct installation of brake bolt
(20A).
Updated IPL Figure caption.
Replaced item 152 by item 152A.
Replaced item 180A by item 180.
Page 1005 Added actual part number for item 40.
Updated the part number of item 90A from 5006425-1 to
5006425.
Page 1006 Updated item 90B and 110 in nomenclature.
Added item 110B.
Page 1007 Updated item 152 and 180A in nomenclature.
Added item 152A.

BRASIL VIDA TAXI AEREO

Highlights
32-43-32 Page 3 of 4
CO: 8462

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THIS PAGE
KEPT
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BRASIL VIDA TAXI AEREO

Highlights
32-43-32 Page 4 of 4
CO: 8462

Aug 12/13
 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

TO: HOLDERS OF AP--455 (32--43--32) COMPONENT MAINTENANCE MANUAL WITH

ILLUSTRATED PARTS LIST FOR BRAKE ASSEMBLIES 5003096, 5003096--1, 5003096--3,
5003096--4, 5003096--5, 5003096--6, AND 5003096--7 USED ON THE LEARJET 25, 31A, 35,
35A, 36, 36A, 55, AND 60 SERIES AIRCRAFT.
Attached to this transmittal letter is Revision No. 8 of AP--455 (basic issue dated 1 August 1975).

REVISION NO. 8 DATED 11 JUNE 2004

HIGHLIGHTS

REVISION NO. 8 CONTAINS ALL PAGES OF THE MANUAL. Pages which have been added or
revised are outlined below, together with the Highlights of the revision.
Please retain all previous HIGHLIGHTS pages inserting them into this manual for future reference.
The purpose of Revision No. 8 is is to incorporate Temporary Revision 32--8 and 32--9 and update the
manual in accordance with procedures used at Aircraft Braking Systems Corporation.

Chapter/Section/Page No. Description of Change

Cover Revised to the latest Aircraft Braking Systems Corporation format.
Added Learjet 31A per request.

Title Page Revised date to current revision date.

Added Learjet 31A per request.

Record of Revisions Added Revision 8.

Record of Temporary Revisions, Added Temporary Revision 32--8 and 32--9.

page 1

Service Bulletin List, Revised to indicate current revisions of Service Bulletins consid-
page 1 ered.

List of Effective Pages, Revised to reflect added, revised, and/or deleted pages.
pages 1 and 2

Table of Contents, Revised to reflect current revision for relocated text.

pages 1 and 2

BRASIL VIDA TAXI AEREO

List of Figures Added list of figures.

Introduction, Revised to latest Introduction and current field office address list.
pages 1 through 4

Highlights
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32--43--32 Jun 11/04
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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

Chapter/Section/Page No. Description of Change

(32--43--32)

All section as required Added Acetone, Specification ASTM D329 as a replacement for
Methyl Isobutyl Ketone. Updated CAUTIONS and WARNINGS.
Changed BARS to BAR. Added equivalent for MIL--C--5541.
Changed MIL--H--5606 to MIL--PRF--5606.
Restructured and rewrote some test for clarity.
Made small editorial changes that did not change content.

page 1 Added swage and tube subassembly to paragraph 2.D.

pages 2 thru 5 Added swage and tube subassembly information to Figure 1.

page 6 Added 150B, 150C, 151, 152, 153, 153A, 210B and 210C to Key
for Figure 1.
Revised paragraphs C. and D.

page 7 Changed maximum operating pressure to 1500 psi..

page 101 Changed addresses of manufacturers in paragraph 1. (Test Equip-

ment and Materials).

page 102 Added specification SAE AMS 2518 for antiseize compound.

Pages 107 thru 108 Modified Hardness Test, paragraph 7.

page 109 Added Rockwell B test to Figure 104. Added * and footnote.

page 301 Added paragraph 1.C.

page 302 Added swage tube subassembly to paragraph 2.E.

Added 210B and 210C insulators to Paragraph 2.F.

pages 401 and 402 Update cleaning materials.

pages 402 and 403 Update cleaning procedures.

BRASIL VIDA TAXI AEREO

page 403 Added 150A grip and tube subassembly to paragraph 2.F.

page 404 Added WARNINGS, updated CAUTION.

pages 406 and 407 Updated NOTE. Modified Method II procedures.

page 501 Updated paragraph 1. Check Materials section. Added NOTE.

Highlights
CO: 8462

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32--43--32 Jun 11/04
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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

Chapter/Section/Page No. Description of Change

(32--43--32)

page 502 Added paragraph 4.F.

page 503 Added paragraph 6.E.

page 505 Added 210B and 210C insulators to paragraph 10. and revised
text. Paragraph 12. moved to page 506 because of the new text
added to paragraph 10.

page 506 Revised paragraph 13.C.

page 507 Added Figure 504 Key Wear Limit.

page 509 Added self--adjusting swage tube and adjuster swage information.
paragraph 15.

pages 601 and 602 Updated Repair Materials list with current addresses

page 603 Modified paragraph 4.C.

pages 605 and 606 Added 120A, 180A, and 200A to Figure 602.

pages 607 and 609 Changed RHR to Ra.

page 610 Added 130B to paragraph 7.

Changed RHR to Ra in paragraph 7.D.

page 612 Modified paragraph 7.E.(1).

page 614 Modified paragraph 9.C.(1).

page 618 Added disk insulators 210B and 210C to paragraph 12. and revised
the text in the paragraph.

pages 620 thru 623 Updated Re--Painting procedure, paragraph 13.

BRASIL VIDA TAXI AEREO

pages 626 thru 631 Added Service Bulletin information on replacing grip and tube
subassemblies with swage tube subassemblies.

pages 632 thru 634 Added Service Bulletin information on inspect brake subassembly
and replace rotating disk if wear is observed.

Highlights
CO: 8462

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32--43--32 Jun 11/04
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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

Chapter/Section/Page No. Description of Change

(32--43--32)

pages 634 thru 636 Added Service Bulletin information on rotor modification for Brake
Assemblies 5003096--5 and --7.

Repair No. 2 Added new repair No. 2 for repairing damaged expander plugs.
pages 601 thru 603

page 701 Updated assembly materials.

pages 701 thru 708 Changed hydraulic pressure fluid specification to MIL--PRF--5606.
Added Pliobond 20 as alternate to Pliobond 5001.
Added additional disk insulators 210A and 210C.
Added swage tube information.

page 704 Change antiseize compound to specification MIL--PRF--83483 in

paragraph 3.L.(1) and following NOTE.

page 705 Change antiseize compound to specification MIL--PRF--83483 in

CAUTION. Changed Lubtork to torque in paragraph 3.L.(3).

page 707 Added if used to CAUTION for grip and tube subassembly.
Added swage tube subassembly information in paragraph 4.J.

page 708 Change antiseize compound to specification MIL--PRF--83483 in

paragraph 4.L.(1), following NOTE and CAUTION.
Changed Lubtork to torque in paragraph 4.L.(3).

page 801 Change Lubtork to Molylube in Figure 801.

page 802 Added Item No. 151, Adjuster Swage.

page 901 Added Figure 613 for tool No.3--7305--1A.

page 902 Updated addresses.

page 903 Added Special tools information.

page 1001 Updated introduction. BRASIL VIDA TAXI AEREO

page 1002 Moved Cage codes to front of section and updated CAGE codes.

page 1003 Updated IPL Figure 1.

Highlights
CO: 8462

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32--43--32 Jun 11/04
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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

Chapter/Section/Page No. Description of Change

(32--43--32)

pages 1005 thru 1009 Changed the following item No’s.

Item --20 Added original part number in nomenclature
Item 20A Added original part number in nomenclature
Item 40A Added original part number in nomenclature
Item 70 Added original part number in nomenclature
Item --90A Changed part number from 5006425 to 5006425--1
item 90B Added *
Item --110 Added original part number in nomenclature
Item 110A Added original part number in nomenclature
Item --120A Added effect codes A BDEG
Item --150 Added replaced by item 150B
Item --150A Added replaced by item 150C
Item 150B Added new item number
Item 150C Added new item number
Item 151 Added new item number
Item 152 Added new item number
Item 153 Added new item number
Item 153A Added new item number
Item 180 Added original part number in nomenclature
Item 180A Added original part number in nomenclature.

pages 1005 thru 1009 Changed the following item No’s.

Item 200A Added effect codes ABDEG

Item --210 Added “Superseded by item 210B” in nomenclature
Item --210A Made as an item not illustrated and added “Super
seded by item 210C” in nomenclature
Item --210B Added new insulator disk
Item 210C Added new insulator disk
Item 240A Added original part number in nomenclature
Item 290 Changed part number from FC6446 to F6446
Item 340 New vendor cage code
Items --430, --430A Added expander plugs
Items --440, --440A Added expander and pin plug for repair.

BRASIL VIDA TAXI AEREO

Highlights
CO: 8462

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32--43--32 Jun 11/04
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BRASIL VIDA TAXI AEREO

Highlights
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32--43--32 Jun 11/04
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CO: 8462 BRASIL VIDA TAXI AEREO EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
CO: 8462 BRASIL VIDA TAXI AEREO EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
CO: 8462 BRASIL VIDA TAXI AEREO EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
CO: 8462 BRASIL VIDA TAXI AEREO EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096
RECORD OF REVISIONS

REV ISSUE DATE BY REV ISSUE DATE BY

NO. DATE INSERTED NO. DATE INSERTED
1 Apr 15/81 Apr 15/81 GAC
2 Oct 01/81 Oct 01/81 GAC
3 Nov 30/82 Nov 30/82 GAC
4 Dec 30/83 Dec 30/83 GAC
5 Aug 31/90 Aug 31/90 ABSC
6 Mar 10/93 Mar 10/93 ABSC
7 Aug 10/93 Nov 21/94 ABSC
8 Jun 11/04 Jun 11/04 ABSC
9 Aug 12/13 Aug 12/13 MABS

BRASIL VIDA TAXI AEREO

Record of Revisions
Page 1
32-43-32
CO: 8462

Aug 12/13
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BRASIL VIDA TAXI AEREO

Record of Revisions
Page 2
32-43-32
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 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

RECORD OF TEMPORARY REVISIONS

TEMPORARY PAGE ISSUE DATE

REVISION NUMBER NUMBER DATE BY REMOVED BY
32-1 1 and 2 May 15/77 GAC Oct 01/81 GAC
32-2 1 thru 5 Jan 15/79 GAC Oct 01/81 GAC
32-3 1 thru 4 Jun 18/82 GAC Dec 30/83 GAC
32-4 1 thru 5 Aug 15/89 ABSC Aug 31/90 ABSC
32-5 1 and 2 Feb 14/91 ABSC Mar 10/93 ABSC
32-6 1 and 2 Apr 22/91 ABSC Mar 10/93 ABSC
32-7 1 and 2 Dec 20/91 ABSC Mar 10/93 ABSC
32-8 1 thru 3 Aug 12/94 ABSC Jun 11/04 ABSC
32-9 1 thru 3 Feb 23/01 ABSC Jun 11/04 ABSC
32-10 1 thru 10 May 20/05 ABSC Aug 12/13 MABS
32-11 1 and 2 July 15/05 ABSC Aug 12/13 MABS
32-12 1 and 2 Mar 09/06 ABSC Aug 12/13 MABS
32-13 1 thru 3 Apr 19/06 ABSC Aug 12/13 MABS
32-14 1 thru 3 Oct 12/07 ABSC Aug 12/13 MABS
32-15 1 thru 2 Feb 04/08 MABS Aug 12/13 MABS

BRASIL VIDA TAXI AEREO

Record of Temporary Revisions

Page 1
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CO: 8462

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BRASIL VIDA TAXI AEREO

Record of Temporary Revisions

Page 2
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COMPONENT MAINTENANCE MANUAL
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SERVICE BULLETIN/SERVICE LETTER LIST

SERVICE BULLETIN/ REV DATE SERVICE BULLETIN/ REV DATE

LETTER NO. NO. INSERTED LETTER NO. NO. INSERTED
Lear 25-32-1 No Effect Lear 36-32-6 Jun 11/04
Lear 25-32-2 No Effect Lear 36-32-7 Jun 11/04
Lear 25-32-3 No Effect Lear 55-32-1 No Effect
Lear 25-32-4 No Effect Lear 55-32-2 No Effect
Lear 25-32-5 Oct 01/81 Lear 55-32-3 2 No Effect
Lear 25-32-6 1 No Effect Lear 55-32-4 2 No Effect
Lear 25-32-7 3 No Effect Lear 55-32-5 2 No Effect
Lear 25-32-8 1 No Effect Lear 55-32-6 1 No Effect
Lear 25-32-9 1 No Effect Lear 55-32-7 1 No Effect
Lear 25-32-10 2 No Effect Lear 55-32-8 1 Jun 11/04
Lear 25-32-11 1 Jun 11/04 Lear 55-32-9 Jun 11/04
Lear 25-32-12 Jun 11/04 Lear 55-32-10 Jun 11/04
Lear 25-32-13 Jun 11/04 Lear 55-32-11 Jun 11/04
Lear 35-32-1 No Effect Lear 60-32-1 Jun 11/04
Lear 35-32-2 No Effect Lear 60-32-2 Jun 11/04
Lear 35-32-3 No Effect Lear 60-32-3 Jun 11/04
Lear 35-32-4 Oct 01/81 Lear 60-32-4 Cancelled
Lear 35-32-5 1 No Effect Lear 60-32-5 Cancelled
Lear 35-32-6 3 No Effect Lear 60-32-6 Jun 11/04
Lear 35-32-7 1 No Effect
Lear 35-32-8 1 No Effect
Lear 35-32-9 1 Jun 11/04
Lear 35-32-10 Jun 11/04

BRASIL VIDA TAXI AEREO

Lear 35-32-11 Jun 11/04
Lear 36-32-1 No Effect
Lear 36-32-2 Oct 01/81
Lear 36-32-3 1 No Effect
Lear 36-32-4 3 No Effect
Lear 36-32-5 1 Jun 11/04

Service Bulletin/Letter List

Page 1
32-43-32
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BRASIL VIDA TAXI AEREO

Service Bulletin/Letter List

Page 2
32-43-32
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 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096
LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

Title Aug 12/13 Cleaning 401 Aug 12/13
402 Aug 12/13
Record of Revisions 1 Aug 12/13
403 Aug 12/13
2 Aug 12/13
404 Aug 12/13
Record of 1 Aug 12/13 405 Aug 12/13
Temporary Revisions 2 Aug 12/13 406 Aug 12/13
407 Aug 12/13
Service Bulletin/ 1 Aug 12/13
408 Aug 12/13
Letter List 2 Aug 12/13
409 Aug 12/13
List of Effective 1 Aug 12/13 410 Aug 12/13
Pages 2 Aug 12/13
Check 501 Aug 12/13
Table of Contents 1 Aug 12/13 502 Aug 12/13
2 Aug 12/13 503 Aug 12/13
3 Aug 12/13 504 Aug 12/13
4 Aug 12/13 505 Aug 12/13
506 Aug 12/13
Introduction 1 Aug 12/13
507 Aug 12/13
2 Aug 12/13
508 Aug 12/13
3 Aug 12/13
509 Aug 12/13
4 Aug 12/13
510 Aug 12/13
Description and 1 Aug 12/13 511 Aug 12/13
Operation 2 Aug 12/13 512 Aug 12/13
3 Aug 12/13 513 Aug 12/13
4 Aug 12/13 514 Aug 12/13
5 Aug 12/13
Repair 601 Aug 12/13
6 Aug 12/13
602 Aug 12/13
7 Aug 12/13
603 Aug 12/13
8 Aug 12/13
604 Aug 12/13
Testing and Fault 101 Aug 12/13 605 Aug 12/13
Isolation 102 Aug 12/13 606 Aug 12/13
103 Aug 12/13 607 Aug 12/13
104 Aug 12/13 608 Aug 12/13
105 Aug 12/13 609 Aug 12/13
106 Aug 12/13 610 Aug 12/13

BRASIL VIDA TAXI AEREO

107 Aug 12/13 611 Aug 12/13
108 Aug 12/13 612 Aug 12/13
109 Aug 12/13 613 Aug 12/13
110 Aug 12/13 614 Aug 12/13
615 Aug 12/13
Disassembly 301 Aug 12/13
616 Aug 12/13
302 Aug 12/13
617 Aug 12/13

List of Effective Pages

Page 1
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 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
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LIST OF EFFECTIVE PAGES (CONTINUED)

SUBJECT PAGE DATE SUBJECT PAGE DATE

Repair (Cont.) 618 Aug 12/13 Special Tools, 901 Aug 12/13
619 Aug 12/13 Fixtures and 902 Aug 12/13
620 Aug 12/13 Equipment 903 Aug 12/13
621 Aug 12/13 904 Aug 12/13
622 Aug 12/13 905 Aug 12/13
623 Aug 12/13 906 Aug 12/13
624 Aug 12/13 907 Aug 12/13
625 Aug 12/13 908 Aug 12/13
626 Aug 12/13 909 Aug 12/13
627 Aug 12/13 910 Aug 12/13
628 Aug 12/13
Illustrated Parts List 1001 Aug 12/13
629 Aug 12/13
1002 Aug 12/13
630 Aug 12/13
1003 Aug 12/13
631 Aug 12/13
1004 Aug 12/13
632 Aug 12/13
1005 Aug 12/13
633 Aug 12/13
1006 Aug 12/13
634 Aug 12/13
1007 Aug 12/13
635 Aug 12/13
1008 Aug 12/13
636 Aug 12/13
1009 Aug 12/13
Repair No. 1 601 Aug 12/13 1010 Aug 12/13
602 Aug 12/13
603 Aug 12/13
604 Aug 12/13
Repair No. 2 601 Aug 12/13
602 Aug 12/13
603 Aug 12/13
604 Aug 12/13
Assembly and 701 Aug 12/13
Storage 702 Aug 12/13
703 Aug 12/13
704 Aug 12/13
705 Aug 12/13
706 Aug 12/13
707 Aug 12/13

BRASIL VIDA TAXI AEREO

708 Aug 12/13
709 Aug 12/13
710 Aug 12/13
711 Aug 12/13
712 Aug 12/13
Fits and Clearances 801 Aug 12/13
802 Aug 12/13

List of Effective Pages

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TABLE OF CONTENTS

SUBJECT PAGE

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. Leading Particulars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5. Brake Differences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6. Brake Modifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

TESTING AND FAULT ISOLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

1. Test Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2. Test Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3. Operational Test and Fault Isolation Procedures . . . . . . . . . . . . . . 102
4. Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5. Brake Flushing Procedure (Optional) . . . . . . . . . . . . . . . . . . . . . . . 105
6. Sampling Procedure (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7. Hardness Test (Heat Damage Test) . . . . . . . . . . . . . . . . . . . . . . . . 108

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
2. Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
1. Cleaning Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
3. Paint Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405

CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1. Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
2. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501

BRASIL VIDA TAXI AEREO

3. Rotating Disk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
4. Stationary Disk Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
5. Backing Plate Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
6. Pressure Plate Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
7. Brake Housing Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
8. Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
9. Brake Bolts and and Self-Locking Nuts . . . . . . . . . . . . . . . . . . . . . 506
10. Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
11. Return Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096
TABLE OF CONTENTS (CONTINUED)

SUBJECT PAGE

CHECK (CONT.)

12. Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507

13. Torque Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
14. Grip and Tube Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
15. Self-Adjusting Swage Tube and Adjuster Swage. . . . . . . . . . . . . . . 510
16. Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
17. Preformed Packing and Packing Retainers . . . . . . . . . . . . . . . . . . . 513
18. Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
19. Spring Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
20. Return Spring Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
21. Bleeder Plug and Bleeder Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . 514
22. Hardness Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Repair Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
3. Straightening Procedures for Pressure Plate, Backing Plate and Disks 602
4. Replacing Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
5. Repair of Rotating Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
6. Repair of Stationary Disk Subassembly. . . . . . . . . . . . . . . . . . . . . . 605
7. Repair of Torque Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610
8. Repair of Backing Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
9. Repair of Pressure Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614
10. Repair of Housing Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
11. Repair of Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
12. Repair of Disk Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
13. Surface Treatment and Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
14. Brake Modification 5003096-1 to 5003096-3 . . . . . . . . . . . . . . . . . . 624
15. Brake Modification 5003096 to 5003096-4 . . . . . . . . . . . . . . . . . . . 625
16. Brake Modification 5003096-1 to 5003096-4 . . . . . . . . . . . . . . . . . . 625
17. Brake Modification 5003096-3 to 5003096-4 . . . . . . . . . . . . . . . . . . 625

BRASIL VIDA TAXI AEREO

18. Brake Modification 5003096-4 to 5003096-6 . . . . . . . . . . . . . . . . . . 626
19. Brake Modification 5003096-5 to 5003096-7 . . . . . . . . . . . . . . . . . . 626
20. Replace Grip and Tube Subassemblies
with Swage Tube Subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . 626
21. Inspect Brake Assembly 5003096-7 and
Replace Rotating Disk 5006888-1 If Uneven Wear is Observed . . . 632
22. Rotor Modification for Brake Assemblies 5003096-5
and 5003096-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096
TABLE OF CONTENTS (CONTINUED)

SUBJECT PAGE

REPAIR NO. 1 - BLEEDER HOLE REPAIR IN BRAKE HOUSING. . . . . . . . . . . . . . . 601

1. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. R1-1 Repair of Bleeder Threads. . . . . . . . . . . . . . . . . . . . . . . . . . . 601

REPAIR NO. 2 - EXPANDER PLUG REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601

1. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. R2-1 - Repair of Damaged Expander Plug Holes. . . . . . . . . . . . . . 601

ASSEMBLY AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701

1. Assembly Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
2. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
3. Assembly Procedures for Brake Assemblies 5003096,
-1, -3, -4 and -6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
4. Assembly Procedures for Brake Assemblies 5003096-5 or -7 . . . . 706
5. Storage Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711

FITS AND CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801

SPECIAL TOOLS, FIXTURES AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 901

ILLUSTRATED PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001

1. Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
2. Commercial and Government Entities (CAGE) Codes. . . . . . . . . . 1003
3. Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1004

BRASIL VIDA TAXI AEREO

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

INTRODUCTION

This manual is written according to Air Transport Association Specification No. 100 for the overhaul
and/or maintenance of the Meggitt Aircraft Braking Systems (MABS) (MABS® is the registered
trademark of Meggitt-USA) assembly(ies) included. THIS MANUAL IS APPLICABLE ONLY FOR
THE OVERHAUL OF THE INCLUDED MABS PRODUCT(S) WITH ONLY MABS PRODUCED OR
APPROVED PARTS AND APPROVED PROCEDURES. THE USE OF UNAPPROVED PARTS OR
THE OMISSION OR ALTERATION OF APPROVED PROCEDURES NEGATES THE VALIDITY OF
THIS MANUAL.

The person or facility that uses unapproved procedures or omits recommended procedures to do
an overhaul or maintenance to MABS products may not rely on this manual, must do so at their own
risk and must assume product liability. All torque values and specific limits apply only to MABS
approved parts/products and must be obeyed. Any alternative procedures, limits, or materials (if
consented to in writing by MABS) must not decrease the performance of the assembly.

The Illustrated Parts List of this manual lists and illustrates only the approved parts required to do
maintenance to the assemblies in this manual. The use of unapproved parts in these assemblies
may change the product's performance capability and will nullify the product warranty. The person
or facility that puts unapproved parts in the assemblies may not utilize this manual, must do so at
their own risk and must assume product liability.

All dimensions and other values are in English units followed by the SI (International System) units
in parentheses. Illustration dimensions are in inches with millimeter conversions in parentheses
unless specified. Dimensions of standard tools or parts are in English units where there are no
equivalent metric tools or parts. Illustrations are for reference only and are not to scale.

Meggitt Aircraft Braking Systems represents that the information contained in this manual is valid
only for use with MABS approved parts and procedures and was current at the time of publication
and verified by comparison to engineering documentation.

The user should make sure that this is the most recent publication before overhaul or maintenance
is performed. Visit www.meggitt-mabs.com and click on publications. Search for the latest revision
information or contact MABS Technical Publication directly at pubs-support@meggitt.com.

If this manual and the aircraft maintenance manual do not agree on the aircraft interface
connections, use the aircraft maintenance manual. This manual may give component functions that
may or may not be used when installed on the aircraft.

BRASIL VIDA TAXI AEREO

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BRAKE ASSEMBLY 5003096

NOTICE

MEGGITT AIRCRAFT BRAKING SYSTEMS (MABS) ASSUMES NO

CONTRACTUAL, WARRANTY, PRODUCT LIABILITY OR OTHER OBLIGATION
FOR ANY SUBSTITUTION OF OR ALTERATION TO ANY PART CONTAINED IN
ANY MABS WHEEL OR BRAKE ASSEMBLY INCLUDING ACCESSORIES NOT
SPECIFICALLY AUTHORIZED BY MABS OR FOR ANY OVERHAUL OR
MAINTENANCE NOT PERFORMED IN ACCORDANCE WITH MABS APPROVED
PROCEDURES.
DATA RIGHTS

The cost for this manual includes printing and shipping costs only and does not
include purchase of the data or design. It does not give the purchaser any rights or
patent to print or make parts from this data.
SAFETY SUMMARY

Obey all manufacturer's Warnings and Cautions for all materials specified in this
manual. In this manual, Warnings and Cautions come before the procedure to which
they apply. Failure to obey a Warning may cause personal injury. Failure to obey a
Caution may cause damage to equipment or components. Wear protective clothing
approved for the materials and tools being used.

CONFORMANCE NOTICE

This assembly for commercial transport usage has a "TSO" marking which identifies
it as having been fully laboratory tested and qualifies to the applicable Federal
Aviation Administration (FAA) regulations.

The conditions and tests required for TSO approval of this article are minimum
performance standards. It is the responsibility of those installing this article on or
within a specific type or class of aircraft to determine that the aircraft installation
conditions are within the TSO standards. TSO articles must have separate approval
for installation in an aircraft. The article may be installed only if performed under 14
CFR part 43 or the applicable airworthiness requirements.

Although this commercial transport category assembly may have been tested and
qualified to the specification requirements of the applicable airframe manufacturer
and certified on the applicable aircraft, it is the responsibility of the installer to
determine that the assembly maintained in accordance with this manual is approved

BRASIL VIDA TAXI AEREO

for installation.

Any replacement of or change to any part, manufacturing process or material that

affects conformance to TSO requirements and/or airframe manufacturer's
specifications is not permitted after certification without applicable requalification of
this assembly and resubmittal of this test data to the FAA and/or airframe
manufacturer for approval.

