Illustred Part Brake assemblyAP-766

EMAIL: dvalencia@arkas.com.
co
COMPONENT
MAINTENANCE
MANUAL
with
ILLUSTRATED
PARTS LIST
AP--766
BRAKE
ASSEMBLY
Part No. 5012609
Used on
AI(R)
ATR42 Series 300, 400 and 500
Aircraft
ARKAS S.A.
CO: 5668
32--43--14
CO: 5668 ARKAS S.A. EMAIL: dvalencia@arkas.com.co
EMAIL: dvalencia@arkas.com.co
COMPONENT MAINTENANCE MANUAL
BRAKE ASSEMBLY 5012609
TO: HOLDERS OF AP--766 (32--43--14) COMPONENT MAINTENANCE MANUAL WITH

ILLUSTRATED PARTS LIST FOR BRAKE ASSEMBLY 5012609 USED ON THE ATR42--300,
ATR42--400 AND ATR42--500 AIRCRAFT.
Attached to this transmittal letter is Revision No. 2 of AP--766 (basic issue dated 27 August
1996).
REVISION NO. 2 DATED 27 SEPTEMBER 2004
HIGHLIGHTS
REVISION NO. 2 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. 2 is to incorporate Temporary Revisions No. 3 through No. 7, and Service
Bulletins ATR42--500--32--4 and 32--5.
All NAS 1611--type preformed packings were deleted and replaced with ABP--002--type preformed
packings per Service Bulletin GS2001--4.
Expander Plugs were added for Housing 5012982--1 with a pin plug repair in REPAIR No.4.
The manual was restructured and reworded per the requirements for Simplified English.
Please retain all previous HIGHLIGHTS pages inserting them into this manual for future reference.
Chapter/Section/Page No. Description of Change

(32--43--14)
Title Page Revised to current revision number and date.
Record of Revisions, Added Revision No. 2.

page 1
Record of Temporary Revisions, Added Temporary Revision Nos. 32--3 through 7.

page 1
Service Bulletin List, Revised to indicate currently Service Bulletins included and added
page 1 Service Bulletins 32--4 and --32--5.
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.

pages 1 through 5
Introduction, Revised to latest Introduction and current field office address list.
pages 1 through 4
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All pages as applies Changed MIL--G--81322 to MIL--PRF--81322,

changed MIL--T--83483 to MIL--PRF--83483,
changed MIL--C--85285 to MIL--PRF--85285
changed MIL--P--23377 to MIL--PRF--23377,
added SAE AMS 2473 to MIL--C--5541,
changed “bars” to “bar” and reduced to one decimal below “1”.
Updated vendor address information and made editorial changes
per the requirement for Simplified English (no changes in content).
page 6 Described improvement in terminal slots design.
page 101 Updated the Materials paragraph.
pages 103 and 104 In paragraph 3.B.(4) the torque for bleeder valve was
120 pound--inches (13,6 N--m).
Revised pressure in paragraphs 3.C. and D. and Figure 102.
page 105 In paragraph 3.E.(3) removed swage tube “(170 or)” from
(170 or 170A) per Temporary Revision No. 32--3.
Changed pressure requirements in paragraphs 3.F. and G.
page 106 In paragraph 3.K.(2) changed preformed packing to 330B.
pages 107 and 108 In paragraph 4.A.(2)(b) revised pressure requirement.

Revised paragraph 4.A.(2)(c), 11,4 liter was 11,36 liter.
page 113 Revised the Hardness Checks per Temporary Revision No. 5.
page 301 Updated the Materials paragraph.
page 302 Modified paragraph D.(6)(b) to state replacement with swage tube
(170A) only. Temporary Revision No. 32--3 was not correct in
instruction.
page 303 In paragraph 3.E.(3) inserted disassembly instructions if stressed

retaining ring (240) was found and has to be replaced.
Added items 330B, 360B, 410B, 430B and 460A where applies.
page 401 Updated supplier addresses, fax and phone numbers, added
ASTM D235 to P--D--680 in paragraph 1.
ARKAS S.A.
page 402 Revised conversion of 15 psi in caution note.
Highlights
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page 403 In paragraph 2.A. and 2.A.(3) revised conversion of 15 psi.

In paragraph 2.A.(1) updated dry--cleaning solvent specification.
In paragraph 2.C. revised the note.
Page 404 Revised warning note to paragraph 3.

Added note referring to AP--842 in place of paint removal
procedures.
page 504 Revised the keyslot width per Temporary Revision No. 6.
page 507 Revised all of paragraph 7.F. since the SK--type expander plug and
pin plug repair was added.
page 511 Added note to paragraph 11.A. to replace retaining ring at each
overhaul (Service Bulletin 32--5).
page 513 Revised paragraph 18. for new preformed packings 330B, 360B,
410B and 430B.
page 514 Added item 460A.
pages 601 to 603 Updated suppliers addresses, phone and fax numbers.
page 603 Corrected fluid specification.
page 605 In paragraph 4.A.(1) rounded off metric drill size.
page 606 In paragraph 4.D. rounded off metric conversion.

In paragraph 4.E. changed references to paragraph numbers.
page 609 Revised paragraph 5. for application to new rotating disks 50A.
In paragraph 5.A.(5) Added Caution note and modified text to
remove kidney shaped rotating disk from paint requirements.
Added paragraph 5.B. for identification of brakes with disks that
have new anchor or kidney shaped relief terminal slots.
page 610 Moved rotating disk with anchor shaped terminal hole to new
Figure 605
page 612 Added Figures 605 and 606, all subsequent figures will move up in
count accordingly.
ARKAS S.A.
Highlights
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32--43--14 Sep 27/04

(32--43--14)
page 613 Added note to paragraph 6.C.

In paragraph 6.C.(5) added paint requirements.
In paragraph 6D. added note for identification of brakes with disks
that have new anchor or kidney shaped relief terminal slots.
page 615 Expanded Figure 608 to include the kidney shaped stationary disk.
Page 616 In paragraph 6.E. added “...as given in paragraph 7.H.”
page 617 In paragraphs 6.I., 7.A.,7B. and 7C. changed references to

paragraph numbers.
Changed square inch into inch2 and square cm into mm2,
dimension 0.050 inch corrected to be (1,25 mm).
page 619 Rewrote all square inch and square mm dimensions to read inch2
or mm2.
page 620 In paragraph 7.G. added reference to paragraph 7.H.
page 622 In paragraph 7.J. changed coating to Rust Veto because previously
noted coating is obsolete.
In paragraphs 7.L. and *.A. changed reference to paragraph
number.
Added “...as given in paragraph 7.”
page 623 Changed to new chemical film specification.
page 625 Made minor editorial corrections.
page 626 In paragraph 9.C. added reference to Repair No. 4.

Modified paragraph 9.E. to refer to the approved Repair sections.
page 629 Updated chemical film solution specification.
page 631 Updated paragraph 15. for Acrylic Topcoat to High Solids
Polyurethane Topcoat per Specification MIL--PRF--85285.
Updated specification for chemical film solution in
paragraph 15.B.(2).
page 632 Notes 1 was revised for application of topcoat only.

ARKAS S.A.
Highlights
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(32--43--14)
page 633 Paragraph 15.C.(3) updated chemical film solution

specification and revised caution note.
Paragraph 15.D.(1) updated chemical film solution specification.
Changed thinning and total paint thickness to conform with
General Service Letter GS--SL--46.
Added Repairs 2 and 3 to Table.
page 634 Paragraph 15.D.(2) updated chemical film solution specification.

Added note to paragraph E.(1)(a) and added paragraph (b).
page 635 In paragraph 15.E.(3)(c) corrected the paint thickness

requirement.
Corrected title of Repair No.1.
Added Repair No’s 2 through 4
page 601 to 603, Repair 1 Added not to paragraph 1.A.

