Section 21, Brake Line Installation, SeaRey, LSA

Progressive Aerodyne, Inc.

3801 State Rd 19
Tavares, FL 32778

Revision Description Remarks Date

01 Initial Creation 04/04/2012
02 Update Major changes adding Matco cylinder, reservoir and thru hull fittings 01/24/2014

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 Section 21, Brake Line Installation, SeaRey, LSA
1.0 Scope
This document will detail the steps necessary to assemble the brake lines.

2.0 Applicable Documents

N/A

3.0 Requirements
3.1 Equipment
3.1.1 The following tools will be necessary to perform this procedure:
 Awl
 Crescent Wrench
 Needle Nose Pliers
 Screwdriver, Straight Blade
 Deburring Tool
 Allen Wrench Set
 Drill Bits, Jobber Length, 1/8”
 Drill Bits, Jobber Length, 3/16”
 Drill, Electric, or Cordless
 Files
 Hammer, Plastic Tip
 Marker
 Open End Wrench, 3/8”
 Open End Wrench, 7/16”
 Screwdriver, Phillips Head
 Socket Set, SAE, 3/8” and 7/16” sockets
 Tape Measure

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 Section 21, Brake Line Installation, SeaRey, LSA
3.2 Materials
The following general supplies will be necessary to perform this procedure:

 Sandpaper, Coarse
 Lacquer thinner (Cleaning labels off of parts)
 Protective gloves

3.3 Procedure (See the following pages)

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 Section 21, Brake Line Installation, SeaRey, LSA

Brake Cylinder

Retainer
Nut Hydraulic
Fitting
Elbow
Upper

Hydraulic
Hydraulic Line Hydraulic
Fitting Ferrule Fitting
Elbow Elbow Hydraulic
Lower Line

Figure 1. Installing the Brake Line into the Brake Cylinder

1.1 Remove the retainer nut and ferrule from the Hydraulic Fitting Male Elbow AP69P22 (#2910-028) located on the pilot side of the Matco
master cylinder (#7610-001). On one end of the end of the Hydraulic Line, 1/8” (#2910-023), slide on the retainer nut, then the ferrule as
shown in the left-hand picture.
1.2 Position the Hydraulic Fitting Male Elbow AP69P22 (#2910-028), so it faces down and will be in a good position to move without binding
through all throttle positions. Insert the end of the Hydraulic Line, 1/8” (#2910-023) into the lower Hydraulic Fitting Male Elbow ( AP69P22)
of the master cylinder. Slide the retainer nut along the Hydraulic Line moving with it the ferrule. Thread the retainer nut onto the Hydraulic
Fitting threads. Tighten down until snug.
1.3 Using a ferrule and a retaining nut, attach a 1/8” hydraulic line to the upper fitting, and run the line to the remote reservoir located on the
aft, copilot side of the bulkhead crosstube upper. Connect the line to the reservoir.

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 Section 21, Brake Line Installation, SeaRey, LSA

Brake Cable Parking

Connection Brake Valve

Outlet
Hydraulic
Park Brake
Inlet Cable

Figure 2. Mounting the Optional Matco Hydraulic Park Brake Valve

2.1 Install a Hydraulic Fitting Male Elbow AP69P22 (#2910-028) to the inlet and outlet end of the Parking Brake Valve (#3240-081).
2.2 Mount the Parking Brake Valve on panel 6, the electrical panel under the nose deck.
2.3 Take the Hydraulic Line, 1/8”, per ft. (#2910-023) coming from the lower fitting on Matco master cylinder (#7610-001) and cut it to the
proper length to reach the Parking Brake Valve.
2.4 Remove the retainer nut and ferrule from the Hydraulic Fitting Male Elbow AP69P22 (#2910-028) on the Inlet side of the parking brake
valve. slide on the retainer nut and then the ferrule.
2.5 Slide on the retainer nut and then the ferrule. Insert the end of the Hydraulic Line, 1/8”, into the parking brake valve inlet Hydraulic Fitting
Male Elbow AP69P22. Slide the retainer nut along the Hydraulic Line moving with it the ferrule. Thread the retainer nut onto the
Hydraulic Fitting threads. Tighten down until snug.
2.6 Install the Hydraulic Line, 1/8” on the Outlet side of the Parking Brake Valve and run the line toward the bulkhead area.

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 Section 21, Brake Line Installation, SeaRey, LSA

Brake Cable Hydraulic Park

Set Screw Brake Cable

Hydraulic
Fitting
Elbow

Hydraulic Park
Brake Cable

Figure 3. Installing the Optional Parking Brake Cable

Note: The position and location of the Parking Brake Handle is up to the builder

3.1 Slide the cable end in through the front of panel 1, the farthest left instrument panel, and seat the handle collar against the mounting
surface. From the back side slide on the retainer nut and thread onto the cable body and tighten.
3.2 Verify the position of the Parking Brake Valve (#3240-081) when the arm is swung forward, that it is in the open position. With the brake
handle of the Hydraulic Park Brake Cable pushed in verify the length needed of cable to reach the Parking Brake Valve arm.
3.3 Adjust the length of the Hydraulic Park Brake Cable by cutting the cable and removing a couple of inches of the sheathing so it reaches
and can be extended through the arm on the Parking Brake Valve.
3.4 Slide the cable wire of the Hydraulic Park Brake Cable into the hole in the Parking Brake Valve. Tighten down the set screw on the arm
and hold the wire into position. Note: This may have to be done after the nosedeck has been permanently secured to the hull.
3.5 Check the rotation of the Parking Brake Valve arm by pulling in and out on the Hydraulic Park Brake Cable.
3.6 Test the parking brake by pulling out the parking brake handle a few inches, and then squeeze the brake lever. The brake
lever should feel solid after a squeeze or two. When the brake lever is released, the parking brakes should working.