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The use of parts manufactured by sources other than MABS and not approved by
MABS in any assembly that has the MABS name and TSO marking will relieve
MABS of any warranty obligation relating to the assembly upon which the
unapproved part has been installed and will relieve MABS of all product liability
responsibility for that assembly or any other assemblies on the aircraft and the
aircraft it may be used on.

The FAA regulations subject Meggitt Aircraft Braking Systems, the airframe
manufacturer and the operator, to constant surveillance to assure that proper quality
assurance, material and processing controls are maintained in order to provide
replacement parts that are the same quality as the parts originally certified in this
assembly.

ON-CONDITION MAINTENANCE

Each operator must schedule maintenance based on the condition of his equipment.
Meggitt Aircraft Braking Systems recommends that on-condition maintenance be
performed.

ATA Common Support Data Dictionary (CSDD) defines on-condition maintenance as

follows:

A primary maintenance process having repetitive inspections or tests to determine

the condition of units, systems or portions of structure with regard to continued
serviceability (corrective action is taken when required by item condition).

MABS CUSTOMER SUPPORT LOCATIONS

To locate your dedicated field customer support representative, go to

www.meggitt-mabs.com and click on the Field support link.

BRASIL VIDA TAXI AEREO

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DESCRIPTION AND OPERATION

1. General

A. Refer to IPL Figure 1.

B. The tri-metallic brake assembly is a hydraulically operated unit. The brake assembly can
be used interchangeably for either right-or-left hand installation.

C. Each main landing gear strut uses two brake assemblies, or a total of four brakes per
aircraft. The two brakes on each strut are bolted together, one on each side of the strut.
Two longer bolts extend through both brakes, only one long bolt is provided with each
brake.

2. Description

A. See Figure 1 and IPL Figure 1.

B. Each brake assembly consists of a housing subassembly, torque tube, pressure plate
subassembly, backing plate subassembly, two rotating disks, one stationary disk
subassembly, five pistons, insulator disks, four return mechanisms, hydraulic fittings,
preformed packings, packing retainer bolts, washers and self-locking nuts.

C. The brake housing is made from forged aluminum alloy. The hydraulic system permits
simultaneous brake actuation to the five pistons incorporated in the housing through fluid
passages interconnecting the piston cavities. Each housing has one inlet and bleeder
port. A torque leg at the top of the housing prevents rotating of the brake on the axle
during braking.

D. The housing contains five pistons. Each piston is sealed against fluid leakage by a
preformed packing and a backup ring, installed into the grooves of the housing piston
cavities. The piston cavities are interconnected by drilled passages to provide
simultaneous piston actuation with equalized pressure on each piston. Heat generated
by braking action is isolated from the housing by insulators fitted to the piston heads.

E. Four return mechanisms installed in the housing provide brake release and automatic
adjustment of the brake to compensate for wear of the friction surfaces. Each return
mechanism consists of a return spring housing, spring, spring guide and retaining ring,
return pin, grip and tube or swage and tube subassembly and self-locking nut.

BRASIL VIDA TAXI AEREO

3. Operation

A. Two rotating disks, driven by radial tangs engaging keyway slots in the wheel, rotate on
either side of a stationary disk keyed to the torque tube. The stationary disk, pressure
plate and backing plate provide rubbing surfaces for the rotating disks. The backing plate
and torque tube are bolted to the housing.

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BRAKE ASSEMBLY 5003096

100 90
170A OR 100 190
170B
90
190A

170
50

30

20 1

FOR 5003096-1 OR
5003096-3 ASSEMBLY

100
170B
90A
190A

130

330 10

40

30 70

220 60

210 OR

BRASIL VIDA TAXI AEREO

210A

80 OR
FOR 5003096-4 AND 240 180 110 OR
324332-001-01.CGM

80A
5003096-6 ASSEMBLY 110B
230 200 OR 120 OR
200A 120A
NOTE:
1 BRAKE BOLT (20) INSTALLED FROM BACKING PLATE SUBASSEMBLY (50) SIDE

Figure 1
Brake Assemblies 5003096, -1, -3, -4 and -6 (Sheet 1 of 4)

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BRAKE ASSEMBLY 5003096

152 OR 152A

153

151

260 160

140

250
280 270 160
150 150B

RETURN ASSEMBLY FOR RETURN ASSEMBLY FOR

GRIP AND TUBE SUBASSEMBLY SWAGE TUBE SUBASSEMBLY

340 320
320 350 310
324332-001-02.CGM

BRASIL VIDA TAXI AEREO

290

Figure 1
Brake Assemblies 5003096, -1, -3, -4 and -6 (Sheet 2 of 4)

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90B OR 90C
100A
190B

50
330B

1 20A
10

130B

30
10
40A

220
70
210B OR
210C 180
60
240 OR 240A
230
170C 80
200 OR
200A
110A

340 120
400
320

320

290

BRASIL VIDA TAXI AEREO

310
324332-001-03.CGM

NOTE:
1 BRAKE BOLT (20A) INSTALLED FROM BRAKE HOUSING SUBASSEMBLY (330B) SIDE

Figure 1
Brake Assemblies 5003096-5 and 5003096-7 (Sheet 3 of 4)

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BRAKE ASSEMBLY 5003096

280 270

160A
140

260

250

150A

RETURN ASSEMBLY FOR

GRIP AND TUBE SUBASSEMBLY

152 OR 152A

153A

151

160A

BRASIL VIDA TAXI AEREO

324332-001-04.CGM

150C

RETURN ASSEMBLY FOR

SWAGE TUBE SUBASSEMBLY

Figure 1
Brake Assemblies 5003096-5 and 5003096-7 (Sheet 4 of 4)

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Table 601
Key To Figure 1
-1. RF 153A. SPACER TUBE
10. SELF-LOCKING NUT 160. RETURN PIN
20. BRAKE BOLT (LONG) 160A. RETURN PIN
20A. BRAKE BOLT (LONG) 170. PRESSURE PLATE SUBASSEMBLY
30. COUNTERSUNK WASHER 170A. PRESSURE PLATE SUBASSEMBLY
40. BRAKE BOLT 170B. PRESSURE PLATE SUBASSEMBLY
40A. BRAKE BOLT 170C. PRESSURE PLATE SUBASSEMBLY
50. BACKING PLATE SUBASSEMBLY 180. RIVET
60. RIVET -180A. RIVET
70. RIVET 190. WEAR PIN
80. WEAR PAD 190A. WEAR PIN
80A. WEAR PAD 190B. WEAR PIN
90. ROTATING DISK 200. WEAR PIN
90A. ROTATING DISK 200A. WEAR PIN
90B. ROTATING DISK 210. DISK INSULATOR
90C. ROTATING DISK 210A. DISK INSULATOR
100. STATIONARY DISK SUBASSEMBLY 210B. DISK INSULATOR
100A. STATIONARY DISK SUBASSEMBLY 210C. DISK INSULATOR
110. RIVET 220. PISTON
-110A. RIVET 230. PACKING RETAINER
110B. RIVET 240. PREFORMED PACKING
120. WEAR PAD 240A. PREFORMED PACKING
120A. WEAR PAD 250. RETAINING RING
130. TORQUE TUBE 260. SPRING GUIDE
-130A. TORQUE TUBE 270. SPRING
130B. TORQUE TUBE 280. RETURN SPRING HOUSING
140. SELF-LOCKING NUT 290. BLEEDER PLUG
150. GRIP AND TUBE SUBASSEMBLY 300. DELETED
150A. GRIP AND TUBE SUBASSEMBLY 310. BLEEDER ADAPTER

BRASIL VIDA TAXI AEREO

150B. SWAGE AND TUBE SUBASSEMBLY 320. PREFORMED PACKING
150C. SWAGE AND TUBE SUBASSEMBLY 330. BRAKE HOUSING SUBASSEMBLY
151. ADJUSTER SWAGE 330A. DELETED
-152. SWAGE TUBE ADJUSTER 330B. BRAKE HOUSING SUBASSEMBLY
152A. SWAGE TUBE ADJUSTER 340. PROTECTIVE PLUG
153. SPACER TUBE 350. IDENTIFICATION PLATES (360, 370,
380, 390, 400, 410 AND 420)
- Item not illustrated.

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

B. The brake assembly is actuated by hydraulic pressure. When brakes are applied,
pressure enters the housing and acts equally on each piston. Piston movement presses
the pressure plate and the alternate rotating and stationary disks against the back plate
to produce the braking action. Upon release of the pressure, brake return springs return
the pressure plate and pistons to the off position.

C. Automatic adjustment of brakes to compensate for brake wear is accomplished as

follows. For brakes using grip and tube subassemblies, as the brakes wear, the return
pins and tubes are pulled through grips by the pressure plate movement. This small
movement between pin and grip is equal to the combined wear of all braking surfaces.

When the brake return springs return the pressure plate to the released position, the
built-in clearance between the pressure plate and disks remains at a preset constant for
brakes using swage and tube subassemblies. As the brakes wear, the piston will
advance the swage through the swage tube subassembly.

The swage tube subassembly is held in place by the self-locking nut, the brake return pin
and the spacer tube. The action of the swage pulling through the swage tube
subassembly supplies the self-adjusting feature

D. Minimum operating clearance for the brake assembly is zero. Brake wear can be
determined by measuring the distance from the brake housing to the pressure plate as
shown in Figure 102. If the dimension from housing to the pressure plate adjacent to the
top pistons is 0.330 inch (8,38 mm) or greater for Brake Assemblies 5003096, -1, -3, -4
and -6 or 0.464 inch (11,79 mm) or greater for Brake Assemblies 5003096-5 and -7, the
brake should be removed for maintenance. The brake must be pressurized with 100 psig
(6,9 bar) when taking the wear measurement.

4. Leading Particulars

Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red Oil, Specification MIL-PRF-5606

Maximum Operating Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 psig (103,4 bar)
Brake Clearance 180° from torque slot . . . . . . . . . . . . . . . . 0.030 inch (0,76 mm) (minimum)
Brake Weight (approximate) 5003096, -1, -3, -4 & -6 . . . . . . . . . . . . .30.3 pounds (13,74 kg)
Brake Weight (approximate) 5003096-5 and -7 . . . . . . . . . . . . . . . . . .33.1 pounds (15,01 kg)
Brake Housing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Forged Aluminum Alloy
5. Brake Differences

BRASIL VIDA TAXI AEREO

A. Brake Assembly 5003096-1 differs from the 5003096 assembly in the pressure plate
subassembly.

(1) The 5003096-1 pressure plate has a different pressure plate contour and wear
pads.

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

B. Brake Assembly 5003096-3 is the same as Brake Assembly 5003096-1 except the
5003096-3 assembly has a different pressure plate contour.

(1) The pressure plate was modified to eliminate interference with torque link when
brakes are applied for added strut clearance.

C. Brake Assembly 5003096-4 is the same as the 5003096-3 assembly except the
5003096-4 assembly has chamfered rotating disk tangs.

D. Brake Assembly 5003096-6 is the same as the 5003096-4 assembly except for the
torque tube difference.

(1) The 5006905 torque tube is steel and the 9550634 torque tube is ductile iron. The
steel torque tube is an upgrade which will provide increased durability and fatigue
life.

E. Brake Assembly 5003096-5 is entirely different than all the other assemblies except for
backing plate, pistons, springs, spring guides, spring housings and bleeder. Brake
Assembly 5003096-5 does not have a milled out area on the large Wear Pad 5005119 for
strut clearance; therefore, it can only be used on the Lear 55 long axle aircraft (starting
with aircraft tail number 101, 107 and subsequent.

F. Brake Assembly 5003096-7 is the same as the 5003096-5 assembly except for the
difference in the materials used in the rotating disk. Rotating Disk 5006888-1 is also
approved as an alternate for Rotating Disk 5006888 used in Brake Assembly 5003096-5.

6. Brake Modifications

A. A modification is provided in REPAIR to convert:

Brake Assembly 5003096 to 5003096-4,
Brake Assembly 5003096-1 to 5003096-3,
Brake Assembly 5003096-1 to 5003096-4, or
Brake Assembly 5003096-3 to 5003096-4,
Brake Assembly 5003096-4 to 5003096-6,
Brake Assembly 5003096-5 to 5003096-7.

BRASIL VIDA TAXI AEREO

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

TESTING AND FAULT ISOLATION

1. Test Equipment and Materials

MATERIAL* POSSIBLE SOURCE**

Hydraulic Gage, High-Pressure Commercially available
Measures from 0 to 3,000 psig
(0 to 206,8 bar)
Hydraulic Gage, Low-Pressure Commercially available
Measures from 0 to 100 psig (0 to
6,90 bar)
Hydraulic Fluid Commercially available
Specification MIL-PRF-5606
Hydraulic Test Stand Commercially available
Supplies 0 to 3,000 psig (0 to 206,8 bar)
pressure gaged to read output pressure to
5 psig (0,35 bar) increments
Hardness Tester Instron Corp/Wilson Instruments
Rockwell (B Scale preferred) 100 Royall Street
Brinell or equivalent Canton, MA 02021-1089
Ph: 800-747-6733
Fax: 617-575-5770
Portable Hardness Tester Suntec Corporation
Model CPT 24371 Catherine Industrial Suite 227
Novi, MI 48375
Ph: 248-449-1188
Fax: 248-449-1199
Petroleum Ether Commercially available
Saran or Mylar Film Commercially available
* Equivalent replacements can be used for the items given.
** Other sources could be available.

BRASIL VIDA TAXI AEREO

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

2. Test Setup

A. See Figure 101.

LOW PRESSURE GAGE

GAGE SHUTOFF VALVE
HIGH PRESSURE GAGE

HYDRAULIC
TEST STAND

324332-101-01.CGM
0 TO 3000 PSIG
BRAKE ASSEMBLY
(0 TO 206,8 BAR)
HYDRAULIC FLUID
MIL-PRF-5606 INLET

Figure 101
Test Setup Block Diagram

3. Operational Test and Fault Isolation Procedures

A. See Figure 101 and IPL Figure 1.

NOTE: Do steps B. through I. to determine the exact condition of, or malfunction of,
the brake assembly. All variations from established leakage rate limits should
be noted for future reference during testing.
Do steps J. through M. as required (See Figure 103)

BRASIL VIDA TAXI AEREO

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

WARNING: TO AVOID POSSIBLE INJURY TO PERSONNEL, TAKE ALL SAFETY

PRECAUTIONS BEFORE CONDUCTING TESTS.

CAUTION: TO AVOID DISTORTING AND DAMAGING BRAKE HOUSING DURING

FUNCTIONAL TESTING, SUBSTITUTE TWO SHORT BRAKE BOLTS FOR
THE TWO LONG BRAKE BOLTS IN THE TOP TWO HOUSING BOLT
HOLES.
LUBRICATE THREADS AND BEARING SURFACES OF BOLTS, NUTS, AND
WASHERS WITH ANTI-SEIZE COMPOUND, SPECIFICATIONS MIL-T-5544
OR SAE AMS 2518 BEFORE INSTALLATION. TORQUE NUTS TO 120
POUND-INCHES (13,56 N-M).

CAUTION: PRESSURE SOURCE MUST CONTAIN SPECIFICATION MIL-PRF-5606

HYDRAULIC FLUID.

B. Connect inlet fitting on brake housing subassembly to a hydraulic pressure source, or

equivalent, and containing hydraulic fluid, Specification MIL-PRF-5606.

C. Apply hydraulic pressure and bleed brake housing as follows:

(1) Connect end fittings of a flexible hose to the bleeder plug (290) and submerge free
end of hose in a clean container partially filled with hydraulic fluid.

(2) While bleeding, hold brake housing perpendicular to the work surface with bleeder
and inlet parts at the highest position, simulating the installed position on the
aircraft.

CAUTION: PREVENT FLUID SPILLOVER FROM ENTERING BRAKE ASSEMBLY.

(3) Open bleeder plug (290) and permit fluid to flow into container until all aeration
disappears. With fluid still flowing from brake, close bleeder plug.

(4) Remove bleeder hoses from bleeder plug and tighten.

(5) Wipe any spilled fluid from brake housing.

D. Cycle brake two or three times between 0 and 500 psig (0 and 34,5 bar) pressure. Check
to see that all pistons extend and retract evenly and smoothly, and pressure plate
subassembly moves easily without binding. Apply 90 psig (6,2 bar) pressure and check
that rotating disks are clamped.

E. Apply 1500 psig (103,4 bar) pressure and hold for five minutes. Check for fluid leaks

BRASIL VIDA TAXI AEREO

around inlet, bleeder plug (290), bleeder adapters (310) and pistons (220). No leakage is
permissible around inlet, bleeder or bleeder adapters. Leakage around pistons must not
be more than one drop per minute.

F. Decrease the pressure to 30 psig (2,1 bar) and check for brake release. The brake
should have a minimum clearance of 0.010 inch (0,25 mm) under torque slot and
0.030 inch (0,76 mm) at 180° from torque slot, and the rotating disks should be free to
move.

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

G. With 100 psig (6,9 bar) pressure applied, check brake assembly for wear. Check the
dimension from the housing subassembIy and pressure plate adjacent to the top pistons
as shown in Figure 102.

(1) For Brake Assemblies 5003096, 5003096-1, -3, -4 and -6; if this dimension is
0.330 inch (8,38 mm) or greater, the disk stack must be removed.

(2) For Brake Assemblies 5003096-5 and -7; if this dimension is 0.464 inch (11,79 mm)
or greater, the disk stack must be removed.

H. Decrease the pressure to 5 to 7 psig (0,35 to 0,48 bar) and hold for five minutes. Check
for fluid leaks around inlet, bleeder, bleeder adapter, and around pistons. No leakage is
permitted.

I. Decrease the hydraulic pressure to zero.

J. If leakage occurred around inlet, bleeder plug, bleeder adapter, check torque on bleeder
plug (290) and bleeder adapter (310). Refer to FITS AND CLEARANCES for correct
torque values. If leakage continues after torque check, replace preformed packings and
retest housing subassembly.

WITH BRAKES APPLIED, REMOVE BRAKE

FOR MAINTENANCE WHEN
DIMENSION FROM HOUSING TO THE
PRESSURE PLATE IS 0.330 (8,38) OR
GREATER FOR BRAKE ASSEMBLIES
5003096, -1,-3, -4 AND -6 OR 0.464
(11,79) OR GREATER FOR BRAKE
ASSEMBLIES 5003096-5 AND -7

BRASIL VIDA TAXI AEREO

324332-102-01.CGM

Figure 102
Brake Wear Measurement

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

CAUTION: IF LEAKAGE OCCURS AROUND TWO OR MORE PISTONS, REPLACE

THE PACKINGS AND RETAINERS ON ALL PISTONS.

K. If leakage limits around piston were exceeded, or if pistons (220) did not extend and
retract evenly and smoothly during test, disconnect pressure source and remove housing
subassembly per DISASSEMBLY.

Remove leaking pistons (220) and check outside diameter of pistons and inside diameter
of piston cavity per CHECK. Check for, and remove, obstructions in fluid passages in
housing subassembly (330 or 330B).

Replace pistons worn beyond limits given in FITS AND CLEARANCES.

Install new preformed packings (240) and packing retainers (230) and re-assemble brake
assembly as per ASSEMBLY AND STORAGE. Retest for leaks.

L. If the pressure plate subassembly did not move smoothly during brake cycling and if
rotating disks or stationary disk subassembly did not move freely on torque tube, remove
torque tube and disk stack per DlSASSEMBLY.

Do a check that subassembIies are flat within 0.015 inch (0,381 mm) and that stationary
disk fits freely on torque tube keys.

Do a check of the torque tube for damage to keys (refer to FITS AND CLEARANCES for
limits). If torque tube is damaged, or if disks do not move freely on keys, replace
defective subassemblies and reassemble brake per ASSEMBLY AND STORAGE.

M. Brakes bled and tested can be stored full of hydraulic fluid to minimize brake bleeding on
aircraft.

NOTE: Following bench testing, remove two short brake bolts (40 or 40A) from the top
two housing bolt holes and install one long bolt (20 or 20A) in each housing.

Lubtork nuts of long mounting bolts (20 or 20A) to 120 pound-inches

(13,56 N-m) after installation of brake on aircraft.

4. Fault Isolation

A. Fault isolate brake problems according to Figure 103.

BRASIL VIDA TAXI AEREO

5. Brake Flushing Procedure (Optional)

A. The following instructions provide a method for flushing brake assemblies after overhaul
to obtain a brake fluid cleanliness level acceptable for use on the aircraft. Flushing can be
done at the option of the operator.

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

ACTUATE
BRAKE LEAKS
BRAKE

CHECK HYDRAULIC IF LOOSE, TIGHTEN

CONNECTIONS CONNECTIONS

CHECK PISTON IF DAMAGED,

PACKINGS REPLACE PACKINGS

CHECK PISTON IF SCRATCHED

CAVITY OR
WORN, REPAIR

IF NOT REPAIR ABLE,

REPLACE
BRAKE HOUSING
RELEASE BRAKE DOES
BRAKE NOT RELEASE
PRESSURE

CHECK PRESSURE IF PRESENT,

PLATE FOR REMOVE
OBSTRUCTIONS OBSTRUCTIONS

CHECK SPRING IF NOT FUNCTIONING

REPLACE
RETURN CAPSULES
DAMAGED PART

CHECK PISTON IF STICKING,

FOR STICKING REPLACE PISTON
AND PACKING

BRASIL VIDA TAXI AEREO

324332-103-01.CGM

CHECK DISK IF NOT FREE,

MOVEMENT REPLACE
ON TORQUE TUBE DAMAGED PART

Figure 103
Fault Isolation Chart

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

CAUTION: PROTECT THE QUICK-DISCONNECT FITTINGS DURING SHELF

STORAGE WITH SUITABLE CAPS.
(1) The cleanliness level of hydraulic fluid dispensed from the brake assemblies must
meet the following requirements:

Micron Size Particle Count

100 + Fibers 40
50 to 100 450
25 to 50 3,500
15 to 25 21,000
5 to 15 87,000

(2) Flushing procedure for brakes not equipped with flush (drain) plugs:

(a) Connect the hydraulic systems of the brake assembly to a hydraulic system
containing hydraulic fluid with a cleanliness level of 10 percent of the above
requirements and a capability of furnishing a minimum pressure of 100 psig
(6,9 bar).

(b) While flushing, hold the brake assembly perpendicular to the work table with
the bleeder ports at the lowest position and using the bleeder and inlet ports
furthest apart.

(c) Apply 100 psig (6,9 bar) pressure to the brake assembly and preflush the
brakes for 20 seconds. Then cycle the brake two or three times by closing and
opening the drain valves. (This will consume approximately 10 to 12 quarts
(9,46 to 11,36 liters) of fluid).

(d) With the exhaust port open and fluid flow continuing, cycle the brake a
minimum of 20 times by opening and closing the valves at the bleeder ports.
Piston movement must cause pressure plate to contact the disk stack during
each cycle.

(e) Turn fluid flow off, open inlet ports, and allow brake to drip drain.
(f) Open supply line and flush brake for three minutes.

BRASIL VIDA TAXI AEREO

(g) Close supply line and drip drain brake assembly.
6. Sampling Procedure (Optional)

A. Use wide-mouth fluid sample bottles with screw tops, and a capacity of 100 milliliters.

B. Before using the sample bottles, clean as follows:

(1) Wash thoroughly in a solution of detergent and hot water, and rinse twice in hot
distilled water.

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

(2) Rinse twice in filtered distilled water.

(3) Rinse the sample bottles with isopropyl alcohol to remove residual rinse water.

(4) Do a final rinse of filtered petroleum ether or fluorinated solvent.

(5) Because of the danger of contaminating the bottle with particles from the screw cap,
place a small square of Saran or Mylar film, which has been thoroughly rinsed with
filtered solvent, over the mouth of the sample bottle before replacing the cap.

C. Do the following procedure to take a control sample of the fluid.

(1) DO NOT touch the rim of the bottle with the flushing hose.

(2) Put Saran or Mylar film over bottle opening and cap.

(3) Identify sample with brake assembly and serial number.

(4) Send to laboratory for Micron Particle Check.

NOTE: Take a contamination sample from one brake in each group of ten.

7. Hardness Test (Heat Damage Test)

A. General

(1) Components of the brake assembly that are suspected of having been overheated,
after a rejected takeoff or equivalent high energy input, must be checked for
hardness in accordance with Table 101.

(2) Two types of Hardness Test are available, Impression (Rockwell or Brinell), and
Conductivity (Eddy Current). Both types of testing are acceptable and can be used.
If a conductivity test indicates a housing is soft, this can be confirmed with an
Impression Test.

(3) Take a minimum of four hardness readings for each part in order to get a
representative reading. If the average of the readings is below the acceptable
hardness requirements, the part must be replaced.

(a) Take all hardness readings in an area free from paint. If one of the four
readings is not similar to the other three, use the three similar readings.

BRASIL VIDA TAXI AEREO

(b) The maximum range of the housing hardness readings is: 2 RB or 4 Brinell
(% IACS does not apply).

(c) Only one hardness reading can be less than the minimum (if more than one is
less than minimum, the housing is too soft).

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B. Impression Test, Rockwell or Brinell

(1) Do a hardness test on the brake housing subassembly at the locations identified in
Table 101.

NOTE: The paint must be removed from the surfaces to be examined.

(2) If the average of the readings is less than the acceptable minimum readings shown
in Table 101, the brake housing subassembly is soft and must be replaced.

NOTE: A second set of hardness test readings is permitted if there is any

question as to the accuracy of the first set. The second set of hardness
readings must be taken as close to the first hardness test readings as
possible.

(3) Either the Brinell test or Rockwell test can be done.

(4) Refinish the areas where the paint has been removed as told in the REPAIR
section.

C. Conductivity Test, Eddy Current

(1) Conductivity readings must be taken in the same location as specified for the Brinell
Test (See Table 101).

NOTE: To get correct readings, the surface finish (paint and anodize layer) in the
test area must not be loose and must be in good condition.

(2) Operational Recommendations:

(a) Follow the procedures given in the instruction manual by the manufacturer of
the test instrument.

(b) Permit the temperatures of the test instrument, the conductivity standard and
the brake housing to become stable before any conductivity readings are
taken.

(c) Take several readings in the same area of the brake housing subassembly and
on the conductivity standard until the same reading is read again.

(d) Do not permit the conductivity standard to touch metal objects (pens, table,

BRASIL VIDA TAXI AEREO

etc.)

(e) Carefully hold the probe on the surface and do not move or slide the probe.