Revised chemical film solution specification as required.
page 601 to 604, Repair 2 Added Repair No. 2, Bleeder Valve Hole Repair.
page 601 and 602, Repair 3 Added Repair No. 3, Self--Locking Insert Repair per
Temporary Revision No. 32--4.
page 601 to 603, Repair 4 Added Repair No. 4, Passage Expander Plug Repair.
page 701 In paragraph 1. corrected supplier addresses, etc.

and material specifications.
page 702 In paragraph 2.D. updated the lubtork specification.
page 703 Changed protective cap to 460A.
pages 704 and 705 Changed to brake piston subassembly per

Temporary Revision No.7 and updated to preformed
packings 330B, 360B, 410B and 430B.
page 706 Added caution note, to replace retaining ring if old part
showed signs of stress.
Revised paragraph 3.D. and removed swage tube “(170 or)”
from (170 or 170A) per Temporary Revision No. 32--3.
ARKAS S.A.
Highlights
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32--43--14 Sep 27/04

(32--43--14)
page 708 Updated antiseize compound specification.
page 710 Added caution note about over--torqued bolts.
pages 802 and 803 Changed the key slot width per Temporary Revision No. 6
and changed dimension for item 150 to “minimum”.
page 902 Added Insert Removal Tool, Drive Wrench and Swage Tool.
Corrected ABSC phone numbers.
Added phone numbers to riveter suppliers.
Added tool P--102L for removal and installation of item 240
and expander plug installation tool.
page 1001 Added new introduction to Illustrated Parts List.
pages 1002 and 1003 Added paragraph C.

Updated vendor addresses.
pages 1005 and 1006 Updated to new key slots and changes in parts list items
50A, 60A, 90A, 170A, 260, 270, 280 and 460A.
page 1007 Added full part number to items 10, 70 and 110.
Added code reference to items 50, 60 and 90.
page 1008 Deleted item 170 per Temporary Revision 32--3.

Moved Retaining Ring, item 260 changed to be item 280,
previous item 270 changed to be item 260,
added full part number to items 200 and 240.
page 1009 Previous items 280 and 280A changed to be items 270 and 270A
previous item 260, now is item 280, added full part number.
Marked item 310 and 320 as not procurable per Temporary Revi-
sion No.7.
Deleted item 330A, added item 330B
Deleted item 360A, Added item 360B.
page 1010 Deleted item 410A, Added item 410B

Deleted item 430A, Added item 430B.
ARKAS S.A.
Deleted item 460 and added item 460A.
Highlights
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32--43--14 Sep 27/04

(32--43--14)
page 1011 Added full part number to item 510.

Removed reference to ATR42--500--32--1 from item 530.
Corrected part number for item 580 and added item 585
per Temporary Revision 32--4.
Added notes where used to items 590 and 610.
page 1012 Added item 610A.

Added item 615 for Repair No. 4.
Added items 620 and 630 for Repair No. 2.
ARKAS S.A.
Highlights
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Highlights
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32--43--14 Sep 27/04
AP--766
WITH
ILLUSTRATED PARTS LIST
FOR
BRAKE ASSEMBLY
PART NO. 5012609
USED ON
AI(R)
ATR42
SERIES 300, 400 AND 500
AIRCRAFT
ARKAS S.A.
BASIC ISSUE AUG 27, 1996

REVISION 2
© ABSC 2004 ALL RIGHTS RESERVED

PUBLICATIONS DEPARTMENT
AKRON, OHIO 44306--4186 32--43--14 Sep 27/04
CO: 5668
CAGE CODE 0B9R9 (RELEASED: 9/27/04 )

RECORD OF REVISIONS
DATE DATE
REV ISSUE PUT INTO REV ISSUE PUT INTO
NO. DATE MANUAL BY NO. DATE MANUAL BY
1 Aug 10/98 Aug 10/98 ABSC
2 Sep 27/04 Sep 27/04 ABSC
ARKAS S.A.
Record of Revisions
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Page 1
32--43--14 Sep 27/04
THIS PAGE
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BLANK
ARKAS S.A.
CO: 5668
Record of Revisions
Page 2
32--43--14 Sep 27/04
TEMPORARY REVISION NO. 32--8
TO: HOLDERS OF AP-766 (32-43--14) COMPONENT MAINTENANCE MANUAL WITH

ILLUSTRATED PARTS LIST FOR BRAKE ASSEMBLY 5012609 USED ON AI(R) ATR42--300,
ATR42--400 AND ATR42--500 AIRCRAFT.
PURPOSE: This Temporary Revision adds instructions on how to flip the heat stack over at half life
if R1 is worn too much on the pressure plate side, and it corrects the torque value for the bleeder valve
adapter.
FILING INSTRUCTIONS: This Temporary Revision supplements the contents of the last revision
of the Component Maintenance Manual specified and, if present, any previous Temporary Revision(s)
that are recorded in the RECORD OF TEMPORARY REVISIONS. Record applicable data on the
RECORD OF TEMPORARY REVISIONS sheet in front of the manual, insert page 1 facing the
RECORD OF TEMPORARY REVISIONS, and insert the pages of this Temporary Revision as given
in the filing instruction on each page.
Retain this Temporary Revision and any previous Temporary Revision(s) pages, except when specified
differently in the filing instruction on each page, until the next manual revision incorporates the
information from this and all previous Temporary Revision(s) into the Component Maintenance Manual.
This Temporary Revision affects page(s) 704, 709, 710 and 801 (32-43--14).
RECORD OF TEMPORARY REVISIONS
TEMPORARY PAGE ISSUE BY DATE BY

REVISION NUMBER NUMBER DATE REMOVED
32--8 1 thru 6 Apr 11/05 ABSC
ARKAS S.A.
Record of Temporary Revisions

CO: 5668
(RELEASED: 4/11/05 )
© ABSC 2005 ALL RIGHTS RESERVED
32--43--14 Page 1 of 6
Apr 11/05
RECORD OF TEMPORARY REVISIONS
TEMPORARY PAGE ISSUE DATE

REVISION NUMBER NUMBER DATE BY REMOVED BY
32--1 1 through 7 Jan 22/97 ABSC Aug 10/98 ABSC
32--2 1 through 8 Jan 05/98 ABSC Aug 10/98 ABSC
32--3 1 through 7 Jul 08/99 ABSC Sep 27/04 ABSC
32--4 1 through 6 Apr 30/00 ABSC Sep 27/04 ABSC
32--5 1 and 2 Mar 15/01 ABSC Sep 27/04 ABSC
32--6 1 through 4 Nov 13/01 ABSC Sep 27/04 ABSC
32--7 1 through 4 Mar 15/04 ABSC Sep 27/04 ABSC
ARKAS S.A.