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 Section 21, Brake Line Installation, SeaRey, LSA

Hydraulic
Line

Inlet

Hydraulic
Outlet Tee Fitting

Bulkhead
Hydraulic Cross Tube,
Tee Fitting Lower
Outlet

Figure 4. Installing the Hydraulic Tee Fitting

4.1 Route the Hydraulic Line, 1/8”, per Ft. (#2910-023) and install into the “Tee” side of the Hydraulic Fitting, Union Tee AP64P2 (#2910-027)
locating the Hydraulic Fitting, Union Tee somewhere along the aft side of the Bulkhead Cross Tube, Lower.
4.2 Install Hydraulic Line, 1/8” into the outlet ends of the Hydraulic Fitting, Union Tee and have enough Hydraulic Line to extend out to each
wheel.
4.3 Secure the Hydraulic Line, 1/8” and the Hydraulic Tee Fitting with Plastic Tie Wraps (#7310-020) to the Bulkhead Cross Tube, Lower
(#5310-003)

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 Section 21, Brake Line Installation, SeaRey, LSA

Thru Hull
Fitting

Hydraulic
Line
Brake
Reservoir

Outlet

Figure 5. Connecting the Hydraulic line to Reservoir and Thru Hull Fitting

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 Section 21, Brake Line Installation, SeaRey, LSA

Thru Hull
Fitting

Hydraulic
Fitting
Elbow

Hydraulic
Hydraulic Line
Line

Brake
Caliper

Figure 6. Connecting the Brake Line to the Brakes

6.1 Using a ferrule and a retaining nut, connect a Hydraulic Line, 1/8” (#2910-023) to both outlets of the Union Tee AP64P2 (#2910-027) , and
route the lines, one to the pilot side, and one to the copilot side Though hull brake line connector (2910-036). Connect the brake lines to
the Thru hull brake line connector using a ferrule and a retainer nut.
6.2 Using a ferrule and a retaining nut, connect a hydraulic line to the outside portion of the thru hull brake line connector.
6.3 Run the Hydraulic Line, 1/8” so it travels down the Gear Leg and has some play for movement as the gear legs swing.
6.4 Remove the retainer nut and ferrule from the Hydraulic Fitting Male Elbow AP69P22 (#2910-028) on the Brake Caliper. Using the end of
the Hydraulic Line, 1/8” slide on the retainer nut and then the ferrule. Note: The fitting should be on top of the brake caliper, and the
bleeder on the bottom.
6.5 Insert the end of the Hydraulic Line, 1/8” inside the Hydraulic Fitting Male Elbow AP69P22. Slide the retainer nut along the Hydraulic Line
moving with it the ferrule. Thread the retainer nut onto the Hydraulic Fitting threads. Tighten down until snug.
6.6 Secure the Hydraulic Line, 1/8” to the Gear Leg and also inside to the Bulkhead with Plastic Tie Wraps (#7310-020).
6.7 Repeat to the other side.

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 Section 21, Brake Line Installation, SeaRey, LSA

Brake
Caliper

Hydraulic
Line

Brake Hydraulic
Cylinder Line

Bleeder
Bleeder Nipple
Nipple

Figure 7. Pressurizing the Brakes with Brake Fluid

Note: Use only MIL-H-5606 Brake Fluid or Equivalent (Aero Shell 41)

7.1 Make sure the Parking Brake Valve (#3240-081) is in the Open position.
7.2 Using a vacuum type brake fluid bleeding system, attach a clear rubber tube over the Bleeder Nipple on the bottom of the Brake Cylinder, and
place the tube into a container of Brake Fluid 5606.
7.3 Using a 1/4” open wrench, open the Bleeder Nipple on the Brake Cylinder about a quarter to half-a-turn. Now place the rubber suction cup from
the vacuum pump over the hole on top of the remote brake fluid reservoir. Squeeze the handle of the vacuum pump a few times to add vacuum
to the brake system. Watch the brake fluid flow through the lines to the fitting of the brake caliper, then to the Tee Fitting, to the parking
brake valve, to the master cylinder, then to the remote reservoir. Continue applying vacuum until all air bubbles are gone.
7.4 Note: It is possible to do step 6.3 to both pilot and copilot side at the same time. Do step 6.2 to both sides.
7.5 Note: To get all of the air out of the system, the master cylinder should be mounted to a length of aluminum pipe, so it can be
moved and tilted around to make sure all the air comes out. The parking brake valve should be loose too. It may have to be
moved around to get any trapped air out.

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 Section 21, Brake Line Installation, SeaRey, LSA
7.6 Note: Keep an eye on the fluid level in the reservoir to make sure that it doesn’t get too high that it get sucked up into the
vacuum pump. Also keep an eye on the level of fluid in the containers for each caliper. If the fluid is too low, air may be sucked
into the system.
7.7 Once you are sure that all the air had been removed from the system, tighten the bleeder valves on the brake calipers, then remove the
vacuum from the system.
7.8 Squeeze the brake lever a few times and check for firmness in the handle and for any air that may be trapped in the master cylinder, of any other
component. Note: Some trapped air in the master cylinder may be sucked out by the vacuum pump without opening the bleeder valves. Try to
roll the plane and see if it rolls freely, and then apply the brakes to see if it stops. Test the parking brakes.

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