(3) Do a conductivity test using a calibrated eddy current instrument (with the
appropriate probe) on the areas specified above. Obtain readings at six equally
spaced areas (120 degrees apart).

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(4) If a reading over IACS 41.3% is obtained, the brake housing subassembly is
considered soft. The soft reading must be verified by the Brinell of Rockwell
impression test. If the soft readings are confirmed, the brake housing subassembly
must be replaced.

Table 101
Hardness Tests

Part Name Minimum Hardness Check

Test Penetrator Load
(Refer to IPL Figure 1) Hardness Location

Torque Tube 120 degree Key wear surfaces

Rockwell C 40 150 kg
(130, 130A or 130B)* Cone (key sides)
Housing Torque Tube
Brinell 110 10 mm dia ball 500 kg
(330 or 330B)* contact surface
Housing 1/16 inch dia Torque Tube
Rockwell B 69 100 kg
(330 or 330B)* ball contact surface
Pressure Plate
Not applicable (pressure plates not heat treated)
(Base Plate)
Back Plate Between bolt hole
Rockwell C 23 120° Cone 150 kg
(Base Plate) (50) counterbores
0.25 inch
Stationary Disk (Base
Rockwell C 25 120° Cone 150 kg (6,35 mm) from
Plate) (100 or 100A)
sides of key slots
NOTE: At least four hardness readings must be taken for each part in order to get a representative
reading. If the average of the readings is below the minimum hardness, the part should be
replaced. All readings should be taken in an area free from paint.
* If the housing and torque tube are below the minimum hardness, discard bolts and nuts.
If the housing and torque tube are not below the minimum hardness, re-use bolts and nuts.
If the housing is below minimum hardness but the torque tube is not, re-use bolts and nuts.
If the torque tube is below minimum hardness but the housing is not, discard bolts and
nuts.

BRASIL VIDA TAXI AEREO

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DISASSEMBLY

1. General
A. Refer to IPL Figure 1.

NOTE: See TESTING AND FAULT ISOLATION for operational test and fault isolation
procedures to establish condition of brake and determine extent of
disassembly required.

CAUTION: BE CAREFUL WITH ALL PARTS AND KEEP ALL PARTS CLEAN.
DO ALL MAINTENANCE IN A CLEAN ENVIRONMENT. PARTICLES OF
DUST OR LINT MAY CAUSE PROBLEMS WITH BRAKE OPERATION.
IF THE BRAKE ASSEMBLY IS NOT ASSEMBLED WITHIN 24 HOURS, THE
PROTECTION OF ALL PARTS AGAINST CORROSION AND DAMAGE IS
MANDATORY.

B. Disassemble the brake assembly as given in the following disassembly procedures.

A. Use power wrenches for brake disassembly as follows:
(1) Do not use power wrenches for disassembly of any threaded parts made of
nonferrous material (such as aluminum, brass, etc) or parts threaded into
nonferrous tapped holes.

(2) The use of power wrenches for disassembly of a ferrous parts or parts threaded
directly into ferrous tapped holes, such as brake fasteners, is acceptable.

B. If brakes are removed for a reason other than wear and the brake stack is to be
continued or returned to service, the brake assembly and adjusters must be retained as a
unit and the brake stack must be retained as a unit. This will ensure the disks will be
re-assembled in the correct location and orientation (up/down) which will maintain the
wear measurement of the brake before it was disassembled.

2. Disassembly Procedures
A. Refer to IPL Figure 1.

B. Put brake assembly on a clean, flat work surface with backing plate up.
CAUTION: REPLACE THE BOLT AND/OR NUT IF IT IS TIGHTENED TO MORE THAN
110 PERCENT OF THE FINAL TORQUE VALUE.

BRASIL VIDA TAXI AEREO

TOO MUCH TORQUE WILL DAMAGE THE BOLT.

C. Remove two brakes from each aircraft strut by removing two self-locking nuts (10), long
brake bolts (20 or 20A) and washers (30).

D. Remove three self-locking nuts (10), bolts (40 or 40A) and washers (30) to release the
disk stack from brake housing subassembly.

NOTE: The use of power wrenches for disassembly of fasteners can decrease the
service life of bolts and nuts.

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BRAKE ASSEMBLY 5003096

E. Remove the backing plate subassembly (50), rotating disks (90, 90A, 90B or 90C),
stationary disk subassembly (100 or 100A) and torque tube (130, 130A or 130B) from
housing subassembly.

NOTE: Do not remove wear pads from stationary disk subassembly and backing plate
subassembly. Instructions for replacing wear pads are in REPAIR.

F. Remove self-locking nuts (140) from brake return pins (160 or 160A) to release return
mechanism, grip and tube subassemblies (150 or 150A) or swage tube subassemblies
(150B or 150C), return pins, and pressure plate subassembly (170, 170A, 170B or
170C).

NOTE: The reusable adjuster swage (151) can be removed by using a steel pin and
an arbor press to drive the swage back out of the tube (do not continue swage
through tube for removal). Adjusting swage tubes are not reusable and require
replacement.

NOTE: Do not remove wear pads from pressure plate subassembly unless necessary.
Instructions for replacing wear pads are given in REPAIR.

G. Carefully remove insulators (210, 210A, 210B or 210C) and pistons (220) from housing
subassembly.

H. Remove packing retainers (230) and preformed packings (240 or 240A) from piston
cavities of housing subassembly.

I. Disassemble return mechanism as follows:

NOTE: Return mechanisms need not be disassembled unless replacement of parts is

required.

(1) Place return spring housing (280) in an arbor press.

(2) Apply pressure to spring guide (260), compressing spring (270).

(3) Remove retaining ring (250).

(4) Slowly relieve pressure on spring guide and separate spring guide (260), spring
(270) and return spring housing (280).

BRASIL VIDA TAXI AEREO

J. Remove bleeder plug (290), bleeder adapter (310) and preformed packing (320) from
housing subassembly (330 or 330B) bleeder port.

K. Remove protective plug (340) and preformed packing (320) from housing subassembly
(330 or 330B) inlet port.

L. Do not remove adhesive backed identification plates (350, 360, 380, 390, 400, 410 or
420) unless replacement is necessary or if paint has to be removed.

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CLEANING

1. Cleaning Materials

MATERIAL* POSSIBLE SOURCE**

Blue Gold Modern Chemical Incorporated
(See NOTE below) 7023 Centennial Road
P.O. Box 368
Jacksonville, AR 72078
Blue Gold Spray Wash Ph: 501-988-1311
(See NOTE below) Fax: 501-988-2229
Detergent Cleaning Unit with an Agitating Commercially available
Platform
Dry-Cleaning Solvent Commercially available
Type I, Stoddard Solvent
Type II, 140°F Solvent
Specification ASTM D235 or MIL-PRF-680
Isopropyl Alcohol Commercially available
Specification TT-I-735
Acetone ASTM D329 Commercially available
Paint Removal Agent: International Specialty Products
ShipShape® Resin Cleaner 1361 Alps Road
Wayne, NJ 07470
or Ph: 800-323-2272
Fax: 732-628-4117

PrepRiteTM Coatings Remove International Specialty Products

ISP Europe
40 Alan Turing Road
Surrey Research Park
Guilford, Surrey
GU25YF England
Paint Removing Solvent (Alternate) Turco Products, Incorporated
Specification SAE-AMS-C-19853, Type II Division of Purex Corporation

BRASIL VIDA TAXI AEREO

2700 Temple Ave. Suite B
Long Beach, CA 90806
Ph: 310-981-8300
Fax: 310-981-8303
* Equivalent replacements can be used for the items given.
** Other sources could be available.
NOTE: For additional cleaning materials and cleaning equipment refer to AP-842 (32-46-35)
Standard Practices Manual with Procedures.

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BRAKE ASSEMBLY 5003096

MATERIAL* POSSIBLE SOURCE**

Oven (Industrial Furnace) Commercially available
Temperature Stability:
225° ± 25° F (107° ± 18° C)
400° ± 25° F (204° ± 18° C)
Minimum Inside Dimensions:
3 ft x 3 ft x 3 ft (0.9 m x 0.9 m x 0.9 m)
Polyplus Plastic Media U.S. Technology Corporation
Screen Size 20/40 (Primary) 220 7th Street SE
Canton, OH 44702
Ph: 800-634-9185
Fax: 800-634-0143
Plastic Reclaimable Abrasive Machine See SPECIAL TOOLS, FIXTURES AND
(PRAM) EQUIPMENT section.
Plastic Media (Dry-Stripping Abrasive) U.S. Technology Corporation
220 7th Street SE
Canton, OH 44702
Ph: 800-634-9185
Fax: 800-634-0143
Pressure Blast Equipment Chamber Commercially available
Minimum Inside Dimensions:
3 ft x 3 ft x 3 ft (0,9 m x 0,9 m x 0,9 m)
Rust Veto 4214 E.F. Houghton and Company
Madison and Van Buren Avenue
Valley Forge, PA 19482
Clean Wiping Cloth Commercially available
Naphtha Commercially available
Soft Wire Brush Commercially available
Soft Bristle Brush Commercially available
* Equivalent replacements can be used for the items given.
** Other sources could be available.
NOTE: For additional cleaning materials and cleaning equipment refer to AP-842 (32-46-35)

BRASIL VIDA TAXI AEREO

Standard Practices Manual with Procedures.

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2. Cleaning Procedures

A. Refer to IPL Figure 1.

WARNING: CLEANING SOLVENTS ARE TOXIC AND VOLATILE.

USE ONLY IN WELL-VENTILATED AREAS.
AVOID PHYSICAL CONTACT WITH SOLVENT AND DO NOT INHALE
VAPORS.

CAUTION: A THOROUGH CLEANING OR IMMERSION OF WHEELS CAN CAUSE

ENTRAPMENT OF SOLVENT IN PASSAGE HOLE.
MAKE SURE TO REMOVE THE INFLATION VALVE BEFORE CLEANING

B. Clean rotating disks (90, 90A, 90B or 90C), stationary disks (100 or 100A), backing plate
(50), and pressure plate (170, 170A, 170B, or 170C) with compressed air. Use a soft wire
brush where necessary.

C. Clean all other metal parts by immersing in dry-cleaning solution per Specification
MIL-PRF-680 or ASTM D329. Use a soft bristle brush to remove hardened grease, dust
and dirt.

D. Dry all metal parts thoroughly after cleaning, using filtered and dried compressed air.

NOTE: Make sure that foreign materials have been removed from all cavities,
threaded holes, pockets and other areas where entrapment might occur.

WARNING: DO NOT USE ISOPROPYL ALCOHOL NEAR SPARKS OR FLAMES.

ISOPROPYL ALCOHOL IS FLAMMABLE.
KEEP ISOPROPYL ALCOHOL AWAY FROM EYES OR SKIN.
DO NOT BREATHE THE FUMES OR DRINK ISOPROPYL ALCOHOL.
ISOPROPYL ALCOHOL IS POISONOUS.
OBEY THE MANUFACTURER'S INSTRUCTIONS.
REFER TO THE MATERIAL SAFETY DATA SHEET (OR EQUIVALENT)
BEFORE ISOPROPYL ALCOHOL IS USED.

E. Preformed packings (240 or 240A and 320) should be replaced at each overhaul. If
packings must be reused, clean preformed packings with isopropyl alcohol, Specification
TT-l-735. Dry with a clean, soft cloth.

BRASIL VIDA TAXI AEREO

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WARNING: DO NOT USE NAPHTHA AND GASOLINE NEAR SPARKS OR FLAMES.

NAPHTHA AND GASOLINE IS FLAMMABLE.
KEEP NAPHTHA AND GASOLINE AWAY FROM EYES OR SKIN.
DO NOT BREATHE THE FUMES OR DRINK NAPHTHA AND GASOLINE.
NAPHTHA AND GASOLINE IS POISONOUS.
OBEY THE MANUFACTURER'S INSTRUCTIONS.
REFER TO THE MATERIAL SAFETY DATA SHEET (OR EQUIVALENT)
BEFORE NAPHTHA AND GASOLINE IS USED.

F. Clean insulator recess of piston and surface of insulator of all film, dirt or remnants of old
cement with naphtha or lead-free gasoline.

G. Clean grip and tube subassembly (150 or 150A) tubes or adjuster swage (151) by
rubbing with a soft bristle brush or rubbing with a cloth dipped in acetone ASTM D329, or
equivalent, to remove contaminants and build-up of brass on tubes.

After cleaning, dip grip and tube subassembly (150 or 150A) or adjuster swage (151) into
Rust Veto 4214 and cycle only the grips several times. Do not cycle adjuster swage in
new tube.

NOTE: Grip-tubes and adjuster swages must not be cleaned by tumbling, polishing
compounds, or with wire brushes. This type cleaning polishes or grinds away
the finish requirement that is necessary to give consistent optimum results with
respect to load.

H. Use the procedures below to clean steel and aluminum parts to remove grease, dust or
dirt.

WARNING: OBEY THE MANUFACTURER'S INSTRUCTIONS.

FOR STEEL AND ALUMINUM PARTS, USE A DILUTION RATE OF 5%
(1 PART BLUE GOLD/20 PARTS WATER).
(1) Put the parts in a cleaning spray cabinet or agitating bath filled with a Blue Gold
cleaning agent. Suspend or position the parts to receive even cleaning to all surface
areas.

NOTE: Use Blue Gold Industrial Cleaner in the detergent cleaning unit with
agitating platform.

BRASIL VIDA TAXI AEREO

NOTE: Use Blue Gold Spray Wash in the cleaning spray wash cabinet. The Blue
Gold Spray Wash contains an anti-foaming additive. Use a dilution rate of
2% (2 parts Blue Gold spray wash to 100 parts water).

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(2) Select the cleaning time to produce clean parts without causing signs of corrosive or
discoloring effects on the metals.

NOTE: Aluminum parts cannot be in the cleaning agent for more than one (1)
hour.

NOTE: The cleaning process should not damage the paint and protective
coating.

(3) As soon as the parts are removed from the cleaning process, rinse the parts with
fresh hot water to remove the cleaning agent residue.

(4) Thoroughly dry the parts with low pressure 15 psig (1.03 bar) filter air, or with dry
nitrogen to eliminate all traces of moisture. The parts can be put in a low humidity,
warm oven for several minutes to make sure they are dried completely.

NOTE: Make sure the unwanted materials and solvents are removed from all
holes. Make sure the unwanted materials and solvents are removed from
the holes that have threads. Make sure the unwanted materials and
solvents are removed from the pockets.

3. Paint Removal Procedures

NOTE: For an update on recommended paint removal processes, refer to AP-842,

Standard Practices Manual with Procedures (32-46-35), which can be downloaded,
free of charge, from our website <www.meggitt-mabs.com>.

A. Strip brake housing as follows - Method I (Dry-Stripping)

NOTE: This section gives general procedures on the dry-stripping procedure of

pneumatic blast removal of paint with plastic particles. This procedure
recommends control variables to safely and fully remove the paint from parts
with the dry-strip ping procedure.

To get correct values, the paint must be removed from parts before the
fluorescent penetrant inspection or the magnetic particle inspection is done. If
the paint is not loose and is in good condition, the removal of paint before an
eddy current inspection is not necessary.

BRASIL VIDA TAXI AEREO

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WARNING: OBEY THE MANUFACTURER'S INSTRUCTIONS WHEN THE

DRY-STRIPPING PROCEDURE IS DONE.
THE DRY-STRIPPING PROCEDURE MUST BE DONE BY AN
APPROVED PERSON.

CAUTION: USE AN ALTERNATE INSPECTION METHOD, SUCH AS EDDY

CURRENT OR ULTRASONIC INSPECTION, TO FIND DEFECTS IN
IMPORTANT AREAS OF THE PARTS THAT HAD THE PAINT
REMOVED BY THE DRY-STRIPPING PROCEDURE.
DEFECTS IN A PART WILL NOT BE FOUND BY DYE PENETRANT
INSPECTION WHEN THE DRY-STRIPPING PROCEDURE WAS USED
TO REMOVE THE PAINT FROM A PART. SEE THE CHECK SECTION.
(1) Completely disassemble the part to be stripped. Remove all parts from the brake
housing according to DISASSEMBLY.

(2) Clean the part to be stripped according to the Cleaning Procedures paragraph.

(3) Seal all holes that have threads and piston cavities as necessary.

(4) Use the dry-stripping procedure to remove the paint as shown in Figure 401 and as
follows:

(a) The media (dry-stripping abrasives) is effective only when used with the
appropriate equipment. Depending on operator requirements, check with
these (or other suitable) manufacturers for advice and application information
concerning their particular equipment.

(b) Refer to Cleaning Materials paragraph for the applicable dry-stripping abrasive
and equipment.

WARNING: DO NOT TOUCH THE HOT WATER WHEN THE BRAKE HOUSING IS
FLUSHED. HOT WATER CAN CAUSE BURNS.

CAUTION: FLUSH PLASTIC MATERIAL FROM THE OPENINGS, HOLES THAT

HAVE THREADS AND OTHER AREAS WHERE THE PLASTIC
MATERIAL CAN GET CAUGHT.
MAKE SURE THERE IS NO PLASTIC MATERIAL IN THE ORIFICES
OR THE FLUID PASSAGES OF THE BRAKE HOUSING.
(5) Remove the brake housing from the dry-stripping equipment. Clean, two times, with

BRASIL VIDA TAXI AEREO

water that has a temperature between 160° to 180° F (71,1° to 82,2° C). Make sure
there is no plastic material in the orifices or the fluid passages of the brake housing.

WARNING: USE EYE PROTECTION WHEN COMPRESSED AIR IS USED.

COMPRESSED AIR CAN CAUSE PARTICLES TO BECOME
AIRBORNE WHICH CAN CAUSE INJURIES.
DO NOT PERMIT AIR PRESSURE FOR CLEANING TO BE MORE
THAN 15 PSIG (1,0 BAR).
(6) Dry the part thoroughly with low-pressure (15 psig or 1,0 bar), filtered air.

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NOZZLE NOZZLE NOZZLE MEDIA ANGLE OF

TYPE/SIZE PRESSURE DISTANCE TYPE APPROACH

1 BMLV-8 45 - 55 psig 36 - 48 inch POLYPLUS® 45 - 75°

1/2 inch (3,10 - 3,79 bar) (914 - 1219 mm) 20/40
4 (12,7 mm)
3
2 VENTURI UNDER 30 psig 6 - 8 inch POLYPLUS® 45 - 75°
5/16 inch (2,07 bar) (152,4 - 203,2 mm) 20/40
4 (7,94 mm)
3

PHYSICAL REQUIREMENTS OF MEDIA

POLYEXTRA® POLYPLUS®
HARDNESS 3.0 ± .25 3.5 ± 0.25
(Mohs Scale)

SPECIFIC GRAVITY 1.15 ± 10% 1.50 ± 10%

(gms/cc)

NOTES:

1 STAND-OFF, OPEN BLASTING.

2 CLOSED-CYCLE BLASTING (DONE IN A PRESSURE BLAST EQUIPMENT

CHAMBER).
3 PRESSURE READINGS MUST BE READ AT THE NOZZLE RATHER THAN
ESTIMATED FROM REGULATOR GAGE READINGS. READ THE PRESSURE
EVERY FOUR HOURS AND EACH TIME THE PRESSURE IS CHANGED AT
THE REGULATOR.

4 PROCESS VARIABLES INCLUDE PRESSURE, DISTANCE FROM THE NOZZLE

TO THE PART, ANGLE OF ATTACK AND NOZZLE SIZE. THE PARAMETERS
USED WILL CHANGE WITH PAINT COATING AGE, TYPE AND NUMBER OF
COATINGS; BUT THE PARAMETERS GIVEN HAVE SUCCESSFULLY REMOVED

BRASIL VIDA TAXI AEREO

VARIOUS COATING TYPES WITH NO EFFECT ON THE METAL.
324332-401-01.CGM

5. RECOMMENDED PLASTIC MEDIA TYPE AND SIZE IS POLYPLUS® 20/40.

POLYEXTRA® 12/20 OR 20/30 CAUSES A SMOOTHER FINISH BUT THE
PAINT REMOVAL RATE IS LOWER. TYPE III PLASTIC MEDIA TYPE IS
NOT TO BE USED ON THESE COMPONENTS.

Figure 401
Recommended Dry-Stripping Variables

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(7) Make an inspection of the brake housing and repair the brake housing, if necessary,
after the paint is removed as told in the CHECK and REPAIR sections.

(8) After the brake housing is repaired, apply chemical film solution, Specification
MIL-DTL-5541 or SAE AMS 2473, and paint to the brake housing as told in the
REPAIR section.

B. Strip brake housing as follows - Method Il (Wet-Stripping):

NOTE: To get correct values, the paint must be removed from parts before the dye
penetrant inspection or the magnetic particle inspection is done. If the paint is
not loose and is in good condition, the removal of paint before an eddy current
inspection is not necessary.

WARNING: DO NOT USE PAINT REMOVAL AGENTS NEAR SPARKS, FLAMES

OR HOT SURFACES.
KEEP PAINT REMOVAL AGENTS AWAY FROM EYES OR SKIN.
DO NOT BREATHE THE FUMES OR DRINK PAINT REMOVAL
AGENTS. PAINT REMOVAL AGENTS ARE POISONOUS.
OBEY THE MANUFACTURER'S INSTRUCTIONS.
REFER TO THE MATERIAL SAFETY DATA SHEET (OR
EQUIVALENT) BEFORE PAINT REMOVAL AGENTS ARE USED.
(1) Completely disassemble the part to be cleaned to prevent solvent from being en
trapped between mating surfaces. Remove all parts from brake housing in
accordance with DlSASSEMBLY.

(2) Clean the part according to the Cleaning Procedures paragraph.

(3) Seal all holes that have threads and piston cavities as necessary.

(4) Use a paint brush to apply paint removal agent (ShipShape® Resin Cleaner or
PrepRiteTM Coatings Remover) to the brake housing. Let the paint removal agent
stay on the brake housing for 30 minutes to two hours. The time necessary for the
paint removal agent to remain on the brake housing subassembly is related to the
condition of the paint. Obey the manufacturer's instructions for the solvent that is
used.

NOTE: It is acceptable for the brake housing to be put in a carbon steel or

stainless steel container that is filled with ShipShape® Resin Cleaner.

BRASIL VIDA TAXI AEREO

Leave the brake housing in the resin cleaner for 30 minutes to two hours.

CAUTION: FLUSH THE PAINT REMOVAL AGENT FROM OPENINGS, HOLES

THAT HAVE THREADS AND OTHER AREAS WHERE THE PAINT
REMOVAL AGENT CAN GET CAUGHT.
(5) If necessary, remove the brake housing from the paint removal agent.

(6) Clean the brake housing, two times, with water that has a temperature between
160° to 180° F (71,1° to 82,2° C).

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WARNING: USE EYE PROTECTION WHEN COMPRESSED AIR IS USED.

COMPRESSED AIR CAN CAUSE PARTICLES TO BECOME
AIRBORNE WHICH CAN CAUSE INJURIES.
DO NOT PERMIT AIR PRESSURE FOR CLEANING TO BE MORE
THAN 15 PSIG (1,0 BAR).
(7) Dry the brake housing with low-pressure (15 psig or 1,0 bar), filtered air.

(8) Make an inspection of the brake housing and repair the brake housing, if necessary,
after the paint is removed as told in the CHECK and REPAIR sections.

(9) After the brake housing is repaired, apply chemical film solution, Specification
MIL-DTL-5541 or SAE AMS 2473, and paint to the brake housing as told in the
REPAIR section.

BRASIL VIDA TAXI AEREO

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THIS PAGE
KEPT
BLANK

BRASIL VIDA TAXI AEREO

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CHECK

1. Reference

REFERENCE NAME
AP-763 Meggitt Aircraft Braking Systems
Nondestructive Testing Manual with Publications Department - D648
Procedures for Ultrasonic Inspection (32-42-04), 1204 Massillon Road
Eddy Current Inspection (32-42-05) and Akron, OH 44306-4186
Magnetic Particle Inspection (32-42-06) Ph: 330-796-8081
Penetrant Inspection (32-42-07) Fax:330-796-9805

2. General

A. Refer to IPL Figure 1.

B. Visually examine all of the parts for cracks, wear, structural damage, corrosion and
damaged threads. Replace all parts that have cracks, structural damage, thread damage
or are worn more than the limits given. Repair small scratches and corrosion.

C. Components of the brake assembly that are suspected of having been overheated after
going through a high-energy stop must be checked for hardness in accordance with the
instructions in TESTING AND FAULT ISOLATION.

NOTE: If brakes are removed for a reason other than wear and the brake stack is to
be continued or returned to service, the brake assembly and adjusters must be
retained as a unit and the brake stack must be retained as a unit. This will
ensure the disks will be re-assembled in the correct location and orientation
(up/down) which will maintain the wear measurement of the brake before it
was disassembled.

3. Rotating Disk (90, 90A, 90B or 90C)

A. Check rotating disk subassembly for cracks and check disk relief slot terminal holes for
cracks and corrosion. Replace cracked disks. Remove corrosion, rust pits and minor
damage as specified in REPAIR.

B. Check disks for wear. Replace disk when minimum thickness across the unchipped mix
reaches 0.300 inch (7,62 mm) on rotating disks (90 or 90A) and 0.375 inch (9,53 mm) on

BRASIL VIDA TAXI AEREO

rotating disk (90B or 90C), or if mix is entirely worn off one side in any segment.

NOTE: Up to 25 percent of the mix can be lost through chipping, provided the chipping
is scattered.

C. Check disks for dishing. Disk can be dished a maximum of 0.030 inch (0,76 mm) when
used with other dished disks. Repair excessively dished disks as given in REPAIR.

D. Replace disks that are out-of-round 0.125 inch (3,18 mm) or more.

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E. Check disks for shrinkage. Replace disks that have shrunk to an outside diameter of
9.120 inches (231,65 mm) or less.

F. Check disk tangs for battering. Replace disks with tangs worn smaller than 0.615 inch
(15,62 mm) in width.

4. Stationary Disk Subassembly (100 or 100A)

A. Visually inspect the disk subassembly for corrosion and cracks. Replace cracked disks.
Remove corrosion and rust pits and minor damage as specified in REPAIR.

NOTE: If the wear pads must be removed in accordance with the following
instructions, inspect the subassembly core plate with the magnetic particle
method.