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32--43--14
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Sep 27/04
SERVICE BULLETIN/SERVICE LETTER LIST
DATE
SERVICE BULLETIN SERVICE LETTER REV PUT INTO
NUMBER NUMBER NO. MANUAL DESCRIPTION
ATR42--500--32--1 Aug 27/96 Introduction of Spring Holder
Subassembly 5013266 to Replace
5012660
ATR42--500--32--2 Aug 10/98 Paint Application for Relief Slot
Terminal Holes on Rotating and
Stationary Disk Cores
ATR42--500--32--3 Aug 10/98 Paint Application for Relief Slot
Terminal Holes on Rotating and
Stationary Anchor Slot Disk
ATR42--500--32--4 Sep 27/04 Making alternative rotating and
stationary disks with redesigned
terminal relief slot holes primary
replacement parts.
ATR42--500--32--5 Sep 27/04 Instructing operators to replace the

external snap ring
P/N 7200--66STZD at every
overhaul.
ATR42--32--40--27 5 Sep 27/04 No effect.
ARKAS S.A.
Service Bulletin/Letter List

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Service Bulletin Letter List
32--43--14
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Sep 27/04
LIST OF EFFECTIVE PAGES
SUBJECT PAGE DATE SUBJECT PAGE DATE
Title Sep 27/04 Testing and 111 Sep 27/04

Record of 1 Sep 27/04 Fault Isolation, 112 Sep 27/04
Revisions 2 Sep 27/04 continued 113 Sep 27/04
114 Sep 27/04
Record of 1 Sep 27/04
Temporary Revisions 2 Sep 27/04 Disassembly 301 Sep 27/04
302 Sep 27/04
Service 1 Sep 27/04 303 Sep 27/04
Bulletin/Letter List 2 Sep 27/04 304 Sep 27/04
List of 1 Sep 27/04 Cleaning 401 Sep 27/04
Effective Pages 2 Sep 27/04 402 Sep 27/04
Table of 1 Sep 27/04 403 Sep 27/04
Contents 2 Sep 27/04 404 Sep 27/04
3 Sep 27/04 Check 501 Sep 27/04
4 Sep 27/04 502 Sep 27/04
List of Figures 1 Sep 27/04 503 Sep 27/04
2 Sep 27/04 504 Sep 27/04
Introduction 1 Sep 27/04 505 Sep 27/04
2 Sep 27/04 506 Sep 27/04
3 Sep 27/04 507 Sep 27/04
4 Sep 27/04 508 Sep 27/04
509 Sep 27/04
Description 1 Sep 27/04 510 Sep 27/04
and 2 Sep 27/04 511 Sep 27/04
Operation 3 Sep 27/04 512 Sep 27/04
4 Sep 27/04 513 Sep 27/04
5 Sep 27/04 514 Sep 27/04
6 Sep 27/04
7 Sep 27/04 Repair 601 Sep 27/04
8 Sep 27/04 602 Sep 27/04
603 Sep 27/04
Testing and 101 Sep 27/04 604 Sep 27/04
Fault Isolation 102 Sep 27/04 605 Sep 27/04
103 Sep 27/04 606 Sep 27/04
104 Sep 27/04 607 Sep 27/04
105 Sep 27/04 608 Sep 27/04
106 Sep 27/04 609 Sep 27/04
107 Sep 27/04 610 Sep 27/04
108 Sep 27/04 611 Sep 27/04
109 Sep 27/04
110 Sep 27/04
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List of Effective Pages

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LIST OF EFFECTIVE PAGES (CONTINUED)
SUBJECT PAGE DATE SUBJECT PAGE DATE
Repair 612 Sep 27/04 Assembly and 701 Sep 27/04

(Continued) 613 Sep 27/04 Storage 702 Sep 27/04
614 Sep 27/04 703 Sep 27/04
615 Sep 27/04 704 Sep 27/04
616 Sep 27/04 705 Sep 27/04
617 Sep 27/04 706 Sep 27/04
618 Sep 27/04 707 Sep 27/04
619 Sep 27/04 708 Sep 27/04
620 Sep 27/04 709 Sep 27/04
621 Sep 27/04 710 Sep 27/04
622 Sep 27/04 711 Sep 27/04
623 Sep 27/04 712 Sep 27/04
624 Sep 27/04 Fits and 801 Sep 27/04
625 Sep 27/04 Clearances 802 Sep 27/04
635 Sep 27/04 803 Sep 27/04
636 Sep 27/04 804 Sep 27/04
626 Sep 27/04 805 Sep 27/04
627 Sep 27/04 806 Sep 27/04
628 Sep 27/04
629 Sep 27/04 Special Tools, 901 Sep 27/04
630 Sep 27/04 Fixtures and 902 Sep 27/04
631 Sep 27/04 Equipment 903 Sep 27/04
632 Sep 27/04 904 Sep 27/04
633 Sep 27/04 905 Sep 27/04
634 Sep 27/04 906 Sep 27/04
635 Sep 27/04 907 Sep 27/04
636 Sep 27/04 908 Sep 27/04
909 Sep 27/04
Repair No. 1 601 Sep 27/04 910 Sep 27/04
602 Sep 27/04
603 Sep 27/04 Illustrated 1001 Sep 27/04
604 Sep 27/04 Parts List 1002 Sep 27/04
1003 Sep 27/04
Repair No. 2 601 Sep 27/04 1004 Sep 27/04
602 Sep 27/04 1005 Sep 27/04
603 Sep 27/04 1006 Sep 27/04
604 Sep 27/04 1007 Sep 27/04
Repair No. 3 601 Sep 27/04 1008 Sep 27/04
602 Sep 27/04 1009 Sep 27/04
Repair No. 4 601 Sep 27/04 1010 Sep 27/04
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602 Sep 27/04 1011 Sep 27/04

603 Sep 27/04 1012 Sep 27/04
604 Sep 27/04
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Handling Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5. Leading Particulars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6. Change in Disk Terminal Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TESTING AND FAULT ISOLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

1. Test Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2. Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3. Operational Test and Fault Isolation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4. Brake Flushing Procedure (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5. Fluid Sampling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6. Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
7. Hardness Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1. Disassembly Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
2. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
3. Disassembly Procedures for the Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
1. Cleaning Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Procedures to Clean the Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
3. Paint Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1. Check Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
2. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
3. Rotating Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
4. Stationary Disk Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
5. Backplate and Torque Tube Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
6. Pressure Plate Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
7. Brake Housing Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
ARKAS S.A.
8. Cylinder Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508

9. Piston Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
10. Return Spring Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
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TABLE OF CONTENTS (CONTINUED)
SUBJECT PAGE
CHECK (CONT)
11. Retaining Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
12. Spring Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
13. Return Compression Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
14. Straight Headed Return Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
15. Adjuster Swage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
16. Bleeder Valve and Bleeder Valve Hydraulic Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
17. Self--Locking Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
18. Preformed Packings, Backup Retainers, and Wiper Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
19. Bolts and Self--Locking Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
20. Machine Bleeder Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
21. Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
22. Torque Tube Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
23. Protective Storage and Shipping Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Repair Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
3. Straightening Base Plates and Disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
4. Replacing Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
5. Repair of Rotating Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
6. Repair of Stationary Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613
7. Repair of Backplate and Torque Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
8. Repair of Pressure Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 622
9. Repair of Brake Housing Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623
10. Repair of Cylinder Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 628
11. Repair of Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
12. Repair of Spring Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
13. Repair of Return Spring Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
14. Repair of Torque Tube Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631
15. Surface Treatment and Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631
16. Approved Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635
REPAIR NO. 1 -- PASSAGE BALL PLUG REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601

1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. R1--1 -- Repair of Damaged Passage Ball Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
ARKAS S.A.
REPAIR NO. 2 -- BLEEDER VALVE HOLE REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601

1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. R2--1 -- Repair of the Damaged Bleeder Valve Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
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SUBJECT PAGE
REPAIR NO. 3 -- SELF--LOCKING INSERT REPAIR (BTMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601

1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. R3--1 — Repair of Damaged Self--Locking Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
REPAIR NO. 4 -- PASSAGE EXPANDER PLUG REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601

1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. R4--1 -- Repair of Damaged Expander Plug Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
ASSEMBLY AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701

1. Assembly Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
2. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
3. Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
4. Storage Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711
FITS AND CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
SPECIAL TOOLS, FIXTURES AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
ILLUSTRATED PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
2. Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1007
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THIS PAGE
KEPT
BLANK
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LIST OF FIGURES
FIGURE PAGE
Figure 1 Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 101 Test Setup Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Figure 102 Brake Wear Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Figure 103 Fault Isolation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Figure 104 Hardness Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Figure 501 Typical Dishing Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502

Figure 502 Rotating Disk Minimum Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
Figure 503 Wear Pad Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
Figure 504 Backplate Subassembly Wear Pad Thickness Limits . . . . . . . . . . . 505
Figure 505 Backplate and Torque Tube Damage Limits . . . . . . . . . . . . . . . . . . . 506
Figure 506 Cylinder Sleeve Wear and Check Limits . . . . . . . . . . . . . . . . . . . . . . 508
Figure 507 Piston Subassembly Wear and Check Limits . . . . . . . . . . . . . . . . . . 509
Figure 508 Return Spring Housing Damage Limits . . . . . . . . . . . . . . . . . . . . . . . 510
Figure 509 Spring Holder Damage Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
Figure 601 Grinding Rivet Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607

Figure 602 Acceptable Limits for Newly Repadded Subassemblies . . . . . . . . . 608
Figure 603 Rotating Disk Terminal Hole Surface Finish Requirements . . . . . . 610
Figure 604 Relief Slot Terminal Hole Painting -- Rotating Disk . . . . . . . . . . . . . . 611
Figure 605 Painting Instructions, Rotating Disk with Anchor Shaped
Relief Slots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
Figure 606 No Painting of Rotating Disk with Kidney Shaped Relief Slots . . . . 612
Figure 607 Stationary Disk Terminal Hole Surface Finish Requirements . . . . . 614
Figure 608 Relief Slot Terminal Hole Painting -- Stationary Disk . . . . . . . . . . . . 615
Figure 609 Weld Data List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
Figure 610 Stationary Disk Machining after Rivet Hole Welding . . . . . . . . . . . . 616
Figure 611 Torque Tube Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
Figure 612 Backplate Machining after Rivet Hole Welding . . . . . . . . . . . . . . . . . 621
Figure 613 Pressure Plate Machining after Rivet Hole Welding . . . . . . . . . . . . . 623
Figure 614 Brake Housing Repair Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624
Figure 615 Installation of Brake Housing Bushings . . . . . . . . . . . . . . . . . . . . . . . 627
Figure 616 Cylinder Sleeve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 628
Figure 617 Spring Holder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630
ARKAS S.A.
Figure 618 Return Spring Housing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630

Figure 619 Painting Diagram for Housing Subassembly . . . . . . . . . . . . . . . . . . . 632
Figure 620 Approved Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635
List of Figures
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LIST OF FIGURES (CONT)
FIGURE PAGE
Repair No. 1
Figure 601 Passage Ball Plug Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Repair No. 2
Figure 601 Bleeder Valve Hole Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Repair No. 3
Figure 601 Repair of Self--Locking Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Figure 602 Repair Dimensions for Plug Installation . . . . . . . . . . . . . . . . . . . . . . . 602
Repair No. 4
Figure 601 Machining Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Figure 701 Preformed Packing and Packing Retainer Installation . . . . . . . . . . . 705
Figure 702 Assembly of Swage Tube Subassembly . . . . . . . . . . . . . . . . . . . . . . 707
Figure 703 Disk Stack Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710
Figure 801 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 802 Spring Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 803 Wear Tolerance (Replacement Dimension) . . . . . . . . . . . . . . . . . . . . 802
Figure 804 Self--Locking Nut Minimum Locking Values . . . . . . . . . . . . . . . . . . . . 804
Figure 805 Operating Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
Figure 806 Acceptable Limits for Newly Repadded Subassemblies . . . . . . . . . 805
Figure 807 Base Plate and Pressure Plate Grinding Limits . . . . . . . . . . . . . . . . 805
Figure 901 Fabrication Details for Register Plates . . . . . . . . . . . . . . . . . . . . . . . . 904
Figure 902 Special Tools for Use with Compression Riveter . . . . . . . . . . . . . . . 905
Figure 903 Special Tools for Use with Bracker Riveter . . . . . . . . . . . . . . . . . . . . 906
Figure 904 Special Tools for Use with Taumel Riveter . . . . . . . . . . . . . . . . . . . . . 907
Figure 905 Brake Wear Measurement Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908
Figure 906 Spring Compression Tool 2--10890 . . . . . . . . . . . . . . . . . . . . . . . . . . . 908
Figure 907 Cylinder Sleeve Wrench Tool 2--6068 . . . . . . . . . . . . . . . . . . . . . . . . . 909
Figure 908 Staking Tool 2--10240--1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 909
IPL Figure 1 Brake Assembly 5012609 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1005
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INTRODUCTION
This manual is written according to Air Transport Association Specification No. 100 for the overhaul
and/or maintenance of the Aircraft Braking Systems Corporation (ABSC*) assembly(ies) included.
THIS MANUAL IS APPLICABLE ONLY FOR THE OVERHAUL OF THE INCLUDED ABSC
PRODUCT(S) WITH ONLY ABSC 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 ABSC 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 ABSC approved
parts/products and must be obeyed. Any alternative procedures, limits, or materials (if consented to
in writing by ABSC) 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.
Aircraft Braking Systems Corporation represents that the information contained in this manual is
valid only for use with ABSC 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. A dealer, distributor or Customer Support Department can tell the user if this is the most
recent manual. Refer to the attached sheets for the nearest Customer Support location. You may
make direct inquires to the Distributor Representative--Marketing, Aircraft Braking Systems
Corporation, 1204 Massillon Road, Akron, Ohio 44306--4186 or to the Technical Publication
Department on e--mail at techpubs@aircraftbraking.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.
NOTICE
AIRCRAFT BRAKING SYSTEMS CORPORATION (ABSC) ASSUMES NO
CONTRACTUAL, WARRANTY, PRODUCT LIABILITY OR OTHER OBLIGATION
FOR ANY SUBSTITUTION OF OR ALTERATION TO ANY PART CONTAINED IN
ANY ABSC WHEEL OR BRAKE ASSEMBLY INCLUDING ACCESSORIES NOT
ARKAS S.A.
SPECIFICALLY AUTHORIZED BY ABSC OR FOR ANY OVERHAUL OR

MAINTENANCE NOT PERFORMED IN ACCORDANCE WITH ABSC
APPROVED PROCEDURES.
* ABSC is the registered trademark of Aircraft Braking Systems Corporation

Introduction
Page 1
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32--43--14 Sep 27/04

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.
PAINT MATERIALS
Paint material system (paint) requirements have been revised from traditional
materials due to federal, state and local environmental rules. These rules, which
are effective as of September 1, 1998, require the use of topcoats and primers that
meet specified Volatile Organic Compound (VOC) and Hazardous Air Pollutant
(HAP) limits. The current paint material system, used in production, complies with
these new rules and is listed in this manual as the primary repaint material.
Aircraft Braking Systems Corporation (ABSC) assumes no responsibility or liability
for complying with federal, state or local environmental or safety laws and
regulations pertaining to the use of coatings identified in this document or any
alternative coatings. The end user shall assume full responsibility and liability for
ensuring compliance with all applicable environmental laws and regulations, and
shall be solely and exclusively responsible for the safety and health of its
employees when using the coatings identified in this document or any alternative
coatings.
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.
ARKAS S.A.
Introduction
CO: 5668
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32--43--14 Sep 27/04
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 for installation.
Any replacement of or change to any part, manufacturing process or material that

affects or may affect 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).
The use of parts manufactured by sources other than ABSC and not approved by
ABSC in any assembly that has the ABSC name and TSO marking will relieve
ABSC of any warranty obligation relating to the assembly upon which the
unapproved part has been installed and will relieve ABSC 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 Aircraft Braking Systems Corporation, 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 ABSC authorized 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. Aircraft Braking Systems Corporation 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).
ADDITIONAL INFORMATION
For an update on recommended 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.aircraftbraking.com>.
ARKAS S.A.
Introduction
Page 3
CO: 5668
32--43--14 Sep 27/04