B. Check disk thickness. Replace wear pads when total thickness measured at a point
midway between wear pad rivets is less than 0.431 inch (10,95 mm) on stationary disk
subassembly (100) and 0.460 inch (11,68 mm) on stationary disk subassembly (100A).

C. Check disks for dishing. Disks can be dished a maximum of 0.030 inch (0,76 mm) when
used with other dished disks. Repair excessively dished disks by procedures specified in
REPAIR.

D. Check the inside diameter of the disks for size. Replace disk if the measurement is more
than 4.68 inches (118,9 mm) or less than 4.25 inches (107,9 mm).

E. Check disks for condition of rivets and wear of segments. Whenever one or more rivets is
sheared or when the dimension shown in Figure 501 is less than 1.43 inches (36,32 mm)
on three or more segments per side, replace all segments as indicated in REPAIR.

NOTE: Wear pads have a tendency to curl away from the base plate and wear to
sharp edges as shown in Figure 501. Slight curling is not a reason for
replacement.

F. Check width of keyslots. Replace base plates with keyslots less than 0.802 inch
(20,28 mm) or greater than 0.832 inch (21,13 mm).

5. Backing Plate Subassembly (50)

A. Visually inspect the backing plate subassembly for cracks. Replace cracked backing

BRASIL VIDA TAXI AEREO

plate subassemblies.

NOTE: If the wear pads must be removed in accordance with the following
instructions, inspect the subassembly core plate with the magnetic particle
method.

B. Check backing plate subassembly thickness. If worn to less than 0.486 inch (12,34 mm),
replace segments as indicated in REPAIR.

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C. Check backing plate for rivet condition and wear of segments. Whenever one or more
rivets is sheared, or when the wear pads measure less than 1.43 inches (36,32 mm)
(See Figure 501) on three or more segments, replace all segments as indicated in
REPAIR.

NOTE: Wear pads have a tendency to curl away from the base plate and wear to
sharp edges, as shown in Figure 501.

D. Check backing plate for dishing. Backing plate can be dished a maximum of 0.040 inch
(1,016 mm) (unbolted). Repair excessively dished backing plate as specified in REPAIR.

6. Pressure Plate Subassembly (170, 170A, 170B or 170C)

A. Visually inspect the pressure plate for cracks. Replace cracked pressure plate.

NOTE: If the wear pads must be removed in accordance with the following
instructions, inspect the subassembly core plate with the magnetic particle
method.

B. Check pressure plate subassembly thickness. Repad pressure plate subassemblies

(170, 170A, or 170B) if worn to 0.321 inch (8,15 mm) or less in accordance with REPAIR.
Repad pressure plate subassembly (170C) if worn to 0.349 inch (8,86 mm) or less as
given in RE PAIR.

C. Check pressure plate subassembly for rivet condition and wear of segments. Whenever
one or more rivets is sheared, or when the wear pads measure less than 1.43 inches
(36,32 mm) (See Figure 501) on two or more small wear pads, or less than 2.92 inches
(74,17 mm) (See Figure 502) on the large wear pads, replace all pads as indicated in
REPAIR.

NOTE: Wear pads have a tendency to curl away from the base plate and wear to
sharp edges, as shown in Figure 501 and Figure 502. Slight curling is not a
reason for re placement.

D. Check pressure plate subassembly for flatness. If the pressure plate is more than
0.030 inch (0,76 mm) out-of-flat, straighten as specified in REPAIR.

E. Check width of keyslots. Replace pressure plates with keyslots less than 0.802 inch
(20,28 mm) or greater than 0.832 inch (21,13 mm).

BRASIL VIDA TAXI AEREO

7. Brake Housing Subassembly (330 or 330B)

A. Check for cracks, using Zyglo or dye-penetrant method. Use material tabulated in Check
Materials. Remove cracked housings from service.

B. Check spring cavities and mating surfaces for corrosion, wear and other damage. See
REPAIR.

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CENTER LINE
BETWEEN RIVETS

1.43 1.43
(36,32) (36,32)
CURLING

324332-501-01.CGM
A SECTION A-A

Figure 501
Wear Limits (Small Wear Pads)

C. Check piston cavities for scoring and wear. To correct, follow procedure specified in
REPAIR. Replace housing if any cylinder cavity exceeds 1.132 inches (28,75 mm) in
diameter.

D. Check threads in bleeder and pressure ports for fit, damage or cross threading. If repair
is required, See Repair No. 1 - Bleeder Hole Repair in Brake Housing.

8. Piston (220)

A. Check pistons for wear. Measure diameter of pistons at three places around
circumference. Replace pistons if diameter measures 1.120 inches (28,45 mm) or less at
one point.

B. Check pistons for burrs, scratches or nicks. Replace any pistons that are damaged more

BRASIL VIDA TAXI AEREO

than 0.003 inch (0,08 mm) deep on seal contacting surfaces. Repair pistons that are
damaged less than 0.003 inch (0,08 mm) deep as described in REPAIR.

C. Verify that pistons are free to move in their cavities.

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COMPONENT MAINTENANCE MANUAL
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PRESSURE PLATE SUBASSEMBLIES

(170A, 170B AND 170C)

CL

2.92
(74,17)

WEAR PAD
(190 OR 190B)

CENTER OF PAD

PRESSURE PLATE SUBASSEMBLY (170)

2.92 2.92
(74,17) (74,17)

324332-502-01.CGM

WEAR PAD (190)

BRASIL VIDA TAXI AEREO

CURLING
CENTER OF PAD

Figure 502
Wear Limits (Large Wear Pads)

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9. Brake Bolts (20 or 20A) and (40 or 40A) and Self-Locking Nuts (10 and 140)

A. Check all bolts and nuts for stripped threads. Replace all bolts and nuts that have
stripped or damaged threads.

B. Check nuts for worn locking feature as follows:

(1) Replace any self-locking nut (10) that can be installed on bolt, past its locking
device, with less than 7 pound-inches (0,80 N-m) torque.

(2) Check self-locking nuts (140) for self-locking feature. Replace nuts after 10
applications or at any time the nut can be turned on the return pins (160 or 160A)
with the fingers.

C. Magnetic-particle check bolts for cracks, especially under bolt head and in threads
adjacent to shank. Replace cracked bolts.

NOTE: For bolts, magnetic particle inspection in the longitudinal direction only is
sufficient to identify fatigue cracks.

10. Insulator (210, 210A, 210B or 210C)

A. Visually examine disk insulators for cracks, nicks and blisters.

(1) Replace damage disk insulators (210 and 210A).

NOTE: Discard the removed disk insulator (210 and 210A) as specified for
asbestos containing items by local regulations.

(2) Repair disk insulators (210B and 210C) as described in REPAIR.

B. Check disk insulators for thickness. Replace insulator (210 or 210B) if minimum
thickness is less than 0.240 inch (6,1 mm) and insulator (210A or 210C) if minimum
thickness is less than 0.307 inch (7,79 mm).

C. If no replacement disk insulators (210) are available, replace with disk insulator (210B).

D. If no replacement disk insulators (210A) are available, replace with disk insulator (210C).

11. Return Pin (160 or 160A)

BRASIL VIDA TAXI AEREO

A. Magnetic-particle check return pins for cracks. Replace cracked pins.

B. Check pins particularly under pin head and in threads. Replace cracked pins.

C. Check for stripped or damaged threads and straightness. Replace all parts that are bent
or have stripped or damaged threads.

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12. Spring (270)

A. Replace springs that do not require a minimum of 67 pounds (298 N) to compress to a

0.635 inch (16,13 mm) height (Refer to Table 802).

13. Torque Tube (130, 130A or 130B)

A. Check torque tube for damage or cracks using the magnetic-particle method. Replace
cracked torque tubes.

B. Replace torque tube if damaged beyond limit shown in Figure 503.

C. Replace torque tube if any key thickness is less than 0.720 inch (18,29 mm) or
0.015 inch (0,38 mm) maximum wear per key face. See Figure 504.

14. Grip and Tube Subassembly (150 or 150A)

A. Check grip and tube subassemblies for bending, damage or corrosion of the tubes.
Replace bent, corroded or damaged tubes with new grip and tube subassemblies.

B. Check grip and tube subassemblies (150 or 150A) for grip strength (See Figure 505).

NOTE: The purpose of the following procedure is to check that the force required to
move the grip on the tube does not fall below 150 pounds (667,233 N) at any
point while moving grip in either direction over the length of the tube to within
0.11 inch (2,79 mm) of tube end. An equivalent procedure is acceptable.

(1) Secure grip and tube arbor press Adapter 3-7305-1A in Dake arbor press, or
equivalent.

(2) Install indicator, Model 7283-10 (Brown and Sharpe).

(3) Assemble setting block, using Body 3-7340-1, Gib 3-7340-2, and two 3-7340-3
flathead machine screws, not shown. Place assembly in position in arbor press.

(4) Position stop Block 2-9690-11 in setting block with the 0.25 inch (6,35 mm) depth of
stop block directly beneath adjustable stop of arbor press adapter.

(5) Loosen and back off adjustable stop.

(6) Bring head of arbor press adapter down on setting block and fully compress head.

BRASIL VIDA TAXI AEREO

Set indicator to zero reading.

(7) While adapter is fully compressed, turn adjustable stop down until stop just contacts
top block. Tighten adjustment locking nut.

(8) Move stop block so that 0.498 inch (12,65 mm) depth is directly beneath the
adjustable stop.

(9) Place grip and tube subassembly in position in setting block.

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THIS SURFACE IS SUBJECT

TO IMPRESSED AREA
CAUSED BY CONTACT WITH
WHEEL BEARING CONE.
DEPRESSION SHOULD NOT
EXCEED 0.015 (0,381)
CHECKED WITH SURFACE
AGAINST A SURFACE PLATE
AND USING FEELER GAGE
MAX. 0.015 (0,381)
DEPRESSED
AREA AT OD
SECTION A-A A

324332-503-01.CGM
SURFACE
PLATE
NOTE:
DEPRESSED AREA SHOWN FOR TORQUE TUBE (130) IS ALSO APPLICABLE TO
TORQUE TUBES (130A AND 130B).

Figure 503
Torque Tube Damage Limit

0.720 (18,29)
MIN.

WEAR

BRASIL VIDA TAXI AEREO

324332-504-01.CGM

0.015 (0,38)
MAX. WEAR

Figure 504
Key Wear Limit

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COMPONENT MAINTENANCE MANUAL
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DAKE ARBOR PRESS NO. 1

DAKE CORP.
GRAND HAVEN, MI 49417

3-7340-2 GIB GRIP AND TUBE ARBOR

PRESS ADAPTER S/A
3-7305-1A
(WITH 150# SPRING)

INDICATOR WITH S/A

9.0 (228,6) SETTING BLOCK S/A

MIN. CAPACITY 3-7340-1A

GRIP AND TUBE

324332-505-01.CGM
SUBASSEMBLY

ADJUSTABLE BODY 3-7340-1

STOP WITH S/A
STOP BLOCK 2-9690-11

Figure 505
Checking Grip and Tube Subassemblies

(10) Bring arbor press down until head contacts grip and tube subassembly. Increase
pressure and move grip to one end of grip and tube subassembly.

(11) Reverse position of grip and tube subassembly in setting block.

(12) Bring arbor press down until head contacts grip and tube subassembly. Increase
pressure until adapter is fully compressed and indicator reads zero.

NOTE: If grip slips before indicator reaches zero reading, replace grip and tube
subassembly.

(13) Increase pressure until tube slides in grip. Continue applying pressure until the

BRASIL VIDA TAXI AEREO

adjustable stop contacts the stop block.

NOTE: The grip must not jump and the indicator reading must not drop below
zero while the grip is moving over the entire length of the tube. If either of
these conditions occur, replace the grip and tube subassembly.

(14) Reverse grip and tube subassembly position in setting block and repeat steps (12)
and (13).

(15) Repeat steps (9) through (14) for each grip and tube subassembly.

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C. Reset grips of grip and tube subassemblies (150 or 150A).

(1) For resetting grip and tube subassembly (150), move stop block so that 0.548 inch
(13,92 mm) height is directly beneath the adjustable stop. For resetting grip and
tube subassembly (150A), move stop block so that 0.518 inch (13,16 mm) height is
directly beneath the adjustable stop.

(2) Place grip and tube subassembly in position in setting block.

(3) Bring head of the arbor press adapter down against tube. Continue pressing tube
until adjustable stop has contacted stop block, preventing further press movement.
At this point, grip has been reset to 0.11 inch (2,79 mm) from end of tube on grip
and tube subassembly (150) and the resetting will be 0.08 inch (2,03 mm) on grip
and tube subassembly (150A).

(4) Repeat steps (1) and (3) for each of the remaining grip and tube subassemblies.

NOTE: When facilities specified for testing as described in paragraphs (1) thru
(3) are not available, reset grips as indicated in Figure 506.

15. Self-Adjusting Swage Tube (152 or 152A) and Adjuster Swage (151)

A. Check adjuster swage for reuse as follows:

NOTE: The square swages, which are made from case hardened steel, can be reused
with no loss of performance. However, in actual service, environmental
conditions may affect swage life, and it is thus necessary to establish a wear
limit acceptance criteria.

(1) Visually check for damage. Examine the swage corners for cracks, gouges, scoring,
excessive pitting and excessive wear. Replace a damaged adjuster swage.

(2) Measure the dimension across the adjuster swage corners. Replace a swage that is
less than 0.420 inch (10,67 mm) across the corners (See Figure 507).

(a) As an aid, the dimensional check can use a go/no-go gauge to check for wear
on the swage corners.

NOTE: This test, along with the visual check, is required for swage
reusability

BRASIL VIDA TAXI AEREO

B. Self-adjusting swage tube (152 or 152A) is not reusable and must be replaced at each
stack change or overhaul.

16. Washers (30)

A. Check washers for wear and damage. Replace if unserviceable.

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0.500 (12,7)

0.281 (7,14) DRILLED HOLE

0.0312 (0,79) x 45° IN TUBE 4130 STEEL
CHAMFER (TYP.)

TOOL-9523467 4.00
(TUBE ONLY) (101,6)
PRESS DOWN UNTIL
GRIP IS IN CONTACT
WITH PLATE
GRIP TUBE
GRIP

0.11 0.08
STEEL PLATE (2,79) (2,03)
APPROX.
2.00 (50,8) SQ.
0.265 (6,73) 2 3
DRILLED HOLE
IN PLATE

NOTES:
324332-506-01.CGM
1. MANUFACTURE GRIP SETTING TOOL LOCALLY
2 DIMENSION FOR GRIP AND TUBE SUBASSEMBLY (150)

BRASIL VIDA TAXI AEREO

3 DIMENSION FOR GRIP AND TUBE SUBASSEMBLY (150A)

Figure 506
Grip Resetting Tool for Grip and Tube Subassemblies 9535045 and 5001423 (Sheet 1 of 2)

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0.500 (12,7)

0.281 (7,14) DRILLED HOLE

0.0312 (0,79) x 45° IN TUBE 4130 STEEL
CHAMFER (TYP.)

TOOL-9523467 4.00
(TUBE ONLY) (101,6)
PRESS DOWN UNTIL
GRIP IS IN CONTACT
WITH PLATE

GRIP TUBE
GRIP

0.11 0.08
STEEL PLATE (2,79) (2,03)
APPROX.
2.00 (50,8) SQ.
0.265 (6,73) 2 3
DRILLED HOLE
IN PLATE

NOTES:
324332-506-02.CGM

1 MANUFACTURE GRIP SETTING TOOL LOCALLY

2 DIMENSION FOR GRIP AND TUBE SUBASSEMBLY (150)

BRASIL VIDA TAXI AEREO

3 DIMENSION FOR GRIP AND TUBE SUBASSEMBLY (150A)

Figure 506
Grip Resetting Tool for Grip and Tube Subassemblies 9535045 and 5001423 (Sheet 2 of 2)

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COMPONENT MAINTENANCE MANUAL
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324332-507-01.CGM
0.420 (10,67)
MINIMUM

Figure 507
Adjuster Swage Wear Limit

17. Preformed Packing (240 or 240A and 320) and Packing Retainers (230)

A. It is recommended that new preformed packings and packing retainers be installed at

each disassembly.

18. Retaining Ring (250)

A. Check retaining rings for structural damage or corrosion. Replace all damaged or
distorted retaining rings.

19. Spring Guide (260)

A. Check spring guide for damage and cracks. Clean up superficial damage and displaced

BRASIL VIDA TAXI AEREO

metal. Replace if excessively damaged or cracked.

20. Return Spring Housing (280)

A. Check return spring housing. Clean superficial damage on spring housing inner surface
and displaced metal on spring housing flange surface abutting brake housing. Replace
spring housings damaged or unserviceable.

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21. Bleeder Plug (290) and Bleeder Adapter (310)

A. Check bleeder adapter and plug for stripped threads or other damage. Replace damaged
parts.

22. Hardness Check

A. A hardness test can be made on brake components in accordance with TESTING AND
FAULT ISOLATION if brakes are suspected of having been overheated after going
through a rejected takeoff or high energy input.

BRASIL VIDA TAXI AEREO

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REPAIR

1. Repair Materials

MATERIAL* POSSIBLE SOURCE**

Chemical Film Solution
Specification MIL-DTL-5541
or SAE AMS 2473
Alodine 1200 Henkel Surface Technologies
32100 Stephenson Hwy
Madison Heights, MI 48071
(CAGE Code not available)
Ph: (800) 521-6895
Fax: (248) 583-9300
Turcoat Alumnigold/4178 Elf Atochem N. A. Inc. /Turco Products
2700 Temple Avenue, Suite B
Long Beach, CA 90806
(CAGE Code 61102)
Ph: (310) 981-8300
Fax: (310) 981-8303
Iridite 14-2 MacDermid, Incorporated
245 Freight Street
Waterbury, CT 06702
(CAGE Code OPX54)
Ph: (800) 325-4158
Fax: (203) 575-5700
Loctite-242 Loctite Corp.
1001 Trout Brook Crossing
Rocky Hill, CT 06067-3582
Ph: 860-571-5100
Fax: 860-571-5465
Acetone, Specification ASTM D329 Commercially available
Acrylic Topcoat/Primer Combination Akron Paint and Varnish, Incorporated
Ultra Low VOC (Volatile Organic Compound) 1390 Firestone Parkway
Acrylic Enamel (Danemil) Akron, Ohio 44301

BRASIL VIDA TAXI AEREO

Ph: 330-773-8911
Fax: 330-773-1028
Oxsol Thinner Contact your local distributor of aviation
products and supplies.
* Equivalent replacements can be used for the items given.
**Other sources could be available.

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BRAKE ASSEMBLY 5003096

MATERIAL* POSSIBLE SOURCE**

Peel Away 5 or Peel Away 7TM Dumond Chemicals, Inc.

Paint Remover (Cured) 1501 Broadway
New York, NY 10036
Ph: 212-869-6350
Fax: 212-764-5762
Dry-Cleaning Solvent, Commercially available
Type I, Stoddard Solvent
Type II, 140°F Solvent,
Specification MIL-PRF-680 or ASTM D235
Aluminum Oxide Cloth Commercially available
(300 to 360 grit, Wet-or-dry)
Rust Preventative E. F. Houghton & Company
Rust Veto 4214 Madison & Van Buren Avenue
Valley Forge, PA 19482
Gas Tungsten Arc Weld (G.T.A.W.) Commercially available
or
Gas Metal Arc Weld (G.M.A.W.)
* Equivalent replacements can be used for the items given.
**Other sources could be available.

2. General
A. Refer to IPL Figure 1.

B. Repair of the brake is limited to the replacement of damaged parts and to the specific
repairs listed in this section. Replace all cracked parts. No repair of cracked, severely
corroded or badly damaged parts should be attempted.

3. Straightening Procedures for Pressure Plate, Backing Plate and Disks

A. Straighten pressure plate, backing plate and stationary disks as follows (Refer to
Figure 901):

(1) Remove wear pads from base plates.

(2) Fabricate upper and lower registers as shown.

(3) Mount upper and lower registers in a hand arbor press.

BRASIL VIDA TAXI AEREO
(4) Put dished base plate on lower register with dished area up.

(5) Apply sufficient pressure with press to straighten disk.

(6) Disks must be flat within 0.010 inch (0,25 mm).

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B. Draw Flattening - If the backing plate, stationary disk or the pressure plate are
excessively dished, they can be straightened as follows:

(1) Remove wear pads from base plates in accordance with Replacing Wear Pads.
(2) Stack base plates back-to-back; hold together with two, one-inch boiler plates and
long bolts through center of stack and boiler plates.

(3) Place in an oven and heat slowly to a temperature of 1075° F to 1150° F (579° C to
621° C); hold temperature for one hour

(4) Remove from oven and retighten bolts.

(5) Replace in oven for two to three hours.

(6) Remove from oven and air-cool to room temperature; then remove bolts and
separate parts.

4. Replacing Wear Pads (80, 80A, 120, 120A, 190, 190A, 190B, 200 and 200A)

A. Replace wear pads on backing plate subassembly (50), stationary disk subassembly
(100 or 100A) and pressure plate subassembly (170, 170A, 170B or 170C) as follows:

NOTE: Replace all wear pads on a disk, backing plate or pressure plate whenever 25
percent of more of the wear pads require replacing.

CAUTION: DO NOT DAMAGE OR ENLARGE RIVET HOLES IN BASE PLATES.

(1) Using a 7/32, 0.219 inch (5,56 mm) drill, remove wear pads by drilling out shop
heads of old rivets and punching out rivets.

B. Magnetic-particle check base plates. Replace cracked base plates.

C. Do a hardness check to determine if base plates are acceptable for repadding. Do a

hardness test as given in TESTING AND FAULT ISOLATION, if there is an indication of
overheating, warpage, or shrinkage.

D. Repair stationary, pressure and backing plate base plates as given in Repair of
Stationary Disk, Repair of Pressure Plate and Repair of Backing Plate as required.

E. Straighten base plates as given in Straightening Base Plates and Disks. Base plates
must be flat within 0.010 inch (0,25 mm) as required.

F. Grit blast base plate to remove rust, paint, scale or brake residue. BRASIL VIDA TAXI AEREO

G. Visually check faces of base plate for burrs and raised metal which can impair seating of
new wear pads. Remove excess weld, burrs or raised metal by localized grinding or by
surface grinding the entire base plate. Refer to Repair of Stationary Disk, Repair of
Pressure Plate and Repair of Backing Plate.

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WARNING: DO NOT USE DRY-CLEANING SOLVENT NEAR SPARKS OR FLAMES.

DRY-CLEANING SOLVENT IS FLAMMABLE.
KEEP DRY-CLEANING SOLVENT AWAY FROM EYES OR SKIN.
DO NOT BREATHE THE FUMES OR DRINK DRY-CLEANING SOLVENT.
DRY-CLEANING SOLVENT IS POISONOUS.
OBEY THE MANUFACTURER'S INSTRUCTIONS.
REFER TO THE MATERIAL SAFETY DATA SHEET (OR EQUIVALENT)
BEFORE DRY-CLEANING SOLVENT IS USED.

H. Clean new wear pads in dry-cleaning solvent, Specification MIL-PRF-680 or equivalent to

remove protective coating, grease, dust or grit.

I. Remove all burrs or raised metal on bottom of the wear pad.

J. Rivet wear pads to base plates as follows, using rivet tools listed in SPECIAL TOOLS,
FIXTURES AND EQUIPMENT:

CAUTION: TWO CRACKS ARE PERMITTED IN SHOP HEAD OF RIVET,

PROVIDED THE CRACKS DO NOT EXTEND INTO RIVET SHANK.
REMOVED AREA OF RIVET HEADS MUST NOT BE MORE THAN 25
PERCENT OF HEAD.
(1) Install rivets so that shop head is formed in wear pad countersink. Install rivets by
compression method.

NOTE: These wear-padded assemblies are designed to maintain the rivet heads
flush or below pad surface. If rivet heads protrude above wear pad
surface, grind as shown in Figure 601 to provide flush rivets.

CAUTION: PRODUCE THE CORRECT RIVET SQUEEZE WHEN ADJUSTING

RIVET MACHINES.
EXCESSIVE SQUEEZE PRESSURE WILL RESULT IN WEAR PAD
CORNER “LIFT-UP”, WHILE INSUFFICIENT SQUEEZE PRESSURE
WILL RESULT IN LOOSE PADS AND IMPROPERLY FORMED HEADS.
(2) Rivets must be snug. Installation procedures must be such that a minimum force of
2 pounds (0,907 kg) and a maximum force of 100 pounds (45,36 kg) is required to
move a pad. Check seating of wear pads by attempting to insert a 0.0015 inch
(0,380 mm) feeler gage between wear pad and base plate. Gage must not pass
centerline of pad between rivets.

(3) Subassemblies must be flat within 0.010 inch (0,25 mm). Thickness of BRASIL VIDA TAXI AEREO
subassemblies to be as shown in Figure 602.

K. Surface treat repadded disk, applying rust inhibitor in accordance with Storage
Instructions if disks are to be stored.

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SHADED PORTION INDICATES

AREA GROUND FROM RIVET
HEAD (MAX. ALLOWABLE 25%)

TOTAL RIVET
HEAD AREA

324332-601-01.CGM
Figure 601
Grinding Rivet Heads

5. Repair of Rotating Disk (90, 90A, 90B or 90C)

A. Magnetic-particle check base plate. Replace a cracked rotating disk.

B. Remove rust pits, corrosion or nicks to 0.020 inch (0,508 mm) deep from relief slot
terminal holes.

C. The surface finish must not be more than 250 Ra as indicated in Figure 603 when
measured on lines which are in the same plane as the center of the terminal hole. The
surface finish must not be more than 125 Ra as indicated on a circle concentric to the
center of hole.

6. Repair of Stationary Disk Subassembly (100 or 100A)

A. Remove wear pads (120 or 120A) as given in Replacing Wear Pads.

B. Magnetic-particle check base plate. Replace a cracked base plates. BRASIL VIDA TAXI AEREO
C. Remove rust pits, corrosion or nicks to 0.020 inch (0,51 mm) deep from relief slot
terminal holes.

D. The surface finish must not be more than 125 Ra as indicated in Figure 604, when
measured on lines which are in the same plane as the center of terminal hole. The
surface finish must not be more than 63 Ra as indicated on a circle concentric to the
center of hole.

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0.444 (11,28) 0.482 (12,24) 0.487 (12,37)

MIN. MIN. MIN.

0.464 (11,79) 0.494 (12,55) 0.504 (12,80)

MAX. MAX. MAX.