AIRCRAFT BRAKING SYSTEMS CORPORATION

CUSTOMER SUPPORT LOCATIONS
California, Los Angeles Kentucky, Hebron
Aircraft Braking Systems Corporation Aircraft Braking Systems Corporation

9552 Caithness Drive P.O.Box 150
Huntington Beach, CA 92646 Hebron, KY 41048
Phone: 714--962--6438 Phone: 859--689--1800

Fax: 714--962--6978 Fax: 859--689--7291
England, London Ohio, Akron (Home Office)

Aircraft Braking Systems Europe, Ltd Aircraft Braking Systems Corporation
683--685 Stirling Road Field Sales and Service Headquarters
Slough, Berkshire, England SL1 4ST 1204 Massillon Road
Akron, Ohio 44306--4186
Phone: 44--1753--696--006
Telex: 846695 ABSEL G Phone: 330--796--4400
Fax: 44--1753--696--012 Fax: 330--796--9805
Customer Service Department

France, Toulouse Aircraft Braking Systems Corporation
1204 Massillon Road
Aircraft Braking Systems Europe, Ltd Manufacturing Maintenance Facility
Centre D’Affaires Partner No. 33121
2 bis rue Marcel Doret Akron, Ohio 44306--4186
31700 Blagnac, France
Oklahoma, Tulsa
Phone: 33--5-- 61--30--9898
33--5--61--30--9862 Aircraft Braking Systems Corporation
Telex: 532463F PARTNER 5103 South Sheridan Road
Fax: 33--5--61--30--9867 Suite 140
Tulsa, Oklahoma 74145--7627
Phone: 918--481--5516
Fax: 918--497--1221
ARKAS S.A.
Introduction
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Page 4
32--43--14 Sep 27/04
DESCRIPTION AND OPERATION
1. General (Refer to Figure 1)
A. The brake assembly is a tri--metallic brake. The brake assembly can be used interchange-
ably for either right or left hand installation.
B. Brakes are designed for use with Phosphate Ester, Type 4, hydraulic fluid and to bleed prop-
erly when mounted with symmetrical centerline of brake 23.7° above groundline reference.
C. An integral torque take--out bushing between inlets of the housing prevents rotating of the
brake on the axle during braking.
2. Description (Refer to Figure 1)
A. Each brake assembly consists of a housing subassembly, an integral backplate/torque tube

subassembly, a torque tube spacer, a pressure plate subassembly, two rotating disks, a sta-
tionary disk subassembly, five cylinder sleeves, five pistons and piston insulators, five self--
adjusting return mechanisms, hydraulic fittings, preformed packings, packing retainers,
bolts, washers, and self--locking nuts.
B. The brake housing subassembly and the backplate and torque tube subassembly are
bolted together as a unit which contains and positions the alternate rotating and stationary
disks. The wear pads are attached to the stationary disk and the pressure plate that is keyed
to the torque tube on the inside diameter to prevent their rotation. Keyslots on the outside
diameter of the two rotating disks engage the drive keys on the wheel and transmit brake
force to the wheel. The wear pads attached to the pressure plate and backplate faces pro-
vide a friction surface for the rotating disks at each end of the disk stack.
C. The forged aluminum alloy brake housing contains one hydraulic system. The system acti-
vates five pistons incorporated into the housing through fluid passages interconnecting the
cylinder cavities. The system has two inlets and two bleeder ports, which permit the brake
to be used interchangeably for either right or left hand installation.
D. Five cylinder sleeves threaded into the brake housing contain the brake pistons. Each cylin-
der sleeve and each piston is sealed against hydraulic fluid leakage with preformed pack-
ings and packing retainers. A wiper ring between the outside diameter of the piston and the
cylinder sleeve inside diameter prevents foreign material from entering between the piston
and cylinder sleeve. An insulator installed on the ends of the pistons prevent heat generated
in the brake from moving to the brake housing.
E. The self--adjusting return mechanisms installed in the brake housing provide brake release
and automatic adjustment of the brake to compensate for wear of the friction surfaces. Five
self--adjusting return mechanisms are installed in openings around the perimeter of the
housing. Each mechanism consists of a return pin, a brake release spring, a swage tube
subassembly, the spring holder, return spring housing, a self--locking nut and a retaining
ARKAS S.A.
ring. The square headed return pin is installed in a slot in the pressure plate subassembly.
The swage tube subassembly, which is installed over the return pin, is held in place by a
self--locking nut.
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DATA PLATE
INSTRUCTION
A DATA PLATE
BLEEDER PORT
INLET WITH
PROTECTIVE PLUG B
B
TORQUE
TAKE--OUT
BUSHING
SOLID PLUG
MACHINE BOLT
SYMMETRICAL
CENTERLINE
BLEEDER PORT OF BRAKE
RETURN MECHANISM
COVER PLATE
SUBASSEMBLY
ARKAS S.A.
Brake Assembly
Figure 1 (Sheet 1 of 3)
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32--43--14 Sep 27/04
BLEEDER VALVE
PRESSURE PLATE
BLEEDER SCREW SUBASSEMBLY
ROTATING DISK
BLEEDER WASHER
STATIONARY DISK
SUBASSEMBLY
PREFORMED
PACKING
BLEEDER
VALVE ADAPTER
PREFORMED PACKING
BACKPLATE
DETAIL C AND TORQUE TUBE
RECESSED WASHER SUBASSEMBLY
SELF--LOCKING NUT TIE BOLT
INBOARD
OUTBOARD
HOUSING BUSHING
HOUSING BUSHING
TORQUE TUBE
SPACER
BRAKE HOUSING
SUBASSEMBLY
DETAIL D
( SELF--ADJUSTING RETURN MECHANISM )
ARKAS S.A.
SECTION A--A
Brake Assembly
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PROTECTIVE PLUG
FITTING REDUCER
PREFORMED PACKING
SECTION B--B
( INLET WITH PROTECTIVE PLUG )
PACKING RETAINER CYLINDER SLEEVE

PREFORMED PACKING
PISTON SUBASSEMBLY
PREFORMED PACKING
PISTON WIPER RING
PACKING RETAINER
DETAIL C
( PISTON AND CYLINDER SLEEVE )
RETAINING RING
SWAGE TUBE SUBASSEMBLY
RETURN PIN
SELF-- LOCKING NUT
SPRING HOLDER RETAINING RING

SPRING
RETURN SPRING HOUSING
ARKAS S.A.
DETAIL D
( SELF--ADJUSTING RETURN MECHANISM )
Brake Assembly
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F. A brake wear determination is made by measurement or with the aid of a locally manufac-
tured brake wear measurement gage. See the TESTING AND FAULT ISOLATION section
and Figure 102 for instructions concerning brake wear indication.
G. The forged steel integral backplate and torque tube subassembly is held to the brake hous-
ing by five bolts, washers, and self--locking nuts with a torque tube spacer. The bolts in-
stalled through the torque tube and into the brake housing transmit the wheel torque from
the torque tube to the housing torque takeout bushing. The backplate for the disk stack is
an integral part of the backplate and torque tube subassembly.
Two bushings in the hub of the brake housing, register on the landing gear axle and position
the brake assembly. Steel wear pads are riveted to the backplate end of the torque tube as
wearing surfaces for the brake rotating disks. Eight keys on the torque tube engage keyslots
in the stationary disk to prevent their rotation and maintain the stationary friction surfaces
for the rotating disks.
H. The brake stack consists of a pressure plate subassembly, located against the brake pis-
tons, two rotating disks and one stationary disk subassembly. Keyslots in the outside diame-
ter of the rotating disks engage the drive keys of the wheel. The sintered wear surface is
on the rotating disk face. Steel wear pads are riveted to the stationary disk, pressure plate,
and backplate section of backplate and torque tube.
I. The brake housing has two bosses for brake temperature monitoring sensors that have an
adjacent attaching feature boss with a threaded self--locking insert. Cover plates have been
provided for use when the brake temperature monitoring sensors are not used. One of the
covers can be removed if a temperature monitoring sensor is installed.
3. Operation (Refer to Figure 1)
A. The brake is operated by hydraulic pressure from the main aircraft hydraulic system, which
uses Phosphate Ester, Type 4 hydraulic fluid. Operation of the brake is initiated by depress-
ing the brake pedals.
B. When brakes are applied hydraulic fluid enters the housing inlet ports and fluid passages
in the housing subassembly to force the five pistons against the pressure plate. Keyslots
on the inside diameter of the pressure plate and stationary disk fit over the keys on the
torque tube and permit the pressure plate and the disks to move toward the backplate por-
tion of the torque tube.
The movement of the pressure plate compresses the rotating and stationary disks between
the pressure plate and the backplate, creating friction between the wearing surfaces of the
disk. The resisting torque caused by friction retards the rotating disks, which are keyed on
their outside diameters to drive keys on the wheel. During the braking process, kinetic ener-
gy is changed to heat in the brake disk stack.
ARKAS S.A.
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C. When the pistons move the pressure plate against the disk stack, the pressure plate pulls
on the return pins. The swage tube subassembly bears against the bottom of the spring
holder, compressing the (return) spring until the bottom of the spring holder contacts the
bottom of the return spring housing. Once the spring holder bottoms, any further movement
of the pressure plate pulls the swage adjuster further into the self--adjusting swage tube.
D. When the brake pressure is released, the (return) spring load against the swage tube sub-
assembly pulls the return pin and pressure plate to the off position. The amount of pressure
plate return is equal to the brake built--in clearance, which is controlled by the distance that
the spring holder is moved by the (return) spring before being stopped by the retaining ring
in the return spring housing.
4. Handling Procedures
A. Careful handling of the brake components will assure a long service life and trouble--free
operation.
B. Strictly observe the torque and Lubtork values specified in this manual. Do not overtighten
any bolt, nut or fitting.
C. Handle all brake parts with extreme care. Many failures can be traced to dropping or mis-
handling the parts during maintenance.
D. The brake housing should be properly maintained to protect the paint surface finishes as
exposed surfaces are susceptible to corrosion. Nicks, scratches and other damage caused
by improper handling of the brake assembly during maintenance invite corrosion, which if
left unattended will eventually lead to fatigue cracks and premature removal from service.
5. Leading Particulars
Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Phosphate Ester, Type 4
Maximum Operating Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000 psi (137,9 bar)
Back Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 psi (3,1 bar)
Operating Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 to 0.050 inch (0,51 to 1,27 mm)
(with 45 psi (3,1 bar) back pressure)
Weight (approximate)
Brake Assembly 5012609 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 pounds (25,1 kg)
Material:
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aluminum Alloy
Torque Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel
Disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aluminum Alloy ARKAS S.A.
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32--43--14 Sep 27/04
6. Change in Disk Terminal Holes
A. ABSC discontinued the manufacture of disks with round terminal holes because of the pos-
sibility that cracks may develop. Use all existing stock of these disks.
B. Improved, previously alternate, rotating and stationary disks at first were made with an-
chor--type slots, then with kidney--type slots. The disks with kidney--type slots will now be
the primary replacement parts. Refer to the REPAIR section in this manual or Service Bulle-
tin ATR42--500--32--4.
C. The part number of Brake Assembly 5012609 was not changed for this improvement.
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THIS PAGE
KEPT
BLANK
ARKAS S.A.
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TESTING AND FAULT ISOLATION
1. Test Equipment and Materials
NOTE: Equivalent replacements can be used for the items given.
Brake Wear Measurement Tool See the SPECIAL TOOLS, FIXTURES

AND EQUIPMENT section Figure 905
Hydraulic Gage, High--Pressure Commercially available

Measures from 0 to 3000 psi
(0 to 206,8 bar)
Hydraulic Gage, Low--Pressure Commercially available
Measures from 0 to 100 psi
(0 to 6,9 bar)
Hydraulic Fluid Commercially available
Phosphate Ester, Type 4
Hydraulic Test Stand Commercially available
Supplies 0 to 3000 psi (0 to 206,8 bar)
pressure gaged to read output pressure to
5 psi (0,3 bar) increments
Grease Commercially available
Specification MIL--PRF--81322
Isopropyl Alcohol Commercially available
Specification TT--I--735
Petroleum Ether Commercially available
Hardness Tester Instron Corporation/Wilson Instruments
Rockwell (B Scale Preferred) 100 Royall Street
Brinell or equivalent Canton, MA 02021
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
Saran or Mylar Film Commercially available
ARKAS S.A.
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Sep 27/04
2. Test Setup
LOW PRESSURE GAGE

GAGE SHUTOFF VALVE
HIGH PRESSURE GAGE
HYDRAULIC
TEST STAND BRAKE ASSEMBLY
0 TO 3000 PSI
(0 TO 20,84 kPa)
INLET *
PHOSPHATE ESTER
TYPE 4
* POSITION ONE INLET AT THE HIGHEST POINT FOR TEST
Test Setup Block Diagram

Figure 101
3. Operational Test and Fault Isolation Procedures (Refer to Figure 101)
NOTE: Do steps A. through H. to determine the exact condition of, or malfunction of, the brake
assembly. Note all variations from established leakage rate limits for future reference
during testing. Do steps l. through O. as required.
WARNING: ♦ KEEP HYDRAULIC FLUID AWAY FROM EYES OR SKIN.

♦ DO NOT BREATHE THE GAS.
♦ OBEY THE INSTRUCTIONS OF THE MANUFACTURER.
♦ REFER TO THE MATERIAL SAFETY DATA SHEET BEFORE HYDRAULIC
FLUID IS USED.
♦ OBEY ALL SAFETY PRECAUTIONS BEFORE THE TESTS ARE DONE.
INJURY TO PERSONS CAN OCCUR IF THESE PRECAUTIONS ARE NOT
OBEYED.
CAUTION: ♦ USE PHOSPHATE ESTER, TYPE 4, HYDRAULIC FLUID IN THE PRESSURE

SOURCE.
ARKAS S.A.
A. Connect the inlet fitting on the brake housing subassembly to a hydraulic pressure source,
or equivalent, containing Phosphate Ester, Type 4, hydraulic fluid.
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32--43--14 Sep 27/04
B. Apply hydraulic pressure and bleed the brake housing as follows:
(1) Remove the bleeder screw (380) and washer (390) at the highest point on the brake
housing.
(2) Connect the end fittings of a flexible hose to the bleeder valve (400 or 400A) and sub-
merge the free end of the flexible hose in a clean container partially filled with Phos-
phate Ester, Type 4, hydraulic fluid.
(3) While bleeding, hold the brake housing perpendicular to the work surface with the
bleeder port at the highest position, simulating the installed position on the aircraft.
CAUTION: ♦ DO NOT LET HYDRAULIC FLUID LEAKAGE GET IN THE BRAKE AS-
SEMBLY.
CAUTION: ♦ GREASE, HYDRAULIC AND/OR CLEANING FLUIDS THAT GET IN THE