RIVET
(110 OR 110B) RIVET (110A) RIVET (60)

WEAR PAD WEAR PAD WEAR PAD (120)

(120 OR 120A) (120)
RIVET RIVET (110A) RIVET (70)
(110 OR 110B)
WEAR PAD (80)

STATIONARY STATIONARY
DISK 9536254 DISK
5006893 BACKING PLATE
9536256

STATIONARY DISK STATIONARY DISK BACKING PLATE

SUBASSEMBLY (100) SUBASSEMBLY (100A) SUBASSEMBLY (50)

324332-602-01.CGM

NOTES:
1. SURFACE MUST BE FLAT WITHIN 0.010 (0,25) AFTER RIVETING.
2. RIVET HEADS MUST BE FLUSH WITH OR BELOW WEAR PAD SURFACE.

BRASIL VIDA TAXI AEREO

Figure 602
Acceptable Limits for Newly Repadded Subassemblies (Sheet 1 of 2)

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

0.325 (8,26) 0.325 (8,26) 0.358 (9,09)

MIN. MIN. MIN.

0.336 (8,53) 0.336 (8,53) 0.369 (9,37)

MAX. MAX. MAX.

RIVET (180) RIVET (180) RIVET (180)

WEAR PAD WEAR PAD

WEAR PAD
(190A) (190B)
(190)

9543995
BACKING
PLATE 5005118 5006891
BACKING BACKING
PLATE PLATE

WEAR PAD
(200 OR 200A)
WEAR PAD WEAR PAD
(200 OR 200A) (200)
RIVET (180)

RIVET (180) RIVET (180)

PRESSURE PLATE
PRESSURE PLATE SUBASSEMBLY PRESSURE PLATE
SUBASSEMBLY (170) (170A OR 170B) SUBASSEMBLY (170C)

BRASIL VIDA TAXI AEREO

324332-602-02.CGM

NOTES:
1. SURFACE MUST BE FLAT WITHIN 0.010 (0,25) AFTER RIVETING.
2. RIVET HEADS MUST BE FLUSH WITH OR BELOW WEAR PAD SURFACE.

Figure 602
Acceptable Limits for Newly Repadded Subassemblies (Sheet 2 of 2)

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

A
1

90°

ORIGIN ARC
2
90° CRITICAL

A
SECTION A-A

NOTES:

1 AREA MUST HAVE A FINISH NOT TO BE MORE THAN 125 RA ON A

CIRCLE CONCENTRIC TO THE CENTER OF THE TERMINAL HOLE

2 AREA MUST HAVE A FINISH NOT TO BE MORE THAN 250 RA WHEN

MEASURED ON LINES WHICH ARE IN THE SAME PLANE AS THE
CENTER OF THE TERMINAL HOLE

3. THE SURFACE FINISH REQUIREMENTS ARE APPLICABLE ONLY

IN THE AREAS WITHIN THE INCLUDED ANGLE OF 90° OPPOSITE
THE RELIEF SLOT
324332-603-01.CGM

4. NO SPIRAL TOOL MARKS. FLAT SPOTS AND IRREGULAR APPEARANCE

ARE ACCEPTABLE PROVIDED THE IRREGULARITIES ARE SMOOTHLY
BLENDED IN THE CRITICAL 90° AREA OF THE TERMINAL HOLE

BRASIL VIDA TAXI AEREO

Figure 603
Rotating Disk Terminal Hole Surface Finish Requirements

Page 608
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 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

A 2

150°

SECTION A-A A
NOTES:
1 63 RA FINISH ON A CIRCLE CONCENTRIC TO THE CENTER OF THE
TERMINAL HOLE

324332-604-01.CGM
2 125 RA FINISH WHEN MEASURED ON LINES IN THE SAME PLANE AS
THE CENTER OF THE TERMINAL HOLE
3. NO SPIRAL TOOL MARKS. FLAT SPOTS AND IRREGULAR APPEARANCE
ARE ACCEPTABLE PROVIDED THE IRREGULARITIES ARE SMOOTHLY
BLENDED IN THE CRITICAL AREA

Figure 604
Stationary Disk Terminal Hole Surface Finish Requirements

E. Repair damaged rivet holes as follows:

CAUTION: DO NOT REPAIR MORE THAN ONE-THIRD OF THE RIVET HOLES IN

A BASE PLATE.
(1) On the stationary disk, holes located on 6.140 inch (155,96 mm) B/C diameter must
not exceed a diameter of 0.281 inch (7,14 mm); and holes located on 8.046 inch
(204,37 mm) B/C diameter must not exceed a diameter of 0.328 inch (8,33 mm) in
accordance with Table 601.

(2) Preheat base plate to 500° F to 600° F (260° C to 316° C).

(3) Weld damaged rivet holes closed. Accepted methods of welding are listed in order
of preference in Figure 601.

(4) Post heat to 700° F to 800° F (371° C to 427° C) and cool slowly. BRASIL VIDA TAXI AEREO
(5) Drill new rivet holes the same size as original rivet holes. Use new wear pad as
template to locate new holes, in accordance with Figure 605.

F. Straighten base plate as given in Straightening Base Plate and Disks. Base plates must
be flat with 0.010 inch (0,25 mm).

G. Grit blast backing plate to remove rust, paint, scale or brake residue.

Page 609
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 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

Table 601
Welding Data List

Method Material
(Order of Preference) (Order of Preference)
AMS6458E
Gas Tungsten Arc Weld (G.T.A.W.) AMS6457
Oxweld No. 32 Rod
AMS6458E
Gas Metal Arc Weld G.M.A.W.) ANS6457
Oxweld No. 32 Rod

H. Visually check the face of backing plate for burrs and raised metal which would impair
seating of new wear pads. Remove an excess weld, burrs or raised metal by localized
grinding or by surface grinding pad seating area. Surface grinding can be done as
follows:

CAUTION: GRINDING IS NOT ACCEPTABLE METHOD OF FLATTENING DISK

EXCEPT FOR LOCAL BULGING OR RAISED METAL BURRS OR
EXCESSIVE WELD.
(1) Stationary Disk Base Plate

(a) Using a grinder with a magnetic chuck, float the base plate on shims until
original surface is level.

(b) Grind raised areas or high spots until parallel to and almost even with,
surrounding surfaces.

(c) Turn plate over and repeat on opposite side without use of shims.

(d) Turn plate over and grind surface flat. Repeat on opposite side until both sides
are parallel and flat within 0.010 inch (0,25 mm).

(e) Minimum thickness of base plate for stationary disk subassembly (100) after
grinding to be 0.200 inch (5,08 mm) and minimum thickness of base plate for
stationary disk subassembly (100A) after grinding to be 0.230 inch (5,84 mm).

I. Apply rust inhibitor on machined surfaces as given in Storage Instructions, if disks are to

BRASIL VIDA TAXI AEREO

be stored.

J. Repad stationary disk base plate as given in Replacing Wear Pads.

7. Repair of Torque Tube (130, 130A or 130B)

A. Remove burrs, corrosion and scratches from torque tube with a file or hand grinder. No
repair permitted in axle bore.

Page 610
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 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

Ø 0.312 +0.006/-0.001
A
Ø 0.266 +0.006/-0.001 (7,925 +0,152/-0,025)
(6,756 +0,152/-0,025) THRU HOLE
THRU HOLE

0.200 (5,08)
MIN.

Ø 6.140
(155,96)
Ø 8.046
(204,37)

A
SECTION A-A
STATIONARY
DISK 9536254

Ø 0.312 +0.006/-0.001
A
0.266 +0.006/-0.001 (7,925 +0,152/-0,025)
(6,756 +0,152/-0,025) THRU HOLE
THRU HOLE

0.230 (5,84)
MIN.

BRASIL VIDA TAXI AEREO

324332-605-01.CGM

A
STATIONARY SECTION A-A
DISK 9536893

Figure 605
Stationary Disk Repair Limits

Page 611
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 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

8. Repair of Backing Plate (50)

A. Remove wear pads (80 or 80A) in accordance with Replacing Wear Pads.

B. Magnetic-particle check backing plate. Replace a cracked backing plates.

C. Remove rust pits, corrosion or nicks to 0.020 inch (0,51 mm) deep from relief slot
terminal holes.

D. The surface finish must not be more than 125 Ra as indicated in Figure 604, when
measured on lines which are in the same plane as the center of terminal hole. The
surface finish must not be more than 63 Ra as indicated on a circle concentric to the
center of hole.

E. Repair damaged rivet holes as follows:

NOTE: Backing plate rivet hole repairs can be made on one or all holes providing the
following procedure is followed:

(1) On backing plate, holes located on 6.140 inch (155,96 mm) B/C diameter must not
exceed a diameter of 0.281 inch (7,14 mm); and holes located on 8.046 inch
(204,37 mm) B/C diameter must not exceed a diameter of 0.328 inch (8,33 mm) as
shown in Figure 606. These are the maximum diameters of damaged holes before
they can be repaired.

(2) Weld damaged rivet holes closed. Accepted methods of welding are listed in order
of preference in Table 601.

CAUTION: BACKING PLATE MUST NOT EXCEED 800° F (427° C) DURING WELD
REPAIR OF RIVET HOLES.
(3) Preheat backing plate to 500° F to 600° F (260° C to 316° C).

(4) Keep weld time to an absolute minimum.

(5) Weld in a criss cross pattern to avoid heat buildup. Do not weld adjacent holes
consecutively.

(6) Use 800° F (427° C) Tempilstik or Tempilaq on plate to prevent overheating.

(7) Postheat to 700° F to 800° F (371° to 427° C) and slow cool to room temperature.

BRASIL VIDA TAXI AEREO

Use of an insulating blanket will slow the cooling process and decrease the
possibility of excessive distortion.

(8) Drill new rivet holes the same size as original rivet holes. Use a new wear pad as a
template to locate new holes in accordance with Figure 606.

F. Straighten backing plate as given in Straightening Base Plate and Disks. Base plates
must be flat within 0.010 inch (0,25 mm).

G. Grit blast backing plate to remove rust, paint, scale or brake residue.

Page 612
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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

Ø 0.312 +0.006/-0.001
(7,925 +0,152/-0,025)
THRU Ø 0.62 (15,74) C'BORE
WITH 0.03 (0,76) COR RAD
TO DIM. SHOWN

Ø 0.266 +0.006/-0.001
(6,756 +0,152/-0,025)
THRU Ø 0.62 (15,74) C'BORE 0.049 +0.005/-0,010
WITH 0.03 (0,76) COR RAD A
(1,24 +0,13/-0,25)
TO DIM. SHOWN

0.281 ± 0.005
(7,14 ± 0,13)

Ø 6.140
(155,96)

A 0.365 (9,27)
Ø 8.046 MIN.
(204,37)

9536256
BACKING PLATE

BRASIL VIDA TAXI AEREO

SECTION A-A
324332-606-01.CGM

DIAMETERS OF HOLES ARE SHOWN IN THE

REPAIRED CONDITION

Figure 606
Backing Plate Repair Limits

Page 613
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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

H. Visually check face of backing plate for burrs and raised metal which would impair
seating of new wear pads. Remove excess weld, burrs or raised metal by localized
grinding or by surface grinding pad seating area. Surface grinding can be done as
follows:

(1) Grind wear pad seating surfaces flat within 0.010 inch (0,25 mm).

(2) Minimum permissible thickness of wear pad seating surface of backing plate is
0.365 inch (9,27 mm).

I. Apply rust inhibitor on machined surfaces as given in Storage Instructions if backing plate
is to be stored.

J. Repad backing plate base plate as given in Replacing Wear Pads.

9. Repair of Pressure Plate (170, 170A, 170B or 170C)

A. Remove wear pads (190, 190A, 190B, 200 or 200A) as given in Replacing Wear Pads.

B. Magnetic-particle check pressure plate. Replace a cracked pressure plate.

C. Repair enlarged or damaged rivet holes as follows:

CAUTION: DO NOT REPAIR MORE THAN ONE-THIRD OF THE RIVET HOLES IN

A BASE PLATE.
(1) The four holes located at 3.329 inches (84,56 mm) radius must not exceed a
diameter of 0.296 inch (7,52 mm) on pressure plate. On pressure plate, holes
located on 6.140 inch (155,96 mm) B/C diameter must not exceed a diameter of
0.281 inch (7,14 mm); and holes located on 8.046 inch (204,37 mm) B/C diameter
must not exceed a diameter of 0.328 inch (8,33 mm) as shown in Figure 607. These
are the maximum diameters of damaged holes before they can be repaired.

(2) Pre-heat base plates to 400° F to 600° F (204° C to 316° C).

(3) Weld rivet holes closed. Accepted methods of welding are listed in order of
preference in Table 601.

(4) Post heat to 400° F to 600° F (204° C to 316° C) and cool slowly.

(5) Drill new rivet holes the same size as original rivet holes. Use a new wear pad as a

BRASIL VIDA TAXI AEREO

template to locate new holes in accordance with Figure 607.

D. Straighten base plate in accordance with Straightening Base Plate and Disks. Base
plates must be flat with 0.010 inch (0,25 mm).

E. Grit blast base plate to remove rust, paint, scale or brake residue.

Page 614
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 Ø 0.62 (15,74) COUNTERBORE WITH
0.03 (0,76) COR RAD TO DIM. SHOWN
Ø 0.281 +0.006/-0.001 (17,137 +0,152/-0,025)
THRU 4 HOLES SPACED AS SHOWN
0.094 ± 0.005
A
(2,388 ± 0,127)

45°
3.760
1.007
(95,504)
(25,58)

3.329 (84,56)
Ø 8.046
RAD
(204,37)

Ø 6.140
(155,96) 0.203 (5,16)
MIN.

Figure 607
DIAMETERS OF HOLES
BRAKE ASSEMBLY 5003096

ARE SHOWN IN THE

REPAIRED CONDITION
COMPONENT MAINTENANCE MANUAL

Pressure Plate Repair Limits (Sheet 1 of 3)

5005118
PRESSURE PLATE
0.094 ± 0.005
(2,388 ± 0,127)

32-43-32
Ø 0.266 +0.006/-0.001 5005118
Ø 0.312 +0.006/-0.001 A (6,756 +0,152/-0,025) PRESSURE PLATE
(7,925 +0,152/-0,025) THRU Ø 0.62 (15,74)
THRU Ø 0.62 (15,74) C'BORE WITH 0.03 (0,76)
C'BORE WITH 0.03 (0,76) COR RAD TO DIM. SHOWN SECTION A-A
COR RAD TO DIM. SHOWN

324332-607-01.CGM

Aug 12/13
Page 615
CO: 8462 BRASIL VIDA TAXI AEREO EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
 Ø 0.62 (15,74) COUNTERBORE WITH
0.03 (0,76) COR RAD TO DIM. SHOWN
Ø 0.281 +0.006/-0.001 (17,137 +0,152/-0,025)
THRU 4 HOLES SPACED AS SHOWN
0.094 ± 0.005
A (2,388 ± 0,127)

45°
3.760
1.007
(95,504)
(25,58)

3.329 (84,56)
Ø 8.046
RAD
(204,37)

Ø 6.140
(155,96)
0.231 (5,87)

Figure 607
MIN.

DIAMETERS OF HOLES
ARE SHOWN IN THE
BRAKE ASSEMBLY 5003096

REPAIRED CONDITION
COMPONENT MAINTENANCE MANUAL

Pressure Plate Repair Limits (Sheet 3 of 3)

5006891
PRESSURE PLATE

0.094 ± 0.005

32-43-32
Ø 0.266 +0.006/-0.001 (2,388 ± 0,127)
Ø 0.312 +0.006/-0.001 A (6,756 +0,152/-0,025)
(7,925 +0,152/-0,025) 5006891
THRU Ø 0.62 (15,74)
THRU Ø 0.62 (15,74) PRESSURE PLATE
C'BORE WITH 0.03 (0,76)
C'BORE WITH 0.03 (0,76) COR RAD TO DIM. SHOWN
COR RAD TO DIM. SHOWN SECTION A-A

324332-607-02.CGM

Aug 12/13
Page 616
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 Ø 0.62 (15,74) COUNTERBORE WITH
0.03 (0,76) COR RAD TO DIM. SHOWN
Ø 0.281 +0.006/-0.001 (17,137 +0,152/-0,025)
THRU 4 HOLES SPACED AS SHOWN
A
0.094 ± 0.005
(2,388 ± 0,127)

45°

Ø 8.046 3.329 (84,56)

(204,37) RAD

Ø 6.140
(155,96)

Figure 607
0.203 (5,16)
MIN.

DIAMETERS OF HOLES
BRAKE ASSEMBLY 5003096

ARE SHOWN IN THE

REPAIRED CONDITION
COMPONENT MAINTENANCE MANUAL

Pressure Plate Repair Limits (Sheet 3 of 3)

9543995
PRESSURE PLATE

32-43-32
0.094 ± 0.005
Ø 0.266 +0.006/-0.001 (2,388 ± 0,127)
Ø 0.312 +0.006/-0.001 A (6,756 +0,152/-0,025) 9543995
(7,925 +0,152/-0,025) THRU Ø 0.62 (15,74) PRESSURE PLATE
THRU Ø 0.62 (15,74) C'BORE WITH 0.03 (0,76)
C'BORE WITH 0.03 (0,76) COR RAD TO DIM. SHOWN SECTION A-A
COR RAD TO DIM. SHOWN

324332-607-03.CGM

Aug 12/13
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 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

F. Visually check face of base plate for burrs and raised metal which would impair seating of
new wear pads. Remove excess weld, burrs or raised metal by localized grinding or by
surface grinding entire base plate. Surface grinding can be accomplished as follows:

CAUTION: GRINDING IS NOT AN ACCEPTABLE METHOD OF FLATTENING

DISK, EXCEPT FOR LOCAL BULGING OR RAISED METAL, BURRS
OR EXCESSIVE WELD.
(1) Grind pad seating surface until flat within 0.010 inch (0,25 mm).

(2) Minimum permissible thickness of pressure plate base plate after grinding is
0.203 inch (5,16 mm) measured between rivet holes for pressure plate
subassemblies (170, 170A or 170B) and 0.231 inch (5,87 mm) minimum thickness
for pressure plate subassembly (170C).

G. Apply rust inhibitor on machined surfaces as given in the storage instructions, if pressure
plate is to be stored.

H. Repad pressure plate base plate as given in Replacing Wear Pads.

10. Repair of Housing Subassembly (330 or 330B)

A. See Figure 608.

CAUTION: REMOVAL OF CORROSION AND SURFACE DAMAGE WILL PREVENT

STRESS CONCENTRATIONS. HOWEVER, THE REMOVAL OF MATERIAL
WILL SHORTEN THE LIFE OF THE BRAKE HOUSING.
LIMIT MATERIAL REMOVAL BY BLENDING TO THE MINIMUM REQUIRED
FOR REMOVING CORROSION OR SURFACE DAMAGE.

B. Remove scratches, nicks, abrasions and corrosion pits on the outside surfaces of
housing subassembly as given in repair limits except bolt bosses. Blend out damage that
might be come a source of corrosion or stress cracks. Maintain a surface finish in
reworked areas of 150 microinches RHR.

C. Thoroughly clean surface. Surface treat and paint reworked areas of housing as given in
Surface Treatment and Paint.

11. Repair of Piston (220)

A. Blend out and polish scratches, nicks and burrs on seal contacting surfaces of piston to

BRASIL VIDA TAXI AEREO

0.003 inch (0,08 mm) deep. Blend repair areas into surrounding surfaces to avoid local
indentations. Replace pistons that are damaged deeper than 0.003 inch (0,08 mm) or if
diameter measures 1.120 inches (28,45 mm) or less.

Page 618
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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

35
3
2

NOTES:
GENERAL: REPAIRS ARE LIMITED IN EACH MARKED AREA TO THE SHOWN AREAS. THE
MATERIAL REMOVED BY BLENDING IS LIMITED TO THE MINIMUM REQUIRED
FOR REMOVING CORROSION OR SURFACE DAMAGE. EXCEPT WHERE
RESTRICTED BY LENGTH OR LOCALE, WHEN DAMAGE DEPTH IS LESS THAN
0.015 INCH (0,38 MM) DEEP, ALL BLEND TYPE REPAIRS MUST BE BLENDED WITH
A DEPTH TO WIDTH RATIO OF 1 TO 100 IN SURFACE WIDTH. WHERE NOT
POSSIBLE, USE AS GENEROUS A WIDTH TO DEPTH RATIO AS PRACTICAL WITH
THE AREA BEING REPAIRED
AREA 1: 0.015 INCH (0,38 MM) DEEP AND 1/2 SQUARE INCH (322,58 SQ MM) MAXIMUM
BLENDING OR DAMAGE AREAS. (ONE REPAIR PER BOLT HOLE LOCATION)
AREA 2: 0.030 INCH (0,76 MM) MAXIMUM BLENDING OF DAMAGE AREA. (0.135 INCH
(3,43 MM) MINIMUM CROSS SECTION IS PISTON BORE BASE)
AREA 3: REMOVE (BLEND) CORROSION (DAMAGE) IN SEAL BORE UP TO 0.003 INCH
(0,08 MM) DEEP. MAINTAIN A SURFACE FINISH OF 32 MICROINCHES RHR.

BRASIL VIDA TAXI AEREO

REMOVE ROUGH EDGES OR BURRS FROM EDGES OF PACKING GROOVES.
BREAK EDGES OF PACKING GROOVES TO A 0.005 TO 0.15 INCH (0,13 TO
3,8 MM) RADIUS
324332-608-01.CGM

AREA 4: 0.010 INCH (0,254 MM) MAXIMUM BLENDING OF DAMAGE AREA

AREA 5: 0.015 INCH (0,38 MM) MAXIMUM BLENDING OF DAMAGE AREA. DAMAGE CAN
NOT FORM A CONTINUOUS PATH ACROSS FACE OF PISTON CAVITY

Figure 608
Brake Housing Repair Limits

Page 619
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 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

WARNING: KEEP CHEMICAL FILM SOLUTION AWAY FROM EYES OR SKIN.

DO NOT DRINK CHEMICAL FILM SOLUTION. DO NOT BREATHE THE
FUMES. CHEMICAL FILM SOLUTION CONTAINS CHROMIC ACID, IS
CAUSTIC AND IS POISONOUS.
OBEY THE MANUFACTURER'S INSTRUCTIONS.
REFER TO THE MATERIAL SAFETY DATA SHEET (OR EQUIVALENT)
BEFORE CHEMICAL FILM SOLUTION IS USED.

B. Surface treat damaged or reworked areas with chemical film solution, Specification
MIL-DTL-5541 or SAE AMS 2473.

12. Repair of Disk Insulator (210B or 210C)

CAUTION: DISK INSULATORS (210 AND 210A) CONTAIN ASBESTOS FIBERS. DO

NOT REPAIR.

A. Remove surface blisters and small nicks from disk insulators with a file or by touching
lightly to an emery wheel.

(1) Replace disk insulator (210B) if less than 0.240 inch (6,1 mm) thick.

(2) Replace disk insulator (210C) if less than 0.307 inch (7,79 mm) thick.

13. Surface Treatment and Paint

A. See Figure 609.

NOTE: For an update on recommended primer and paint materials and processes,
refer to AP-842, Standard Practices Manual with Procedures (32-46-35), which
can be downloaded, free of charge, from our website
<www.meggitt-mabs.com>.

B. Repaired areas of the brake subassemblies and those having the paint and surface
treated finish removed, must be surface treated and painted in accordance with the
following procedures:

WARNING: DO NOT USE THE ACETONE NEAR SPARKS OR FLAMES. THE

ACETONE IS FLAMMABLE.
KEEP THE ACETONE AWAY FROM EYES OR SKIN.

BRASIL VIDA TAXI AEREO

DO NOT BREATHE THE FUMES OR DRINK THE ACETONE. THE
ACETONE IS POISONOUS.
OBEY THE MANUFACTURER'S INSTRUCTIONS.
REFER TO THE MATERIAL SAFETY DATA SHEET (OR EQUIVALENT)
BEFORE THE ACETONE IS USED.

C. Surface Treatment

(1) Thoroughly clean surface to be surface treated and painted. Clean with hot water or
acetone, Specification ASTM D329 and dry thoroughly with compressed air.

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

2 2

NOTES:

324332-609-01.CGM
1 APPLY ONE MIST COAT ONLY 0.0004 TO 0.0006 (0,010 TO 0,015) THICK
ON SURFACE INDICATED.
2 MASK ALL THREADED HOLES AND PISTON CAVITIES.

BRASIL VIDA TAXI AEREO

Figure 609
Painting Diagram for Housing Subassembly

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 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

WARNING: KEEP CHEMICAL FILM SOLUTION AWAY FROM EYES OR SKIN.

DO NOT DRINK CHEMICAL FILM SOLUTION. DO NOT BREATHE
THE FUMES. CHEMICAL FILM SOLUTION CONTAINS CHROMIC
ACID, IS CAUSTIC AND IS POISONOUS.
OBEY THE MANUFACTURER'S INSTRUCTIONS.
REFER TO THE MATERIAL SAFETY DATA SHEET (OR
EQUIVALENT) BEFORE CHEMICAL FILM SOLUTION IS USED.
(2) Surface treat all the exposed surfaces of brake subassemblies with chemical film
solution per Specification MIL-DTL-5541 or SAE AMS 2473 as given in the
manufacturer's instructions. Refer to Repair Materials for recommended solution.

D. Do touch-up painting as follows:

(1) The part or area requiring touchup painting must be thoroughly clean and free of all
contaminants.

(2) Prepare area to be painted (scratches, nicks, chipped paint, etc) by sanding lightly
to feather out all edges of adjacent finish, using 300-360 grit, wet-or-dry, aluminum
oxide cloth. Wet sanding is preferred. Avoid removing more primer than is
absolutely necessary from damaged area.

WARNING: DO NOT USE THE ACETONE NEAR SPARKS OR FLAMES. THE

ACETONE IS FLAMMABLE.
KEEP THE ACETONE AWAY FROM EYES OR SKIN.
DO NOT BREATHE THE FUMES OR DRINK THE ACETONE. THE
ACETONE IS POISONOUS.
OBEY THE MANUFACTURER'S INSTRUCTIONS.
REFER TO THE MATERIAL SAFETY DATA SHEET (OR
EQUIVALENT) BEFORE THE ACETONE IS USED.
(3) Wipe repaired surface with a cloth moistened with acetone, Specification
ASTM D329 and wipe surface dry with clean cloth.

CAUTION: IF BARE METAL IS EXPOSED BY SANDING, IT MUST BE

SURFACE TREATED BEFORE APPLYING PRIMER.
(4) Starting with the last intact paint layer, reapply paint coats as given in Painting.

NOTE: Remove the gloss in the area to be touched up, with an abrasive

BRASIL VIDA TAXI AEREO

material; the defective area smoothed and edges feathered. The area
must then be cleaned removing all loose and foreign material.

E. Paint brake assembly as follows:

WARNING: CLEANING SOLVENTS ARE TOXIC AND VOLATILE. USE ONLY IN
WELL-VENTILATED AREAS. AVOID PHYSICAL CONTACT WITH
SOLVENT AND DO NOT INHALE VAPORS.
(1) Thoroughly clean all surfaces to be surface treated and/or painted. Brake
subassembly should be washed with acetone Specification ASTM D329.

Page 622
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 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

WARNING: KEEP CHEMICAL FILM SOLUTION AWAY FROM EYES OR SKIN.

DO NOT DRINK CHEMICAL FILM SOLUTION. DO NOT BREATHE
THE FUMES. CHEMICAL FILM SOLUTION CONTAINS CHROMIC
ACID, IS CAUSTIC AND IS POISONOUS.
OBEY THE MANUFACTURER'S INSTRUCTIONS.
REFER TO THE MATERIAL SAFETY DATA SHEET (OR
EQUIVALENT) BEFORE CHEMICAL FILM SOLUTION IS USED.
(2) Surface treat all the exposed metal surfaces of brake subassemblies with chemical
film solution per Specification MIL-DTL-5541 or SAE AMS 2473.

CAUTION: DO NOT PAINT INTERIOR OF PISTON CAVITIES, INLET OR

BLEEDER PORTS.
(3) Mask all hydraulic cavities and all threaded holes to avoid getting paint on these
surfaces.

(4) Mix the acrylic topcoat/primer combination until a viscosity of approximately 25

seconds in a No. 2 Zahn cup is obtained.

NOTE: Aluminum topcoat/primer combination to be at the proper viscosity. If

required, thinning can be done with Oxsol thinner.

CAUTION: APPLY ONLY ONE MIST COAT OF TOPCOAT/PRIMER COMBINATION

TO REGISTER SURFACES, MATING SURFACES, AND BOLT
BOSSES. EXCESSIVE PAINT ON THESE SURFACES CAN
CONTRIBUTE OR RESULT IN LOSS OF BOLT PRELOAD.
(5) Apply two coats of acrylic topcoat/primer combination enamel as follows:

(a) Spray one mist coat to a dry film thickness of approximately 0.0002 to
0.0006 inch (0,005 to 0,015 mm).

(b) Air dry for a minimum of 45 minutes before applying a second coat.

(c) Spray a full cross coat to a dry film thickness of approximately 0.0004 to
0.0025 inch (0,010 to 0,064 mm).

(d) When the surface is dry enough (tacky), spray another coat in the bead seat
area.
NOTE: Due to abrasion in the tire bead contacting surfaces, it is

BRASIL VIDA TAXI AEREO

recommended that tire bead contacting surfaces have a minimum of
0.0015 inch (0,038 mm) thickness of paint.

(e) Air dry 45 minutes before handling. Paint will reach full cure in 24 hours after
paint application at room temperature or 30 minutes at 200° F.

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

14. Brake Modification 5003096-1 to 5003096-3

A. Modify Pressure Plate Subassembly 5005117 as follows:

(1) Remove pressure plate subassembly from Brake Assembly 5003096-1 in

accordance with DISASSEMBLY.

(2) Grind or machine pressure plate in accordance with Figure 610. Wear pad need not
be removed for this rework.

(3) Apply rust inhibitor on machined surface as given in the Storage Instructions.

(4) Re-identify Pressure Plate Subassembly 5005117 to 5005117-1 by metal stamping

(previously was identified to 5005117, Rev B).

(5) Re-assemble brake assembly as given in ASSEMBLY AND STORAGE.

(6) Re-identify Brake Assembly 5003096-1 to 5003096-3 by grinding off last digit and
restamping last digit with 0.09 inch (2,29 mm) character. Replace decal 5006251
with 5006499.

(7) Surface treat and paint bare metal surfaces on housing as given in Surface
Treatment and Paint.

1.29 (32,77)
CL ORIGINAL PLATE CONTOUR

0.75 (19,0) RAD BLEND

24°

Ø 9.19 (233,4)
4.595 (116,7) RAD

4.00
(101,6)

BRASIL VIDA TAXI AEREO

TYPICAL
324332-610-01.CGM

RAD
2 PLACES

Figure 610
Modification of Pressure Plate Subassembly 5005117

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 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

15. Brake Modification 5003096 to 5003096-4

A. Disassemble brake as given in DISASSEMBLY.

B. Replace pressure plate subassembly (170) with (170B).

C. Replace rotating disks (90) with (90A) and re-assemble brake as given in ASSEMBLY
AND STORAGE.

D. Replace identification plate (350) with (390).

E. Metal stamp “-4” after assembly number in 0.12 inch (3,05 mm) characters to read
“5003096-4”.

F. Surface treat and paint bare metal surfaces on housing as given in Surface Treatment
and Paint.

16. Brake Modification 5003096-1 to 5003096-4

A. Disassemble brake as given in DISASSEMBLY.

B. Replace pressure plate subassembly (170A) with (170B).

C. Replace rotating disks (90) with (90A) and reassemble brake as given in ASSEMBLY
AND STORAGE.

D. Replace identification plate (360) with (390).

E. Grind off “-1” from assembly number 5003096-1 and restamp with “-4” in 0.12 inch
(3,05 mm) characters to read “5003096-4”.

F. Surface treat and paint bare metal surfaces on housing as given in Surface Treatment
and Paint.

17. Brake Modification 5003096-3 to 5003096-4

A. Disassemble brake as given in DISASSEMBLY.

B. Replace rotating disks (90) with (90A) and reassemble brake as given in ASSEMBLY
AND STORAGE.

C. Replace identification plate (380) with (390).

BRASIL VIDA TAXI AEREO
D. Grind off “-3” from the assembly number 5003096-3 and restamp “-4” in 0.12 inch
(3,05 mm) characters to read “5003096-4”.

E. Surface treat and paint bare metal surfaces on housing as given in Surface Treatment
and Paint.

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

18. Brake Modification 5003096-4 to 5003096-6

A. Disassemble brake in as given in DlSASSEMBLY.

B. Replace torque tube (130) with (130A) and reassemble brake as given in ASSEMBLY
AND STORAGE.

C. Replace identification plate (390) with (410).

D. Grind off “-4” from assembly number 5003096-4 and restamp “-6” in 0.12 inch (3,05 mm)
characters to read “5003096-6”.

E. Surface treat and paint bare metal surfaces on housing as given in Surface Treatment
and Paint.

19. Brake Modification 5003096-5 to 5003096-7

A. Disassemble brake in accordance with DISASSEMBLY section.

B. Replace rotating disk (90B) with (90C) and reassemble brake in accordance with
ASSEMBLY AND STORAGE section.

C. Replace identification plate (400) with (420).

D. Grind off “-5” from assembly number 5003096-5 and restamp “-7” in 0.12 inch (3,05 mm)
characters to read “5003096-7”.

E. Surface treat and paint bare metal surface on housing in accordance with Surface
Treatment and Paint.

20. Replace Grip and Tube Subassemblies (150 and 150A) with Swage Tube Subassemblies
(150B and 150C) (Service Bulletin Lear 25-32-11, Lear 35-32-9, Lear 36-32-5,
Lear 55-32-8, Lear 60-32-1)

A. Disassemble the Grip and Tube Adjustor as follows (See Figure 611):

(1) Remove four nuts (140) from the four Return Pins (160) (used on Brake Assemblies
5003096-1, -3, -4, -6) or nuts (140) from Return Pins (160A) (used on Brake
Assemblies 5003096-5, -7).

BRASIL VIDA TAXI AEREO

(2) Remove the Grip and Tube Subassembly (150) (used on Brake Assemblies
50036096-1, -3, -4, -6) or Grip and Tube Subassembly (150A) (used on Brake
Assemblies 5003096-5, -7) in four places.

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 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

GRIP AND TUBE SUBASSEMBLY (150) (USED

ON BRAKE ASSEMBLY 5003096, -1, -3, -4 & -6)

GRIP AND TUBE SUBASSEMBLY (150A) (USED

ON BRAKE ASSEMBLY 5003096-5 & -7)
9522164 GRIP SUBASSEMBLY
(USED ON BRAKE ASSEMBLY
5003096, -1, -3, -4, -5, -6 & -7)

NUT (140)

RETURN PIN (160)

(USED ON BRAKE
ASSEMBLY 5003096,
-1, -3, -4 & -6)

RETURN PIN (160A)

(USED ON BRAKE
ASSEMBLY 5003096-5 & -7)
5001422 TUBE (USED
ON BRAKE ASSEMBLY
5003096-5 & -7)
9535046 TUBE (USED
ON BRAKE ASSEMBLY
5003096, -1, -3, -4 & -6)

324332-611-01.CGM

BRASIL VIDA TAXI AEREO

NOTE: SHOWN IN "BRAKE ON" CONDITION

Figure 611
Grip and Tube Automatic Adjustor

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

B. Assemble the Swage and Tube Subassemblies (150B and 150C) as follows:

(1) The adjuster swage can be installed into the adjusting tube using a arbor press, vice
or similar device. The correct procedure for such installation is as follows:

(a) Place the adjuster swage on one end of the adjuster tube with dye-color
showing per Figure 613 and in an arbor press or vice.

(b) Press the Adjustor Swage (151) into Adjustor Tube (152) until the top of the
swage is flush with the top of the adjuster for Swage and Tube Subassembly
(150C) or 0.18 inches below flush for Swage and Tube Subassembly (150B).
NOTE: This operation requires the adjuster swage and tube be
perpendicular and square to each other before the installation
begins (See Figure 612).

Failure to do so can result in cocking of the swage in the tube which

is unacceptable. It is acceptable to assemble multiple
subassemblies simultaneously as long as perpendicularity is
maintained.

C. Install the square swage adjuster for Brake Assemblies 5003096, -1, -3, -4, -6 (See
Figure 613) as follows:

(1) For installation of the square swage adjuster, install the Spacer Tube (153) over
Return Pin (160).

(2) Install four of the Swage Tube Subassemblies (150B) on the Spacer Tube (153) and
Return Pin (160) with the swage adjuster nearest the threaded end of the return pin.

(3) Reinstall four (140) nuts previously removed and tighten to a torque value of
30 lb-in (3,39 N-m).

NOTE: Use (140) nuts only. Substitute nuts can interfere with the inside diameter
of the swage tube and prevent the swage and tube from functioning
properly.

D. Install the square swage adjuster for Brake Assemblies 5003096-5 and -7 (See
Figure 614).

(1) For installation of the square swage adjuster, install the Spacer Tube (153A) over

BRASIL VIDA TAXI AEREO

Return Pin (160A).

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 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

ARBOR PRESS

DYE-COLOR
SHOWING

ADAPTER

SWAGE TUBE SUBASSEMBLY

SETTING BLOCK (SWAGE SHOWN FLUSH WITH
TOP OF SWAGE TUBE)

SWAGE (151) SWAGE (151)

PRESS TO
FLUSH
PRESS TO
SWAGE TUBE SWAGE TUBE 0.18 INCHES
(152 OR 152A) (152 OR 152A) BELOW
FLUSH

BRASIL VIDA TAXI AEREO

324332-612-01.CGM

FOR BRAKE ASSEMBLIES FOR BRAKE ASSEMBLIES

5003096-5 & -7 5003096, -1, -3, -4 & -6

Figure 612
Swage and Tube Adjustor Assembly Setup

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 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

ADJUSTER SWAGE TUBE

(152 OR 152A)
SPACER TUBE (153)

ADJUSTER SWAGE (151)

RETURN PIN (160)

SWAGE AND TUBE SUBASSEMBLY (150B)

324332-613-01.CGM

NOTE: SHOWN IN "BRAKE ON" CONDITION

BRASIL VIDA TAXI AEREO

Figure 613
Square Swage Adjustor for Brake Assemblies 5003096, -1, -3, -4, -6

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 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

ADJUSTER SWAGE TUBE

(152 OR 152A)
SPACER TUBE (153A)

ADJUSTER SWAGE (151)

RETURN PIN (160A)

SWAGE AND TUBE SUBASSEMBLY (150C)

324332-614-01.CGM
NOTE: SHOWN IN "BRAKE ON" CONDITION

BRASIL VIDA TAXI AEREO

Figure 614
Square Swage Adjustor for Brake Assemblies 5003096 -5, -7

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

(2) Install four of the Swage Tube Subassemblies (150C) on the Spacer Tube (153A)
and Return Pin (160A) with the swage adjuster nearest the threaded end of the
return pin.

NOTE: Use (140) nuts only. Substitute nuts can interfere with the inside diameter
of the swage tube and prevent the swage the swage and tube from
functioning properly.

E. Disassemble Swage and Tube Subassemblies (150B and 150C), if required.

(1) The reusable Adjustor Swage (151) can be removed by using a steel pin and an
arbor press driving the swage back out of the tube.

Do not continue the swage through the tube for removal.

(2) Adjusting swage tubes are not reusable and require replacement.

21. Inspect Brake Assembly 5003096-7 and replace Rotating Disk 5006888-1 if uneven wear is
observed (Service Bulletin Lear 60-32-3)

A. With the brakes applied, check brake assembly for wear. Check the brake wear
dimension from the housing subassembIy and pressure plate adjacent to the top pistons
as shown in Figure 615.

B. If this dimension is 0.359 inch (9,12 mm) or more, inspect the brake assembly on the
aircraft as follows:

(1) Looking down on the brake stack from overhead, look for abnormal wear of the
friction mix on the rotating disk. Pay special attention to the faces of the rotating
disks towards the stationary disk. See Figure 616.

NOTE: Rotating disks with abnormal wear typically appear to have all or most of
the friction mix worn away from the faces contacting the stationary disk.
At the same time, the other face of the rotating disk appears to be
wearing regularly.

(a) If the friction mix appears to be worn to the disk core proceed as follows:

1 Inspect the disk stack.

2 Replace the rotating disk(s).

3 Inspect and replace stationary disks as required. BRASIL VIDA TAXI AEREO

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

(b) If the friction mix does not appear to be worn to the disk core, continue to
inspect the brake assemblies at an interval not less than every 25 flight cycles.

1 If the friction mix does not appear to be worn to the disk core at each
inspection, continue to keep the brake in service until the dimension from
the housing subassembIy and pressure plate adjacent to the top pistons
is 0.464 inch (11,79 mm), the normal full wear dimension.

Replace or overhaul the disk stack when this dimension is 0.464 inch
(11,79 mm).
2 If the friction mix does not appear to be worn to the disk core at each
inspection, continue to keep the brake in service until the dimension from
the housing subassembIy and pressure plate adjacent to the top pistons
is 0.464 inch (11,79 mm), the normal full wear dimension.

Replace or overhaul the disk stack when this dimension is 0.464 inch
(11,79 mm).
a Inspect the disk stack.
b Replace the rotating disk(s).
c Inspect and replace stationary disks as required.

22. Rotor Modification for Brake Assemblies 5003096-5 and 5003096-7 (Service Bulletin Lear
60-32-6)

A. Inspect the rotating disks on Brake Assemblies 5003096-5 and 5003096-7. On the rotor
closest to the tire, there should be a chamfer on each tang that engages with the wheel's
outrigger. (See Figure 616).

B. If both rotating disks have chamfered tangs, continue to use the brake assembly.

NOTE: No further inspection or rework is needed.

C. If the rotating disk closest to the brake housing does not have chamfered tangs, but the
rotating disk closest to the tire does have chamfered tangs, continue to use the brake
assembly.

NOTE: No further inspection or rework is needed.

BRASIL VIDA TAXI AEREO

D. If the rotating disk closest to the brake housing does have chamfered tangs, but the
rotating disk closest to the tire does not have chamfered tangs, do as follows:

(1) Remove the brake assembly.

(2) Switch the rotors within the brake assembly, so the rotor with chamfered tangs is
closest to the tire (or the back plate)

(3) Reassemble and functionally test the brake assembly in accordance with TEST
section.

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

BRAKE WEAR DIMENSION

324332-615-01.CGM
Figure 615
Brake Wear Measurement

E. If neither of the rotating disks have chamfered tangs, remove the brake assembly and do
as follows:

(1) If it is possible to have the chamfers on the tangs ground or machined locally, do as
follows:

(a) On the OD of the rotors, mark a “1” on the rotor closest to the pressure plate,
and mark a “2” on the rotor closest to the back plate. On rotor “2” also mark
“BP” on the side of one of the tangs closest to the back plate. These markings

BRASIL VIDA TAXI AEREO

are for ease of reassembly.

(b) Remove the rotors from the brake assembly.

(c) For rotor “2” only, grind or machine a 0.08 ± 0.02 inch (2.0 ± 0.5 mm) X 45°
± 0.5° chamfer on the side of the tang marked “BP”. Do this for all seven (7)
tangs, on the specified side only.

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

ROTATING DISKS

ROTATING DISK ROTATING DISK

FRICTION MIX FRICTION MIX

STATIONARY DISK

WEAR PADS

AREA WHERE
ROTATING DISK
FRICTION MIX
APPEARS TO
BE WORN TO
DISK CORE

BRASIL VIDA TAXI AEREO

DETAIL SHOWING
324332-616-01.CGM

NORMAL WEAR
CONDITION
ABNORMAL WEAR CONDITION SHOWN

Figure 616
Rotating Disk Wear Check

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

(d) Reassemble the brake in accordance with ASSEMBLY section putting the
rotors back in the assembly at the same locations from which they were
removed.
NOTE: Make sure the chamfered tangs on rotor “2” are closest to the tire
(or the back plate).

(e) Reassemble and functionally test the brake assembly as given in the TEST
section.

(2) If it is not possible to locally have the chamfers on the tangs ground or machined, do
as follows:

(a) Remove the four swage tube subassemblies and both rotors from the brake
assembly.

(b) Return the parts to the source from which they were purchased, and obtain
replacement parts.

(c) Assemble the brake with the replacement parts and functionally test as given
in the TEST section.

OPTIONAL REQUIRED REQUIRED

324332-617-01.CGM

ACCEPTABLE ACCEPTABLE BRASIL VIDA TAXI AEREO

ROTOR TANG CHAMFERS ROTOR TANG CHAMFERS

Figure 617
Acceptable Rotor Tang Chamfers

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 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

REPAIR NO. 1 - BLEEDER HOLE REPAIR IN BRAKE HOUSING

1. General

A. Refer to IPL Figure 1.

B. This repair is used for the repair of damaged bleeder threads in housing subassembly
(330 or 330B).

C. This repair provides for machining of bleeder threads for installation of Bleeder Valve
Adapter Bushing 9535617 (311) and Preformed Packing MS28775-014 (321).

2. R1-1 Repair of Bleeder Threads

A. Repair damaged bleeder threads in the housing as given below:

(1) Counterbore, countersink, tap drill, and thread damaged bleeder hole oversize as
shown in Figure 601.

(2) Remove all burrs and sharp edges from hole especially on the surfaces that will
contact the preformed packing.

WARNING: KEEP CHEMICAL FILM SOLUTION AWAY FROM EYES OR SKIN.

DO NOT DRINK CHEMICAL FILM SOLUTION. DO NOT BREATHE
THE FUMES. CHEMICAL FILM SOLUTION CONTAINS CHROMIC
ACID, IS CAUSTIC AND IS POISONOUS.
OBEY THE MANUFACTURER'S INSTRUCTIONS.
REFER TO THE MATERIAL SAFETY DATA SHEET (OR
EQUIVALENT) BEFORE CHEMICAL FILM SOLUTION IS USED.
(3) Clean and surface treat machined brake housing with chemical film solution,
Specification MIL-DTL-5541.

(4) Metal stamp “R1-1” in 0.09 inch (2,3 mm) characters adjacent to the brake housing
subassembly number.

(5) Metal stamp “5R84-024-8” in 0.12 (3,05 mm) characters in area adjacent to brake
housing part number.

BRASIL VIDA TAXI AEREO

REPAIR
Repair No. 1
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 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

WARNING: KEEP CHEMICAL FILM SOLUTION AWAY FROM EYES OR SKIN.

DO NOT DRINK CHEMICAL FILM SOLUTION. DO NOT BREATHE
THE FUMES. CHEMICAL FILM SOLUTION CONTAINS CHROMIC
ACID, IS CAUSTIC AND IS POISONOUS.
OBEY THE MANUFACTURER'S INSTRUCTIONS.
REFER TO THE MATERIAL SAFETY DATA SHEET (OR
EQUIVALENT) BEFORE CHEMICAL FILM SOLUTION IS USED.
(6) surface treat metal stamped areas with chemical film solution, Specification
MIL-DTL-5541 or equivalent.

B. Assemble and install oversize adapter bushing (311) as follows: (See Figure 601).

WARNING: KEEP HYDRAULIC FLUID AWAY FROM EYES OR SKIN.

DO NOT BREATHE THE FUMES OR DRINK HYDRAULIC FLUID.
HYDRAULIC FLUID IS POISONOUS.
OBEY THE MANUFACTURER'S INSTRUCTIONS.
REFER TO THE MATERIAL SAFETY DATA SHEET (OR
EQUIVALENT) BEFORE HYDRAULIC FLUID IS USED.
(1) Lubricate preformed packing (321) with hydraulic assembly fluid, Specification
MIL-PRF-5606.

(2) Install lubricated preformed packing (321) on bleeder valve adapter bushing (311).

(3) Wet contacting surfaces of all other parts that contact hydraulic fluid with hydraulic
assembly fluid, Specification MIL-PRF-5606 immediately prior to installing parts.

(4) Install bleeder valve adapter bushing (311) with preformed packing (321) in
reworked brake housing (330 or 330B) and tighten to a torque value of
20 pound-feet (27 N-m).

(5) Install Bleeder Valve Adapter 511951 (310) into reworked hole and tighten to a
torque value of 120 pound-inches (13,56 N-m).

BRASIL VIDA TAXI AEREO

REPAIR
Repair No. 1
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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

0.025 +0.015 -0.000

1 (0,64 +0,38 -0,00) RAD
4
32 C

T
B
2

32
3

120° REF.
A
5

45° REF.
D

324332-RP01-601-01.CGM
C
0.020 (0,51)
RADIUS
MAXIMUM

MACHINING DETAIL

Figure 601
Housing Bleeder Thread Repair
Table 601
Housing Bleeder Thread Repair
SEQUENTIAL OPERATION DIAMETER/SIZE DEPTH REMARKS
SPOTFACE CLEAN-UP 0.000-0.005
0.000-0.010
1 OR ENLARGE 0.915 MIN (23,24 MIN) A (0,00-0,13)
(0,00-0,25)
COUNTERBORE COR RAD
0.020 (0,51)
ENLARGE EXISTING 0.643 +0.005 -0.000 0.094 +0.015 -0.000
2 B MAX COR RAD 90°
COUNTERBORE (16,33 +0,13 -0,00) (2,39 +0,38 -0,00)
POINT ANGLE
ENLARGE EXISTING 0.578 +0.004 -0.001 0.500 +0.020 -0.000 FLAT BOTTOM TAP
3 C
THREADED HOLE (14,68 +0,10 -0,03) (12,7 +0,508 -0,00) DRILL

BRASIL VIDA TAXI AEREO

0.750 +0.015 -0.000
4 COUNTERSINK 120° - - -
(19,05 +0,38 -0,00)
TAP FULL THREADS 0.460 +0.020 -0.000
5 0.6250-18UNJF-3B D BOTTOMING TAP
PER SAE-AS8879 (11,68 +0,508 -0,00)
COUNTERSINK CONCENTRIC WITH 0.643 +0.005 -0.000 (16,33 +0,13 -0,00) DIA C'BORE WITHIN 0.005
(0,13) TIR
INSTALL ADAPTER BUSHING 9535617 AND PACKING MS28775-014 @ 20 LB FT

REPAIR
Repair No. 1
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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

THIS PAGE
KEPT
BLANK

BRASIL VIDA TAXI AEREO

REPAIR
Repair No. 1
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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

REPAIR NO. 2 - EXPANDER PLUG REPAIR

1. General

A. Use this procedure to replace Expander Plugs HK050CK11-111 (430) or Expander Plugs
SK550-050 (430A) in brake housing subassembly (330, 330B or 330C) that leak or have
damage.

B. This repair gives instructions to remove expander plugs (430 or 430A), repair the
expander plug hole and install oversized Pin Plug 2500010A (440A).

2. R2-1 - Repair of Damaged Expander Plug Holes

A. Remove the existing expander plug (430 or 430A) as follows:

(1) Use a punch that is less than the diameter of the expander plug mandrel end to
push the mandrel out of the expander plug sleeve.

(2) Drill the expander plug sleeve with a #29 (0.136 inch or 3,54 mm) diameter drill and
tap with an 8-32 UNC thread.

(3) Use an extraction tool with threads to pull the expander sleeve out of the brake
housing (330, 330B or 330C).

(4) Remove the expander plug mandrel from the hole. Make sure all chips are removed
from the hole.

(5) Make an inspection of the hole for damage.

B. Repair the expander plug hole as follows:

(1) Machine and ream the hole to the dimensions shown in Table 601 and Figure 601 in
this section.

(2) Clean the machined surfaces as told in the CLEANING section.

WARNING: KEEP CHEMICAL FILM SOLUTION AWAY FROM EYES OR SKIN.

DO NOT DRINK CHEMICAL FILM SOLUTION. DO NOT BREATHE
THE FUMES. CHEMICAL FILM SOLUTION CONTAINS CHROMIC
ACID, IS CAUSTIC AND IS POISONOUS.

BRASIL VIDA TAXI AEREO

OBEY THE MANUFACTURER'S INSTRUCTIONS.
REFER TO THE MATERIAL SAFETY DATA SHEET (OR
EQUIVALENT) BEFORE CHEMICAL FILM SOLUTION IS USED.
(3) Apply chemical film solution, Specification SAE AMS 2473 or MIL-DTL-5541, to all
repaired surfaces as told in “Surface Treatment and Paint” in the REPAIR section.

REPAIR
Repair No. 2
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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

C. Install Pin Plug 2500010A (440A) as follows:

(1) Insert the plug portion of pin plug set into the reamed hole until it is firmly seated on
the shoulder of the hole. The open end of the plug to face outward.

CAUTION: THE PINS ARE PRE-LUBRICATED. DO NOT USE ADDITIONAL

LUBRICANT.
DRIVE THE PIN STRAIGHT INTO THE PLUG HOLE, DO NOT PERMIT
THE PIN TO TILT.
(2) Insert the smaller (chamfered) end of the pin into the hole in the plug.

(3) Use Tool CUT A2500203A to press or drive the pin portion of the pin plug set until
the top of the pin is between 0.005 inch (0,13 mm) above flush to 0.002 inch
(0,08 mm) below flush to the top of the plug.

Table 601
Repair Dimensions for Plug Installation

Ream Diameter, Material

Part Number Ream Depth
Class 2 Remaining
(Short Pin) (B)
(A) (C)
Minimum Maximum Minimum Minimum
2500010A 0.2500 inch 0.2515 0.212 inch 0.125 inch
(6,350 mm) (6,388 mm) (5,39 mm) (3,18 mm)

D. Identify the brake housing subassembly (330, 330B or 330C) as follows:

(1) Metal stamp “R2-1” in 0.09 inch (2,3 mm) characters adjacent to the brake housing
subassembly number.

WARNING: KEEP CHEMICAL FILM SOLUTION AWAY FROM EYES OR SKIN.

DO NOT DRINK CHEMICAL FILM SOLUTION. DO NOT BREATHE
THE FUMES. CHEMICAL FILM SOLUTION CONTAINS CHROMIC
ACID, IS CAUSTIC AND IS POISONOUS.
OBEY THE MANUFACTURER'S INSTRUCTIONS.
REFER TO THE MATERIAL SAFETY DATA SHEET (OR
EQUIVALENT) BEFORE CHEMICAL FILM SOLUTION IS USED.

BRASIL VIDA TAXI AEREO

(2) Apply chemical film solution, Specification SAE AMS 2473 or MIL-DTL-5541, and
paint to all metal-stamped surfaces as told in “Surface Treatment and Paint” in the
REPAIR section.

REPAIR
Repair No. 2
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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

B C

0.0003 (0,008)

A 45° 0.013 (0,33)

MINIMUM
16-63

324332-RP02-601-01.CGM
0.003 (0,08)
MAXIMUM

Figure 601
Machining Details

BRASIL VIDA TAXI AEREO

REPAIR
Repair No. 2
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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

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KEPT
BLANK

BRASIL VIDA TAXI AEREO

REPAIR
Repair No. 2
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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

ASSEMBLY AND STORAGE

1. Assembly Materials

MATERIAL* POSSIBLE SOURCE**

Hydraulic Fluid Commercially available
Specification MIL-PRF-5606
Anti-seize Compound (Molylube) Convoy Oil Company
Specification MIL-PRF-83483 1412 North Front Street
(Alternate for MIL-T-5544 Philadelphia, PA 19122
use until stock depletion) CAGE Code 6A438
Ph: 215-739-5281
Fax: 215-739-6933
Cement WJ Ruscoe & Company
Pliobond 5001 483 Kenmore Boulevard
(alternate Pliobond 20) Akron, OH 44301
Rust Preventative E.F. Houghton & Company
Rust Veto 4214 Madison & Van Buren
Valley Forge, PA 19482
Isopropyl Alcohol Commercially available
Specification TT-I-735
* Equivalent replacements can be used for the items given.
**Other sources could be available.

2. General

A. Refer to IPL Figure 1.

CAUTION: ASSEMBLE BRAKE ON A CLEAN FLAT SURFACE, BEING CAREFUL NOT

TO NICK, SCRATCH, OR SCUFF THE PAINT OR PROTECTIVE FINISH.
ENSURE PROPER PARTS ARE USED FOR EACH BRAKE ASSEMBLY.

B. Assemble brake as follows:

C. It is recommended that new preformed packings and packing retainers be installed at

BRASIL VIDA TAXI AEREO

each overhaul.

D. The use of power wrenches for the brake assembly is governed by the following:

(1) Do not use power wrenches for assembly of threaded parts made of nonferrous
material or parts threaded directly into nonferrous tapped holes.

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

(2) When power wrenches, other than automatic wrenching systems, are used to
assemble bolts and nuts, fastener tightness must not be more than 50 percent of
final torque value. Tightening to final torque value must be done using manual
torque wrenches.

(3) Automatic wrenching systems which provide a preload or torque accuracy of ± 4

percent or better can be used to tighten bolts and nuts to final torque value.

3. Assembly Procedures for Brake Assemblies 5003096,-1, -3, -4 and -6

A. Refer to IPL Figure 1.

NOTE: For Brake Assemblies 5003096-5 and -7, assemble as given in paragraph 4.

CAUTION: ASSEMBLE THE BRAKE WITH CARE. ENSURE PROPER PARTS ARE
USED FOR EACH BRAKE ASSEMBLY.

B. Place brake housing subassembly (330) on a clean flat surface with piston cavities up.

C. Install piston as follows:

NOTE: Use new packings and retainers at re-assembly.

WARNING: KEEP HYDRAULIC FLUID AWAY FROM EYES OR SKIN.

DO NOT BREATHE THE FUMES OR DRINK HYDRAULIC FLUID.
HYDRAULIC FLUID IS POISONOUS.
OBEY THE MANUFACTURER'S INSTRUCTIONS.
REFER TO THE MATERIAL SAFETY DATA SHEET (OR
EQUIVALENT) BEFORE HYDRAULIC FLUID IS USED.
(1) Lubricate preformed packings (240), packing retainers (230), housing piston
container and seal grooves and contacting surfaces of pistons (220) with a light coat
of hydraulic fluid, Specification MIL-PRF-5606.

CAUTION: BE CAREFUL NOT TO STRETCH OR TWIST PACKINGS DURING

INSTALLATION.
(2) Carefully install one preformed packing (240), then one packing retainer (230) in the
groove of each piston cavity.

BRASIL VIDA TAXI AEREO

CAUTION: DO NOT DAMAGE OR DISPLACE THE PREFORMED PACKING
DURING INSTALLATION OF PISTONS.
(3) Install a piston (220) in each piston cavity (with recessed end for insulator out)
carefully, so as not to displace packing or retainer.

NOTE: Piston installation can be facilitated by turning the piston slightly during
installation.

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

D. Install one disk insulator (210B) in each piston recess with the impressed part numbers
toward piston as follows:

(1) Apply a coat of Pliobond 5001 (alternate Pliobond 20) cement approximately
0.010 inch (0,25 mm) thick and one inch (25,4 mm) in diameter to center of piston
recess and to center of insulator.

(2) Air dry cement for three to five minutes and install insulator into recess of pistons.

(3) Alternatively, if the piston and insulator will be installed in the brake in the next three
days, a small amount of bearing grease applied to the center of the insulator can be
used to hold the insulator in the piston.

E. Bottom pistons/insulator into brake housing subassembly.

F. Install protective plug as follows:

WARNING: KEEP HYDRAULIC FLUID AWAY FROM EYES OR SKIN.

DO NOT BREATHE THE FUMES OR DRINK HYDRAULIC FLUID.
HYDRAULIC FLUID IS POISONOUS.
OBEY THE MANUFACTURER'S INSTRUCTIONS.
REFER TO THE MATERIAL SAFETY DATA SHEET (OR
EQUIVALENT) BEFORE HYDRAULIC FLUID IS USED.
(1) Lubricate preformed packing (320) with a light coat of hydraulic fluid, Specification
MIL-PRF-5606.

(2) Install lubricated preformed packing (320) on protective plug (340) and install in inlet
port of housing subassembly.

G. Install bleeder adapter and bleeder plug as follows:

(1) Lubricate preformed packing (320) with a light coat of hydraulic fluid, Specification
MIL-PRF-5606.

NOTE: Use new preformed packings at each re-assembly.

(2) Install lubricated preformed packing (320) on bleeder adapter (310).

(3) Install bleeder adapter in bleeder port of housing subassembly and tighten to a

BRASIL VIDA TAXI AEREO

torque value of 120 pound-inches (13,6 N-m).

(4) Install bleeder plug (290) on bleeder adapter (310).

H. Assemble each of the four return mechanisms as follows:

(1) Place return spring (270) in return spring housing (280).

(2) Place spring guide (260) in spring (270).

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

(3) Depress spring guide (260) using an arbor press, and install retaining ring (250) in
groove of return spring housing (280).

(4) Release arbor press slowly and remove return mechanism.

I. Install pressure plate subassembly on brake housing subassembly as follows:

CAUTION: PRESSURE PLATE SUBASSEMBLY (170) MUST BE INSTALLED WITH

THE TWO LONG WEAR PADS (190) AT THE TOP OF THE BRAKE
HOUSING OVER THE OPEN SECTION BETWEEN HOUSING ENDS.
PRESSURE PLATE SUBASSEMBLY (170A OR 170B) MUST BE
INSTALLED WITH THE ONE LONG WEAR PAD (190A) AT THE TOP
OF THE BRAKE HOUSING OVER THE OPEN SECTION BETWEEN
HOUSING ENDS.
(1) Insert the heads of the return pins (160) into the return pin slots of the pressure
plate subassembly (170, 170A, or 170B) and position the pressure plate against the
disk insulators (210B) with the return pins in the return mechanism holes.

(2) Grasp the assembled unit firmly and turn the unit over. Place the unit with the wear
pads down on the working surface.

J. Install each of the four assembled return mechanisms over the return pin (160) and into
the brake housing subassembly (330).

CAUTION: IF USED, GRIP AND TUBE SUBASSEMBLY MUST BE RESET TO 0.11 INCH
POSITION FROM TUBE END BEFORE INSTALLATION IN BRAKE.
INSTALL GRIP AND TUBE SUBASSEMBLY WITH THE SHORT END
(0.11 INCH) OF THE TUBE FACING THE PRESSURE PLATE.

K. If used, install each of the four grip and tube subassemblies (150) on return pin (160),
install each of the four self-locking nuts (140), and tighten to a torque value of
25 pound-inches (2,83 N-m). Refer to REPAIR, paragraphs 20.B and C, if installing
swage and tube subassemblies.

L. Build up disk stack as follows:

NOTE: All disks should have approximately the same amount of wear; if dished,
dishing must be oriented in the same direction.

When building up the disk stack, use Illustrated Parts List to determine part

BRASIL VIDA TAXI AEREO

numbers of disks to be used in each position.

(1) Position brake housing/pressure plate subassembly with wear pad up.

(2) Put torque tube (130 or 130A) over pressure plate (170, 170A or 170B) with the axle
flange away from the pressure plate and the solid key facing the open section of the
brake housing subassembly (330). Slide torque tube into pressure plate and align
with bolt holes in housing.

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

(3) Put the stationary disk subassembly (100) between the two rotating disks (90 or
90A) and slide the entire stack on the torque tube (130 or 130A).

(4) Put the backing plate subassembly (50) on the torque tube with the backing plate
wear pads facing the rotating disk (90 or 90A). Align bolt holes with open torque
tube keys.

M. Install brake fasteners as follows:

(1) Lubricate bolt threads and bearing surface of bolts (20 and 40), countersunk
washers (30), and self-locking nuts (10) with anti-seize compound, Specification
MIL-PRF-83483.

NOTE: It is suggested that operators use Molylube instead of other compounds

meeting Specification MIL-PRF-83483.

CAUTION: PUT THE COUNTERSUNK WASHER ON THE BOLT WITH THE

COUNTERSINK FACING THE BOLT HEAD.
THE HEADS OF BOLTS MUST BE FULLY SEATED IN THEIR
RECESSES IN THE HOUSING SUBASSEMBLY BEFORE
TIGHTENING NUTS.
(2) Insert three bolts (40) with washer (30) in the three holes in the bottom of the brake
housing subassembly (330) opposite the open section, through the housing torque
tube and backing plate and secure with self-locking nuts (10).

CAUTION: A BRAKE BOLT ACCIDENTALLY TIGHTENED TO MORE THAN 120

PERCENT OF THE RECOMMENDED FINAL TORQUE VALUE MUST
BE REPLACED.
IF POWER WRENCHES ARE USED, FASTENERS TIGHTENED TO
MORE THAN 50 PERCENT, BUT LESS THAN 120 PERCENT, OF
FINAL TORQUE VALUE MUST BE DISASSEMBLED AND
RELUBRICATED WITH ANTI-SEIZE COMPOUND, SPECIFICATION
MIL-PRF-83483, BEFORE REASSEMBLY.
(3) Draw self-locking nuts (10) up evenly in a criss-cross pattern first to a torque value
of 60 pound-inches (6,8 N-m) and then to a final torque value of 120 pound-inches
(13,6 N-m).

(a) When power wrenches other than automatic wrenching systems are used to
assemble bolts and nuts, fastener tightness must not be more than 50 percent

BRASIL VIDA TAXI AEREO

of final torque value. Tightening to final torque value must be done using
manual torque wrenches.

(b) Automatic wrenching systems which provide a preload or torque accuracy of

± 4 percent or better can be used to tighten bolts and nuts to final torque value.
NOTE: The use of high speed power wrenches for installation of fasteners
can decrease the service life of bolts and nuts.

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

(4) When installing the two brake assemblies on each strut, insert two bolts (20) with
washers (30) in the two remaining bolt holes in the backing plate subassembly (50)
and secure with self-locking nuts (10).

NOTE: One long brake bolt (20) is furnished with each of the brake assemblies
and is used to fasten the brakes to the strut during installation.

N. Install instruction data plate (350, 360, 370, 380, 390 and 410) as follows (Refer to
IPL Figure 1)

WARNING: DO NOT USE ISOPROPYL ALCOHOL NEAR SPARKS OR FLAMES.

ISOPROPYL ALCOHOL IS FLAMMABLE.
KEEP ISOPROPYL ALCOHOL AWAY FROM EYES OR SKIN.
DO NOT BREATHE THE FUMES OR DRINK ISOPROPYL ALCOHOL.
ISOPROPYL ALCOHOL IS POISONOUS.
OBEY THE MANUFACTURER'S INSTRUCTIONS.
REFER TO THE MATERIAL SAFETY DATA SHEET (OR
EQUIVALENT) BEFORE ISOPROPYL ALCOHOL IS USED.
(1) Area in which plate is to be installed must be clean. Use a clean cloth dampened
with isopropyl alcohol, Specification TT-l-735.

(2) Remove paper backing from adhesive surface being careful not to touch the
adhesive.

(3) Apply plate to the correct location, press firmly with roller (minimum five pounds
(2,268 kg) pressure applied to roller) to ensure good contact to both surfaces. Be
sure that edges of plate are rolled down firmly.

(4) A setup or curing time of approximately 48 hours is required to permanently set the
adhesive. Plate should not be disturbed during this time.

O. Test brake assembly as given in TESTING AND FAULT ISOLATION.

4. Assembly Procedures for Brake Assemblies 5003096-5 or -7

A. Refer to IPL Figure 1.

CAUTION: ASSEMBLE THE BRAKE WITH CARE. ENSURE PROPER PARTS ARE
USED FOR EACH BRAKE ASSEMBLY.

B. Place brake housing subassembly (330B) on a clean flat surface with piston cavities up. BRASIL VIDA TAXI AEREO
C. Install piston as follows:

NOTE: It is recommended all preformed packings and packing retainers removed at

disassembly be replaced with new packings and retainers at reassembly.

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

WARNING: KEEP HYDRAULIC FLUID AWAY FROM EYES OR SKIN.

DO NOT BREATHE THE FUMES OR DRINK HYDRAULIC FLUID.
HYDRAULIC FLUID IS POISONOUS.
OBEY THE MANUFACTURER'S INSTRUCTIONS.
REFER TO THE MATERIAL SAFETY DATA SHEET (OR
EQUIVALENT) BEFORE HYDRAULIC FLUID IS USED.
(1) Lubricate preformed packings (240A), packing retainers (230), housing piston
cavities and seal grooves and contacting surfaces of pistons (220) with a light coat
of hydraulic fluid, Specification MIL-PRF-5606.

CAUTION: BE CAREFUL NOT TO STRETCH OR TWIST PACKINGS DURING

INSTALLATION.
(2) Carefully install one preformed packing (240A), then one packing retainer (230) in
the groove of each piston cavity.

CAUTION: USE CARE DURING INSTALLATION OF PISTONS TO AVOID

DAMAGING OR DISPLACING PREFORMED PACKINGS.
(3) Install a piston (220) in each piston cavity (with recessed end for insulator out)
carefully, so as not to displace preformed packing or retainer.

NOTE: Piston installation can be facilitated by turning the piston slightly during
installation.

D. Install one disk insulator (210C) in each piston recess with the impressed part numbers
toward piston as follows:

(1) Apply a coat of Pliobond 5001 (alternate Pliobond 20) cement approximately
0.010 inch (0,25 mm) thick and one inch (25,4 mm) in diameter to center of piston
recess and to center of insulator.

(2) Air dry cement for three to five minutes and install insulator into recess of pistons.

E. Bottom pistons/insulator into brake housing subassembly.

F. Install protective plug as follows:

(1) Lubricate preformed packing (320) with a light coat of hydraulic fluid, Specification
MIL-PRF-5606.

(2) Install lubricated preformed packing (320) on protective plug (340) and install in inlet BRASIL VIDA TAXI AEREO
port of housing subassembly.

G. Install bleeder adapter and bleeder plug as follows:

(1) Lubricate preformed packing (320) with a light coat of hydraulic fluid, Specification
MlL-PRF-5606.

NOTE: New preformed packings are recommended at each overhaul.

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

(2) Install Iubricated preformed packing (320) on bleeder adapter (310).

(3) Install bleeder adapter in bleeder port of housing subassembly and tighten to a
torque value of 120 pound-inches (13,6 N-m).

(4) Install bleeder plug (290) on bleeder adapter (310).

H. Assemble each of the four return mechanisms as follows:

(1) Place spring (270) in return spring housing (280).

(2) Place spring guide (260) in spring (270).

(3) Depress spring guide (260) using an arbor press and install retaining ring (250) in
groove of return spring housing (280).

(4) Release arbor press slowly and remove return mechanism.

I. Install pressure plate subassembly on brake housing subassembly as follows:

CAUTION: PRESSURE PLATE SUBASSEMBLY (170C) MUST BE INSTALLED

WITH THE TWO LONG WEAR PADS (190B) AT THE TOP OF THE
BRAKE HOUSING OVER THE OPEN SECTION BETWEEN HOUSING
ENDS.
(1) Insert the heads of the return pins (160A) into the return pin slots of the pressure
plate subassembly (170C) and position the pressure plate against the disk
insulators (210C) with the return pins in the return mechanism holes.

(2) Grasp the assembled unit firmly and turn the unit over. Place the unit with the wear
pads down on the working surface.

J. Install each of the four assembled return mechanisms over return pin (160A) and into the
brake housing subassembly (330B).

CAUTION: IF USED, GRIP AND TUBE SUBASSEMBLY (150A) MUST BE RESET TO

0.08 INCH POSITION FROM TUBE END BEFORE INSTALLATION IN
BRAKE. INSTALL GRIP AND TUBE SUBASSEMBLY WITH THE SHORT
END (0.08 INCH) OF THE TUBE FACING THE PRESSURE PLATE.

K. If used, install each of the four grip and tube subassemblies (150A) on return pin (160A),
install each of the four self-locking nuts (140), and tighten to a torque value of

BRASIL VIDA TAXI AEREO

25 pound-inches (2,83 N-m). Refer to REPAIR, paragraphs 20.B. and D., if installing
swage and tube subassemblies.

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L. Build up disk stack as follows:

NOTE: All disks should have approximately the same amount of wear; if dished,
dishing should be oriented in the same direction.

When building up disk stack, use Illustrated Parts List to determine part
numbers of disks to be used in each position.

(1) Position brake housing/pressure plate subassembly with wear pad up.

(2) Position torque tube (130B) over pressure plate (170C) with the axle flange away
from the pressure plate and the solid key facing the open section of the brake
housing subassembly (330B). Slide torque tube into pressure plate and align with
bolt holes in housing.

(3) Place the stationary disk subassembly (100A) between the two rotating disks (90B
or 90C) and slide the entire stack on the torque tube (130B).

(4) Position the backing plate subassembly (50) on the torque tube with the backing
plate wear pads facing the rotating disk (90B or 90C). Align bolt holes with open
torque tube keys.

M. Install brake fasteners as follows:

(1) Lubricate bolt threads and bearing surface of bolts (20A and 40A), countersunk
washers (30), and self-locking nuts (10) with anti-seize compound, Specification
MIL-PRF-83483.

NOTE: It is suggested that operators use Molylube in lieu of other compounds

meeting Specification MlL-PRF-83483.

CAUTION: COUNTERSUNK WASHER MUST BE PLACED ON THE BOLT WITH

THE COUNTERSINK FACING THE BOLT HEAD.
THE HEADS OF BOLTS MUST BE FULLY SEATED IN THEIR
RECESSES IN THE HOUSING SUBASSEMBLY BEFORE
TIGHTENING NUTS.
(2) Insert three bolts (40A) with washers (30) in the three holes in the bottom of the
brake housing subassembly (330B) opposite the open section, through the housing
torque tube and backing plate. Secure with self-locking nuts (10).

BRASIL VIDA TAXI AEREO

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COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

CAUTION: A BRAKE BOLT OR NUT ACCIDENTALLY TIGHTENED TO MORE

THAN 120 PERCENT OF THE RECOMMENDED FINAL TORQUE
VALUE MUST BE REPLACED.

CAUTION: IF POWER WRENCHES ARE USED, FASTENERS TIGHTENED TO

MORE THAN 50 PERCENT, BUT LESS THAN 120 PERCENT OF FINAL
TORQUE VALUE MUST BE DISASSEMBLED AND RELUBRICATED
WITH ANTI-SEIZE COMPOUND, SPECIFICATION MIL-PRF-83483,
BEFORE REASSEMBLY.
(3) Draw self-locking nuts (10) up evenly in a criss-cross pattern first to a torque value
of 60 pound-inches (6,8 N-m) and then to a final torque value of 120 pound-inches
(13,6 N-m).

(a) When power wrenches other than automatic wrenching systems are used to
assemble bolts and nuts, fastener tightness must not be more than 50 percent
of final torque value. Tightening to final torque value must be done using
manual torque wrenches.

(b) Automatic wrenching systems which provide a preload or torque accuracy of

+4 percent or better can be used to tighten bolts and nuts to final torque value.
NOTE: The use of high speed power wrenches for installation of fasteners
can decrease the service life of bolts and nuts.

(4) When installing the two brake assemblies on each strut, insert two bolts (20A) with
washers (30) in the two remaining bolt holes in the brake housing subassembly
(330B) and secure with self-locking nuts (10).

NOTE: One long brake bolt (20A) is furnished with each of the brake assemblies
and is used to fasten the two brakes to each strut during installation.

N. Install instruction data plate (400 or 420) as follows (Refer to Figure 1):

WARNING: DO NOT USE ISOPROPYL ALCOHOL NEAR SPARKS OR FLAMES.

ISOPROPYL ALCOHOL IS FLAMMABLE.
KEEP ISOPROPYL ALCOHOL AWAY FROM EYES OR SKIN.
DO NOT BREATHE THE FUMES OR DRINK ISOPROPYL ALCOHOL.
ISOPROPYL ALCOHOL IS POISONOUS.
OBEY THE MANUFACTURER'S INSTRUCTIONS.

BRASIL VIDA TAXI AEREO

REFER TO THE MATERIAL SAFETY DATA SHEET (OR
EQUIVALENT) BEFORE ISOPROPYL ALCOHOL IS USED.
(1) Area in which plate is to be installed must be clean. Use a clean cloth dampened
with isopropyl alcohol, Specification TT-l-735.

(2) Remove paper backing from adhesive surface being careful not to touch the
adhesive.

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BRAKE ASSEMBLY 5003096

(3) Apply plate to proper location, press firmly with roller (minimum five pounds
(2,268 kg) pressure applied to roller) to ensure proper contact to both surfaces. Be
sure that edges of plate are rolled down firmly.

(4) A setup or curing time of approximately 48 hours is required to permanently set the
adhesive. Plate should not be disturbed during this time.

O. Test brake assembly as given in TESTING AND FAULT ISOLATION.

5. Storage Instructions

A. Brake Assembly

CAUTION: IN BRAKES EQUIPPED WITH QUICK-DISCONNECT FITTINGS

PROTECT THE FITTINGS DURING SHELF STORAGE BY SUITABLE
CAPS OR EQUIVALENT.
(1) Store the brake assembly in moisture-proof material and a sealed corrugated
cardboard container, or equivalent.

(2) The brake assembly should be stored in a clean, dry storeroom. The desirable store
room temperature range is from 50° F to 70° F (10° C to 21° C). If this temperature
range cannot be maintained, temperatures as high as +125° F (+52° C) and as low
as -20° F (-29° C) can be tolerated for short periods. Total time above 100° F
(38° C) must not be more than three months.

B. Subassemblies

(1) Surface treat torque tube, pressure plates, backing plates and stationary disks that
are to be stored for an indefinite period as follows:

(a) Vapor degrease subassemblies to remove all oil and residue.

WARNING: DO NOT USE RUST INHIBITOR NEAR SPARKS OR FLAMES.

RUST INHIBITOR IS FLAMMABLE.
KEEP RUST INHIBITOR AWAY FROM EYES OR SKIN.
DO NOT BREATHE THE FUMES OR DRINK RUST INHIBITOR.
RUST INHIBITOR IS POISONOUS.
OBEY THE MANUFACTURER'S INSTRUCTIONS.
REFER TO THE MATERIAL SAFETY DATA SHEET (OR

BRASIL VIDA TAXI AEREO

EQUIVALENT) BEFORE RUST INHIBITOR IS USED.
(b) Immerse in Houghton's Rust Veto 4214, or equivalent. Use in the “as received”
condition without dilution. Allow parts to drip and air dry for five minutes. Clean
compressed air can be used to speed drying.

(c) Wrap subassembly in moisture-barrier material and package in a cardboard

container.

(d) Prior to placing subassembly back in service, degrease in a vapor degreaser.

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BRAKE ASSEMBLY 5003096

C. Protective Coating

(1) Surface treat newly ground disks that are not immediately put into service as
follows:

(a) Degrease disk in a vapor degreaser to remove all oil and grinding material.

(b) Immerse disks in Houghton's Rust Veto 4214 or equivalent. Use in the
as-received condition without dilution. Let disks drip and air dry for five
minutes. Clean compressed air can be used to speed drying.

BRASIL VIDA TAXI AEREO

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FITS AND CLEARANCES

1. Fits and Clearances

Table 801
Torque Values
Item No.
Nomenclature Torque Value
(Refer to IPL Figure 1)
10 Brake Bolt Nut 120 pound-inches (13,56 N-m) Lubtork)*
140 Return Pin Nut 25 pound-inches (2,83 N-m)
310 Bleeder Adapter 120 pound-inches (13,56 N-m)
*Lubetork: At each installation, lubricate bolt threads and bearing surfaces of nuts, bolt heads and
washers with anti-seize compound conforming to Specification MIL-PRF-83483. Use
full strength. Do not dilute.

Table 802
Spring Values

Item No.
Nomenclature Compressed Length Load
(Refer to IPL Figure 1)
0.635 inch 67 lb (298 N)
270 Return Spring
(16,13 mm) (minimum)

Table 803
Out-of-Flatness (Dishing) Tolerance

Item No Maximum
Nomenclature
(Refer to IPL Figure 1) Out-of-Flatness
50 Back Plate Subassembly 0.040 inch (1,02 mm)
90, 90A, 90B or 90C Rotating Disk 0.030 inch (0,762 mm)
100 or 100A Stationary Disk Subassembly 0.030 inch (0,762 mm)
170, 170A, 170B or 170C Pressure Plate Subassembly 0.030 inch (0,762 mm)

BRASIL VIDA TAXI AEREO

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Table 804
Wear and Shrinkage Tolerance (Replacement Dimension)

Item No.
Nomenclature Wear Dimension

Back Plate
50 0.486 inch (12,34 mm) thick
Subassembly

0.300 inch (7,62 mm) thick for 90 or 90A

0.375 inch (9,53 mm) thick for 90B or 90C
90, 90A, 90B or 90C Rotating Disk
9.10 inches (231,1 mm) outside diameter
Maximum out-of-round 0.125 inch (3,18 mm)

Stationary Disk 0.431 inch (10,95 mm) thick for 100

Subassembly 0.461 inch (11,71 mm) thick for 100A
Inside diameter less than 4.25 inches (107,9 mm)
and greater than 4.68 inches (118,9 mm)
100 or 100A
Minimum keyslot width 0.802 inch (20,37 mm)

Maximum keyslot width 0.832 inch (21,13 mm)

Pressure Plate 0.321 inch (8,15 mm) thick for 170, 170A or 170B
Subassembly 0.349 inch (8,86 mm) thick for 170C
Inside diameter less than 4.25 inches (107,9 mm)
170, 170A, 170B or and greater than 4.68 inches (118,9 mm)
170C
Minimum keyslot width 0.802 inch (20,37 mm)

Maximum keyslot width 0.832 inch (21,13 mm)

0.720 inch (18,29 mm) minimum key thickness or

130, 130A or 130B Torque Tube 0.015 inch (0,38 mm) wear maximum per key
face

0.420 inch (10,7 mm) minimum thickness across

151 Adjuster Swage
corners

BRASIL VIDA TAXI AEREO

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BRAKE ASSEMBLY 5003096

SPECIAL TOOLS, FIXTURES AND EQUIPMENT

1. Special Tools, Fixtures and Equipment

Figure No. Tool/Fixture No. Description Application

Grip and Tube Used to test and adjust grip and tube
504/613 3-7305-1A (Swage and Tube) Arbor subassemblies and Swage and Tube
Press Adapter subassemblies.
Used to test and adjust grip and tube
7283-10 Indicator
subassemblies.
Used to test and adjust grip and tube
3-7340-1 Body
subassemblies.
Used to test and adjust grip and tube
3-7340-2 Gib
subassemblies.
Used to test and adjust grip and tube
3-7340-3 Screw
subassemblies.
Used to test and adjust grip and tube
3-9690-11 Stop Block
subassemblies.
Grip and Tube Adjusting Used to adjust grip and tube
505 -
Fixture subassemblies.
Used to straighten dished disks, back
901 - Straightening Fixture
plate and pressure plate.
Round-Head Driver for
Used as an anvil for roundhead Rivets
Chicago Pneumatic or
902 1-25310 GY18B and GYR8B when repadding
U.S. Industrial Tool
pressure and back plates.
Riveter
Swaging Peen for
Chicago Pneumatic or Used to form shop head for Rivets
902 1-25311
U.S. Industrial Tool GY18A, GY18B, GYR8A and GYR8B.
Riveter
Form Tool for Chicago
Used to machine contour on Swaging
902 1-71219 Pneumatic or U.S.
Peen 1-25311.
Industrial Tool Riveter
Flathead Anvil for
Used as anvil for flathead Rivets

BRASIL VIDA TAXI AEREO

Chicago Pneumatic or
902 1-25309 GY18A and GYR8A when repadding
U.S. Industrial Tool
stationary disks.
Riveter
Swaging Peen for Taumel Used to form shop heads on Rivets
903 1-25807
Riveter GY18 and GYR8.
Flathead Anvil for Taumel Used to install flathead Rivets GY18A
903 2-10066
Riveter and GYR8A.

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Figure No. Tool/Fixture No. Description Application

Round Head Driver for
Used to install round head Rivets
903 2-10067 Taumel Riveter or
GY18B.
Bracker Riveter
Taumel Riveter Tool
903 2-10080 Used to hold tools.
Holder
903 T-21 (2-10080) Taumel Riveter Head Used to hold tool holder.
Swaging Peen for RN211 Used to form shop heads on 1/4 inch
904 1-26120
Bracker Riveter diameter rivets.
Swaging Peen for RN311 Used to form shop heads on 1/4 inch
904 1-26126
Bracker Riveter diameter rivets.
Flat Head Anvil for
Used to install 1/4 inch diameter flat
904 2-10066 RN211 or RN311 Bracker
head rivets.
Riveter
Plastic Reclaimable
PRAM 31
- Abrasive Machine Equipment used for dry paint strip ping.
(V06UZ8)*
(PRAM)
CUT Installation tool for pin Used to drive the pin portion of the
-
A2500203A plug pin plugs set into the housing.
used to remove wear pad from old
- 7/32 Drilling Tool
rivets and punching out rivets.
NOTE: The following types of riveters are used in the manufacturer and repair of brakes
Compression Riveter Chicago Pneumatic Systems Division
No. CP-0450-CEJAF Chicago Pneumatic Tool
(12-inch reach) 1800 Overview Drive
Rockhill, SC 29730
Ph: 803-817-7000
Fax: 800-232-6611
Compression Riveter U.S. Industrial Tool & Supply Company
Model 150 (or equivalent) 15101 Cleat Street
Plymouth, MI 48170
Bracker Radial Bracker Corporation
Models RN180 or RN211 130 Technology Dr.
and RN280 or RN311 Canonsburg, PA 15317

BRASIL VIDA TAXI AEREO

Ph: 800-806-6157
Fax: 724-873-5858
Spin Riveter Taumel Assembly Systems
Model BK1000 or TC320 Route 22 Robin Hill, Corp. Park
Patterson, NY 12563
Ph: 914-878-3100
Fax: 914-878-4838
* See IPL Commercial and Government Entities (CAGE) Codes for manufacturer's names and
addresses.

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NOTE:

For information concerning Special Tools and Equipment contact your local MABS
Technical Support Engineer in Akron, Ohio US or Coventry, England UK. To locate your dedicated
Technical Support Engineer, go to www.meggitt-mabs.com and click on the Technical support link.

NOTE: MABS Special Tools can be purchased by contacting:

Sales Manager CAGE Code 6L817

National Machine Company
4880 Hudson Drive
Stow, Ohio 44224
Ph: 330-688-6494
Fax: 888-235-6006
Email address: sales@nmc-oh.com

For equipment required for testing, refer to TESTING AND FAULT ISOLATION.

BRASIL VIDA TAXI AEREO

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2 x 2 (51 x 51) ANGLE IRON WELDED TO DIE

POINT OF ATTACHMENT TO HAND ARBOR PRESS

2.00 (50,8)

A A

1/32 (0,8) x 45°

1.50
(38,1)
SECTION A-A
UPPER REGISTER
6.50 (165,0)

B B 0.375
(9,53)

0.125
0.75 (3,18) 0.1875
(19,05) (4,763)

SECTION B-B
LOWER REGISTER

5.00 (127,0)

BRASIL VIDA TAXI AEREO

8.50 (215,9)
324332-901-01.CGM

9.25 (235,0) NOTE:

LOCAL MANUFACTURE
10.35 (262,9)

Figure 901
Fixture for Straightening Disks, Pressure Plate and Backing Plate

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Ø 0.440 +0.005/-0.000
(11,176 +0,127/-0,000)
ETCH TOOL #1-25309

Ø 0.500 Ø 0.310 +0.001/-0.000

(12,7) 0.19 (4,826) (7,874 +0,025/-0,000)

1.25 (31,75)

2.00 (50,8)

FLATHEAD ANVIL 1-25309

NOTES:

324332-902-01.CGM
1. MATERIAL - AISI TYPE S5 HARDEN TO ROCKWELL C-50-55 AND GRIND FOR
USE ON COMPRESSION RIVETER
2. TO BE USED FOR FLATHEAD RIVETS ONLY STYLE GY18A OR GYR8A 0.250 (6,35)

BRASIL VIDA TAXI AEREO

Figure 902
Special Tools for Use with Compression Riveter (Sheet 1 of 3)

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62
0.563 (14,30) SPHER R

ETCH TOOL #1-25310

Ø 0.500 (12,7)

-A-
Ø 0.310 +0.001/-0.000
0.058 (1,473) (7,874 +0,025/-0,000)
REF.
A 0.005 (0,13) TIR

1.25 (31,75)

2.00 (50,8)

ROUND HEAD DRIVER/ANVIL 1-25310

NOTES:
1. MATERIAL - AISI TYPE S5 HARDEN TO ROCKWELL C-50-55 AND GRIND FOR 324332-902-02.CGM
USE ON COMPRESSION RIVETER
2. TO BE USED FOR ROUND HEAD RIVETS ONLY STYLE GY18B OR GYR8B 0.250 (6,35)

BRASIL VIDA TAXI AEREO

Figure 902
Special Tools for Use with Compression Riveter (Sheet 2 of 3)

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SEE VIEW A 0.250 (6,350)

0.250 (6,350) RAD

1.500
(38,10) 0.078 (1,981)

0.145 (3,683) 30°

20° 0.250 (6,350) 0.047 (1,194)
30°
MATERIAL-MOMAX OR EQUIV. TOOL BIT
THIS TOOL IS USED TO MACHINE CONTOUR ON VIEW A
RIVET PEEN 1-25311. FORM TOOL 1-71219

0.114 ± 0.003
SEE NOTE 4 (2,896 ± 0,0762)
0.250 ± 0.005 1.875 (47,625)
(6,35 ± 0,127) RAD
0.750 (19,05)
Ø 0.310 +0.001 -0.000
0.313 (7,950) (7,874 +0,0254 -0,000)
(10,312 ± 0,762)

30°
Ø 0.406 ± 0.003

A
0.145 ± 0.003
(3,683 ± 0,0762)
Ø 0.500 ETCH TOOL NO. 1-25311
(12,70)
SEE VIEW B
34° NOTES:

0.078 ± 0.003 (1,981 ± 0,0762) 1. MATERIAL-AISI TYPE S5

2. HEAT TREAT-ROCKWELL "C"
0.047 ± 0.003 (1,194 ± 0,0762) RAD (48-50) AND POLISH CONTOUR
VIEW B AREA FREE OF MARKS. 5 TO 10
RMS AFTER HND
0.125 (3,175)
0.133 - 0.136 3. SERVICE-GY18A, GY18B, GYR8A
(3,378 - 3,454) & GYR8B RIVETS (SEMI-TUBULAR).
4. EDGE OF FORMING TOOL MUST BE
ON CENTER LINE OF PEEN (AS SHOWN

BRASIL VIDA TAXI AEREO

Ø 0.250 ± 0.002 WHEN FORMING CONTOUR OF PEEN-TOOL
(6,350 ± 0,051) NO. 1-71219)
324332-902-03.CGM

U.S. INDUSTRIAL TOOL & SUPPLY CO. 5. LOCAL MANUFACTURE

RETAINING RING 92707Y
VIEW A
OPTIONAL SHANK
SWAGING PEEN 1-25311

Figure 902
Special Tools for Use with Compression Riveter (Sheet 3 of 3)

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SWAGING PEEN 1-25807

FLATHEAD ANVIL 2-10066

ROUNDHEAD ANVIL 2-10067

TOOL HOLDER 2 - 10080

TAUMEL RIVETER HEAD T-21

BRASIL VIDA TAXI AEREO

2-10080
324332-903-01.CGM

NOTES:
SWAGING PEEN, FLATHEAD ANVIL, ROUNDHEAD DRIVER AND TOOL HOLDER SHOWN
ARE FOR USE WITH TAUMEL SPIN RIVETER, PART NUMBER BK 1000 OR BK 1500 WITH
RIVETER HEAD T-21

Figure 903
Special Tools for Use with Taumel Riveter

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SWAGING PEEN
1-26120
(RN-211)

SWAGING PEEN
1-26126
(RN 311)

FLATHEAD ANVIL
2-10066
(RN211 OR RN311)

324332-904-01.CGM

NOTE:

BRASIL VIDA TAXI AEREO

SWAGING PEEN AND FLATHEAD ANVIL SHOWN ARE FOR USE WITH BRACKER
RIVETER, PART NUMBER RN211 OR RN311

Figure 904
Special Tools for Use with Bracker Riveter

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THIS PAGE
KEPT
BLANK

BRASIL VIDA TAXI AEREO

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ILLUSTRATED PARTS LIST

1. Introduction

A. General

(1) The Illustrated Parts List (IPL) section contains a figure(s) and a list(s) of parts of the
assembly(ies) in this manual.

B. Parts List

(1) The figure is an exploded view of assembly(ies) included in the parts list.

(2) The components in the parts list are shown in the sequence of disassembly.

(3) The attaching parts are after the part which they attach.

(4) Alternate, optional or repair parts are given after the primary part.

(5) The figure and the Item column contain the figure and the item number for each
part.

(6) The item numbers in the parts list agree with the item numbers in the figure.

(7) The Part Number column gives the part number that is compliant with the ATA
Specification 2000.

(8) When the part number is not compliant with Specification 2000, it is in the
Nomenclature column in parentheses.

(9) Use the part number in its initial format in the Nomenclature column to make sure
you order the correct part.

(10) The Airline Stock Number column is for the operator to write airline part numbers.

(11) The Nomenclature column gives the noun name of each part in upper case letters.

(12) Details, dimensions and specifications that identify the part are given after the noun
name.

(13) The names of the parts are indented to show the relation of the parts to their
subassemblies and the top assembly.

BRASIL VIDA TAXI AEREO

(14) Data in parentheses can identify optional, alternate, and repair parts. The data can
give other data to identify and order the part (the data includes the initial part
number.

(15) Commercial and Government Entities (CAGE) codes identify the suppliers of
vendor parts. The letter “V” is put before the five-digit CAGE code.

(16) The Effect Code column shows the parts used for each top assembly.

(17) Each top assembly is given a letter for example A, B, C, D, etc.

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(18) This letter is in the Effect Code column of each part used in that top assembly.

(19) A part number identified by an effectivity code shows that the coded part is used
with other parts. The effectivity code is a single, upper case alpha designation.
Identify the other parts with the same alpha designation.

(20) A part with a code is used with all other non-coded parts (Effect Code column will be
blank).

(21) The Units Per Assembly column gives the number of parts contained in each
assembly or subassembly.

(22) An RF in this column is an indication that the item is listed for REFERENCE ONLY.

(23) An AR in this column is an indication that the item quantity is AS REQUIRED and
could vary if alternate build options are used.

C. Parts Replacement Data

(1) Parts can be interchanged only as permitted by the terms that follow. These terms
are given when necessary in the DESCRIPTION column of the parts list.

TERM DEFINITION
Alternate for This part is equal to the primary part in form, fit and
function.
This part can be used in place of the primary part at the
option of the operator.
Superseded By This part is no longer available.
This part can be used until stock is depleted.
Supersedes This part replaces a part that was superseded or deleted.
This part is interchangeable with the part it supersedes.
Order this part.
Deleted This part is no longer used in the assembly.
Deletion of this part and replacement with the new part is
mandatory.
Optional This part is sold separately.
Use of this part in the assembly is not required.

BRASIL VIDA TAXI AEREO

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2. Commercial and Government Entities (CAGE) Codes

Code No. Name and Address

V0B9R9 Meggitt Aircraft Braking Systems
1204 Massillon Rd
Akron OH 44306
Ph: 330-796-4440
Fax: 330-796-9791
V0VNM9 Sherex Industries
7 Orchard Park Rd
Madison CT 06443
Ph: 716-875-0176
V56878 SPS Technologies LLC,
DBA Aerospace Division
301 Highland Avenue
Jenkintown PA 19046
Ph:215-572-3357
Fax:215-572-3194
V63477 Federal Mogul Corp
Sub Wagner Brake
Moog Automotive Div
6565 Wells Ave
Saint Louis MO 63177
Ph: 314-977-0300
V07382 Rotor Clip Company Inc.
DBA Rotor Clamp
187 Davidson Ave
Somerset NJ 08873
Ph: 732-469-7333
Fax: 732-805-6474
V86460 Elf Atochem North America Inc
2000 Market St.
Philadelphia PA 19103
Ph: 215-419-7000
Fax: 215-419-7343
V06UZ8 Pauli Systems, Inc.

BRASIL VIDA TAXI AEREO

1820 Walters Ct
Fairfield CA 94533
Ph: 7074-292-434
Fax: 7074-292-434

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3. Parts List

70
60 120

10
120
80 OR
80A 110A
50

10

90C
180 100A
190B
90C

170C

170C
160A

130B
210C
220
230 290
240A
320 310

420
280
270
190B 260 152A
250
151
200 OR 340 320
200A

BRASIL VIDA TAXI AEREO

330B 30
324332-1001-01.CGM

40A 153A
180 30
150C
20A
140

IPL Figure 1
Brake Assemblies 5003096-5 and 5003096-7

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AIRLINE NOMENCLATURE UNITS

FIGURE EFFECT
PART NUMBER STOCK PER
ITEM CODE
NUMBER 12345678 ASSY
1–1 5003096* BRAKE ASSEMBLY (Order -6) A RF
–1A 5003096-1* BRAKE ASSEMBLY (Order -6) B RF
–1B 5003096-2 DELETED
–1C 5003096-3* BRAKE ASSEMBLY (Order -6) D RF
–1D 5003096-4* BRAKE ASSEMBLY (Order -6) E RF
–1E 5003096-5* BRAKE ASSEMBLY (Order -7) F RF
–1F 5003096-6 BRAKE ASSEMBLY G RF
–1G 5003096-7 BRAKE ASSEMBLY H RF
10 GYN145 . NUT, Self-Locking 4
–20 GYS225P116 . BOLT, Brake ABDEG 1
(GYS225-P116)
20A GYS225P128 . BOLT, Brake FH 1
(GYS225-P128)
30 MS20002C5 . WASHER, Countersunk 4
–40 GY165MSP40 . BOLT, Brake ABDEG 3
(GY165MS-P40)
40A GY165MSP47 . BOLT, Brake FH 3
(GY165MS-P47)
50 9544027 . BACKING PLATE 1
SUBASSEMBLY
60 GY18B7 . . RIVET 12
(GY18B-7)
70 GY18B15 . . RIVET 12
(GY18B-15)
80 5006029 . . WEAR PAD 12
–80A 9536248 . . WEAR PAD 12

BRASIL VIDA TAXI AEREO

(Alternate for item 80)
–90 5003147* . ROTATING DISK ABD 2
(Replaced by item 90A)
–90A 5006425 . ROTATING DISK EG 2
– Item not illustrated.
* Item not procurable - Use until stock depletion.

Page 1005
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CO: 8462

Aug 12/13
 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

AIRLINE NOMENCLATURE UNITS

FIGURE EFFECT
PART NUMBER STOCK PER
ITEM CODE
NUMBER 12345678 ASSY

–90B 5006888* . ROTATING DISK F 2

(Replaced by item 90C)
90C 5006888-1 . ROTATING DISK FH 2
–100 9544028 . STATIONARY DISK ABDEG 1
SUBASSEMBLY
–100A 5006892 . STATIONARY DISK FH 1
SUBASSEMBLY
–110 GY18A15 . . RIVET ABDEG 24
(GY18A-15)
(Superseded by item 110B)
110A GYR8A23 . . RIVET FH 24
(GYR8A-23)
–110B GYR8A20 . . RIVET ABDEG 24
(GYR8A-20)
(Supersedes item 110)
120 5006029 . . WEAR PAD 24
–120A 9536248 . . WEAR PAD ABDEG 24
(Alternate for item 120)
(See Effect Code)
–130 9550634* . TUBE, Torque ABDE 1
(Replaced by item 130A)
–130A 5006905 . TUBE, Torque G 1
130B 5006894 . TUBE, Torque FH 1
140 FN12-02 . NUT, Self-Locking 4
(V56878)
–150 9535045 . GRIP AND TUBE ABDEG 4
SUBASSEMBLY
(Replaced by item 150B)

BRASIL VIDA TAXI AEREO

–150A 5001423 . GRIP AND TUBE FH 4
SUBASSEMBLY
(Replaced by item 150C)
150B 5012939 . SWAGE TUBE ABDEG 4
SUBASSEMBLY
150C 5012940 . SWAGE TUBE FH 4
SUBASSEMBLY
– Item not illustrated.
* Item not procurable - Use until stock depletion.

Page 1006
32-43-32
CO: 8462

Aug 12/13
 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

AIRLINE NOMENCLATURE UNITS

FIGURE EFFECT
PART NUMBER STOCK PER
ITEM CODE
NUMBER 12345678 ASSY

151 5010711 . . SWAGE, Adjuster ABDEFGH 4

–152 5012943 . . TUBE, Self-adjusting Swage ABDEFGH 4
(Superseded by item
152A)
152A 5011319 . . TUBE, Self-adjusting Swage ABDEFGH 4
(Supersedes item 152)
153 5012941 . TUBE, Spacer ABDEG 4
153A 5012942 . TUBE, Spacer FH 4
–160 9535044 . PIN, Return ABDEG 4
160A 5001421 . PIN, Return FH 4
–170 9544029* . PRESSURE PLATE A 1
SUBASSEMBLY
(Order item 170B)
170A 5005117* . PRESSURE PLATE B 1
SUBASSEMBLY
(Order item 170B)
170B 5005117-1 . PRESSURE PLATE ABDEG 1
SUBASSEMBLY
170C 5006890 . PRESSURE PLATE FH 1
SUBASSEMBLY
180 GY18B9 . . RIVET ABDEFGH 20
(GY18B-9)
–180A GYR8B8 . . RIVET FH 20
(Replaced by item 180)
(GYR8B-8)
190 9536249 . . WEAR PAD A 2
190A 5005119 . . WEAR PAD BDEG 1
190B 5007328 . . WEAR PAD FH 1

BRASIL VIDA TAXI AEREO

200 5006029 . . WEAR PAD 8
200A 9536248 . . WEAR PAD ABDEG 8
(Alternate for item 200)
(See Effect Code)
–210 9535042 . INSULATION DISK ABDEG 5
(Superseded by item 210B)
– Item not illustrated.
* Item not procurable - Use until stock depletion.

Page 1007
32-43-32
CO: 8462

Aug 12/13
 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

AIRLINE NOMENCLATURE UNITS

FIGURE EFFECT
PART NUMBER STOCK PER
ITEM CODE
NUMBER 12345678 ASSY

–210A 5006895 . INSULATION DISK FH 5

(Superseded by item 210C)
–210B 9535042-1 . INSULATION DISK ABDEG 5
(Supersedes item 210)
210C 5006895-1 . INSULATION DISK FH 5
(Supersedes item 210A)
220 9536273 . PISTON 5
230 MS28774-216 . RETAINER, Packing 5
–240 MS28775-216 . PACKING, Preformed ABDEG 5
(Alternate for item 240A)
240A M834611-216 . PACKING, Preformed FH 5
(M83461/1-216)
(Optional for item 240)
250 N5000-106MD . RING, Retaining 4
(V79136)
260 9536264 . GUIDE, Spring 4
270 9536255 . SPRING 4
280 9536262 . HOUSING, Return Spring 4
290 F6446 . PLUG, Bleeder 1
(V63477)
–300 DELETED
310 511951 . ADAPTER, Bleeder 1
–311 9535617 . BUSHING, Bleeder Adapter 1
(Repair Only)
320 MS28778-4 . PACKING, Preformed 2
–321 MS28775-014 . PACKING, Preformed 1
(Repair Only)

BRASIL VIDA TAXI AEREO

–330 9536282 . HOUSING SUBASSEMBLY, ABDEG 1
Brake
–330A 9536263 DELETED
330B 5006886 . HOUSING SUBASSEMBLY, FH 1
Brake
– Item not illustrated.
* Item not procurable - Use until stock depletion.

Page 1008
32-43-32
CO: 8462

Aug 12/13
 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

AIRLINE NOMENCLATURE UNITS

FIGURE EFFECT
PART NUMBER STOCK PER
ITEM CODE
NUMBER 12345678 ASSY

–330C 5006886-1 . HOUSING SUBASSEMBLY, G 10

Brake
(Alternate for item 330)
340 1604-73 . PLUG, Protective 1
(V79555)
–350 5003404 . PLATE, Identification A 1
–360 5006251 . PLATE, Identification B 1
–370 5006424 DELETED
–380 5006499 . PLATE, Identification D 1
–390 5006500 . PLATE, Identification E 1
–400 5006885 . PLATE, Identification F 1
–410 5006950 . PLATE, Identification G 1
420 5012137 . PLATE, Identification H 1
–430 HK050CK11-111 . . PLUG, Expander 4
(V0VNM9)
–430A SK550-050 . . PLUG, Expander 4
(V0VNM9)
–440 HK053CK11-111 . . PLUG, Expander, Oversize, AR
(Repair only) (V0VNM9)
–440A 2500010A . . PLUG, Pin, (Repair only) AR
– Item not illustrated.
* Item not procurable - Use until stock depletion.

BRASIL VIDA TAXI AEREO

Page 1009
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CO: 8462

Aug 12/13
 EMAIL: PHELIPE FLEURY <phelipe@brasilvida.com.br>
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5003096

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KEPT
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BRASIL VIDA TAXI AEREO

Page 1010
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