BRAKE ASSEMBLY CAN CAUSE FIRE OR DECREASE THE BRAKE
PERFORMANCE.
(4) Unscrew the bleeder valve (400 or 400A) and permit fluid to flow into the container until
all aeration disappears. With fluid still flowing from the brake, close the bleeder valve
and torque to 70 pound--inches (7,9 N--m).
(5) Remove the bleeder hose from the bleeder valve and install the bleeder screw (380)
and washer (390) in the valve and tighten.
(6) Wipe all spilled fluid from the brake housing.
C. Cycle the brake two or three times between 45 and 2000 psi (3,1 and 137,9 bar) pressure.
(1) Examine to see that all pistons and return pins extend and retract evenly and smoothly,
and the pressure plate subassembly (190) moves easily without binding.
(2) Apply 120 + 10 psi (7,3 bar) pressure and do a check that the rotating disks are
clamped.
D. Apply 2000 psi (137,9 bar) pressure and hold for five minutes.
(1) Examine for fluid leaks around the fitting reducer (470), bleeder valve (400 or 400A),
bleeder valve adapter (420), solid plug (440), cylinder sleeves (290), and pistons
(320).
(2) No leakage is permitted around the inlet fitting reducer, bleeder valve, bleeder valve
adapters, or solid plug.
(3) Leakage around the cylinder sleeves and pistons cannot be more than a trace.
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SELF -- ADJUSTING SWAGE TUBE

BRAKE HOUSING SUBASSEMBLY
RETURN PIN
RETAINING RING
BRAKE WEAR
MEASUREMENT
TOOL
RETAINING RING
RETURN SPRING HOUSING

TOP OF THE
SELF--ADJUSTING RETURN SPRING
SWAGE TUBE
SPRING HOLDER
NOTES:
1. APPLY A BRAKE PRESSURE OF 2000 PSI (137,9 BAR) WHEN BRAKE WEAR
MEASUREMENTS ARE MADE.
ARKAS S.A.
2 REMOVE THE BRAKE FOR OVERHAUL WHEN GAGE BECOMES FLUSH WITH THE
TOP OF THE SELF -- ADJUSTING SWAGE TUBE (BRAKE ON).
3 VIEW NOT TO SCALE.
Brake Wear Indication

Figure 102
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32--43--14 Sep 27/04
E. Determine brake wear as follows (Refer to Figure 102).
(1) Apply brake pressure of 2000 psi (137,9 bar) when brake wear measurements are
made.
(2) Use the brake wear measurement tool (Go--No--Go gage), as shown in Figure 905,
to measure the brake wear as shown in Figure 102 or measure the distance from the
return pin to the top of the swage tube. The maximum depth of the recess is 0.10 inch
(2,52 mm).
NOTE: The brake wear measurement tool can be made as shown in Figure 905.
(3) If the brake wear measurement gage becomes flush with the self--adjusting swage
tube (170A) before touching the return pin (180), remove the brake for overhaul and
replace the disk stack components as necessary.
NOTE: Make sure the disk stack components are examined as told in the CHECK
section.
F. Decrease the pressure to 30 psi (2,1 bar) and inspect for minimum clearance between the
pressure plate subassembly (190) and the friction surfaces of first rotating disk.
(1) Minimum clearance for a brake with new disks is 0.030 to 0.050 inch (0,76 to 1,27 mm);
(2) For a brake containing used disks, the clearance can be as low as 0.010 inch
(0,254 mm).
(3) Clearance to be even all the way around the pressure plate.
G. Decrease the pressure to 5 to 10 psi (0,3 to 0,7 bar) and hold for five minutes.
(1) Examine for fluid leaks around the inlet fitting reducer, bleeder valve, bleeder valve
adapter, solid plug, and around the pistons.
(2) No leakage is permitted.
H. Decrease the hydraulic pressure to zero.
I. lf leakage occurred around inlet fitting reducer, bleeder valve or bleeder valve adapter, do
as follows:
(1) Do a check of the torque on fitting reducer (470), bleeder valve (400 or 400A), bleeder
valve adapter (420), or solid plug (440).
(2) Tighten the fitting reducer (470) to a torque of 30 pound--feet (41 N--m), bleeder valve
(400 or 400A) to 70 pound--inches (7,9 N--m), bleeder valve adapter (420) to
70 pound--inches (7,9 N--m), and solid plug (440) to 30 pound--feet (41 N--m).
ARKAS S.A.
(3) If leakage continues after a torque check, replace the preformed packings and retest
the housing subassembly.
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Sep 27/04
CAUTION: ♦ REPLACE ALL OF THE PISTONS AND PREFORMED PACKINGS IF LEAKS

OCCUR AROUND TWO OR MORE PISTONS.
J. If leakage limits around piston were above the limits, or if pistons (320) did not extend and
retract evenly and smoothly during the test, disconnect the pressure source and remove
the housing subassembly as told in the DISASSEMBLY section.
(1) Remove leaking pistons (320) and inspect the outside diameter of pistons and inside
diameter of cylinder sleeves (290) as told in the CHECK section.
(2) Inspect for, and remove, obstructions in the fluid passages in the brake housing subas-
sembly (530 or 530A).
(3) Replace pistons and cylinder sleeves worn beyond the limits given in the FITS AND
CLEARANCES section
(4) Install new preformed packings (360 or 360A) and packing retainers (370) on the pis-
ton and reassemble the brake assembly as told in the ASSEMBLY AND STORAGE
section.
(5) Retest for leaks.
K. lf leakage occurred around the cylinder sleeves (290), do as follows:
(1) Remove the cylinder sleeve as told in the DISASSEMBLY section.
(2) Replace the preformed packing (330B) and packing retainers (340) on cylinder
sleeve.
(3) Reassemble the brake assembly as told in the ASSEMBLY AND STORAGE section.
(4) Retest for leaks.
L. When the end of a return pin (180) is level with the gage (Refer to Figure 102), remove the
brake for a complete overhaul.
NOTE: New swage tube subassemblies (150) must be installed if new disks are installed
in the disk stack.
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M. If the pressure plate subassembly (190) did not move smoothly during brake cycling and
if the rotating disks (50 or 50A) or stationary disk subassembly (60 or 60A) did not move
freely on the torque tube section, do as follows:
(1) Remove the backplate and torque tube subassembly and disk stack as told in the DIS-
ASSEMBLY section.
(2) Make sure the subassemblies are flat within 0.015 inch (0,38 mm) and that the station-
ary disk fits freely on torque tube keys.
(3) Examine the torque tube for damage to keys (refer to the FITS AND CLEARANCES
section for limits).
(4) If the backplate and torque tube subassembly is damaged, or if disks do not move free-
ly on keys, replace the subassemblies and reassemble the brake as told in the AS-
SEMBLY AND STORAGE section.
N. lf the pressure plate subassembly (190) did not extend and retract fully during brake cycling,
remove the swage tube subassembly (150) and spring (260) as told in the DISASSEMBLY
section.
(1) Replace each swage tube subassembly (150).
(2) Inspect the spring (260) as given in the CHECK section.
(3) Replace the parts and reassemble as told in the ASSEMBLY AND STORAGE section.
O. Brakes bled and tested can be stored full of hydraulic fluid to minimize brake bleeding on
the aircraft.
4. 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.
(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
ARKAS S.A.
15 to 25 21,000
5 to 15 87,000
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(2) Flushing procedure for brakes:

(a) Connect the hydraulic systems of the brake assembly to a hydraulic system con-
taining hydraulic fluid with a cleanliness level of 10 percent of the above require-
ments and a capability of furnishing a minimum pressure of 100 psi (6,9 bar).
(b) While flushing, the brake assembly should be held 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 psi (6,9 bar) pressure to the brake assembly and preflush brakes for
20 seconds. Then cycle the brake two or three times by closing and opening the
bleeder port. (This will require approximately 10 to 12 quarts (9,5 to 11,4 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 move-
ment must cause pressure plate to contact the disk stack during each cycle.
(e) Turn fluid flow off, open the bleeder ports, and allow the brake to drip drain.
(f) Open the supply line and flush the brake for three minutes.
(g) Close the supply line and drip drain the brake assembly.
5. Fluid Sampling Procedure
A. Fluid sample bottles should be wide mouth, screw top, and have a capacity of 100 milliliters.
B. Before using the sample bottles, they should be cleaned as follows:
(1) Wash thoroughly in a solution of detergent and hot water, and rinse twice in hot distilled
water.
(2) Rinse twice in filtered distilled water.
(3) Rinse the sample bottles with isopropyl alcohol to remove the residual rinse water.
(4) A final rinse of filtered petroleum ether or fluorinated solvent is desirable.
(5) Because of the danger of contaminating the bottle with particles from the screw cap,
place a small square, which has been thoroughly rinsed with filtered solvent, of saran
or mylar film over the mouth of the sample bottle before replacing the cap.
C. The following procedure should be used for taking the control sample of fluid:
(1) Care must be taken to eliminate touching the rim of the bottle with the flushing hose.
(2) Place saran or mylar film over bottle opening and cap.
(3) Identify the sample with the brake assembly and serial number.
(4) Send the sample to the laboratory for a Micron Particle Check.
ARKAS S.A.
NOTE: Take a sample from one brake in each group of ten to do a check for contam-
ination.
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6. Fault Isolation
A. Use the Fault Isolation Chart in NO TAG to isolate the cause of faults found when the opera-
tional tests were done. If a brake assembly is not within the necessary limits or does not
operate correctly, refer to the applicable “Trouble” in the Fault Isolation Chart. This chart
gives the possible causes and corrective procedures for brake faults.
Refer to the DISASSEMBLY, ASSEMBLY AND STORAGE or REPAIR section for replace-
ment of parts. Parts must be clean before they are examined. After the brake assembly is
repaired, do the test again.
Trouble Probable Cause Correction

Hydraulic fluid leaks Defective hydraulic connec- Tighten the connection.
around bleeder valves, tion
cylinder sleeves, pistons
or expander plugs
Replace the fitting.
Defective packing, preformed Replace the packings, preformed
packing, backup ring or packings, backup rings and retainers
retainer where necessary. (If leakage occurs
around two or more pistons or cylin-
der sleeves, replace all packings and
backup rings or retainers on all cylin-
der sleeves and pistons.)
Defective bleeder valve Tighten the bleeder valve to the ap-
plicable torque value. See the FITS
AND CLEARANCES section.
If the bleeder valve hole has been re-
paired, tighten the bushing or insert
to the necessary torque value. See
the FITS AND CLEARANCES sec-
tion.
Examine the repair bushing or insert
as told in the CHECK section. Re-
place any damaged bushing or in-
sert.
Examine the bleeder valve as told in
the CHECK section. Replace any
damaged bleeder valve.
Fault Isolation Chart

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Sep 27/04

Hydraulic fluid leaks Defective bleeder valve Examine the bleeder valve hole in
around bleeder valves, (continued) the brake housing. Repair the dam-
cylinder sleeves, pistons aged bleeder valve hole as told in the
or expander plugs REPAIR section. If the brake housing
(continued) cannot be repaired within the appli-
cable limits, replace the brake hous-
ing.
Defective expander plugs Replace the expander plugs as told
in the REPAIR section. If leakage
from the expander plug continues af-
ter repair, replace the brake housing.
Damaged or worn pistons Measure the outside diameter of the
piston as told in the CHECK section.
Repair the piston as told in the RE-
PAIR section. Replace any pistons
worn more than the limits given in the
FITS AND CLEARANCES section.
Damaged or worn cylinder Measure the inside diameter of the
sleeves cylinder sleeve as told in the CHECK
section. Repair the cylinder sleeve
as told in the REPAIR section. Re-
place any cylinder sleeves worn
more than the limits given in the FITS
Examine the cylinder sleeve cavity in
the brake housing as told in the
CHECK section. Repair the cylinder
sleeve cavity as told in the REPAIR
section. If the brake housing cannot
be repaired within the applicable lim-
its, replace the brake housing.
Clearance dimension is Blockage in the hydraulic line Remove the blockage.
smaller than the speci- or fluid passage
fied limit or the brake
does not release correct-
ly

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32--43--14 Sep 27/04

Clearance dimension is Defective compression spring Examine the compression spring as
smaller than the speci- told in the CHECK section. Replace
fied limit or the brake any damaged spring or any spring
does not release correct- that has a compression force that is
ly not within the limits given in the FITS
(continued) AND CLEARANCES section.
Worn adjuster swage Examine the adjuster swage as told
in the CHECK section. Replace if
worn or damaged.
Worn or damaged pistons or Measure the outside diameter of the
pistons that do not move freely piston as told in the CHECK section.
Damaged torque tube Examine the torque tube as told in
the CHECK section. Repair the
torque tube as told in the REPAIR
section. If the torque tube cannot be
repaired within the applicable limits,
replace the torque tube.
Pressure plate, rotating disk Examine the part as told in the
subassembly or stationary CHECK section. Repair the part as
disk subassembly does not told in the REPAIR section. Replace
move freely on the torque tube any defective part.

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Sep 27/04

Clearance dimension is Retainer ring for the spring Visually examine the piston to see if
smaller than the speci- holder is not there the retainer ring is installed. Replace
fied limit or the brake the retainer ring if it is not there. Refer
does not release correct- to the REPAIR section.
ly
(continued)
Brake does not engage Blockage in the hydraulic line Remove the blockage.
correctly or fluid passage
Worn or damaged pistons or Measure the outside diameter of the
pistons that do not move freely piston as told in the CHECK section.
Damaged torque tube Examine the torque tube as told in
the CHECK section. Repair the
torque tube as told in the REPAIR
section. If the torque tube cannot be
repaired within the applicable limits,
replace the torque tube.
Pressure plate, rotating disk Examine the part as told in the
subassembly or stationary CHECK section. Repair the part as
disk subassembly does not told in the REPAIR section. Replace
move freely on torque tube any defective part.

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32--43--14 Sep 27/04
7. Hardness Check
A. Components of the brake assembly that are suspected of having been overheated after go-
ing through a rejected takeoff or equivalent high energy input can be tested for hardness
in accordance with Figure 104.
Take at least four hardness readings for each part in order to get a representative reading.
Replace the part if the average of the readings is below the acceptance hardness. All hard-
ness readings should be taken in an area free from paint.
PART NAME HARDNESS

(REFER TO TEST MINIMUM PENETRATOR LOAD CHECK
IPL FIGURE 1) HARDNESS LOCATION
Backplate (130) Rockwell C 32 120° Cone 150 kg Between rivet
hole counter-
bore
Torque Tube Rockwell C 40 120° Cone 150 kg Sides of keys
(130)
Brake Housing Brinell 110 10 mm dia ball 500 kg Flat adjacent
(540 or 540A) to cylinder
bores
Pressure Plate Rockwell C 30 120° Cone 150 kg 0.25 inch
(Base Plate) (6,35 mm)
(220) from sides of
keyslots
Stationary Disk Rockwell B 86 1/16 inch ball 100 kg 0.25 inch
(90 or 90A) (6,35 mm)
(Core) from sides of
keyslots
Rotating Disk Rockwell B 86 1/16 inch ball 100 kg 0.25 inch
(50 or 50A) (6,35 mm)
(Core) from sides of
keyslots
NOTE: At least four hardness readings must be taken for each part in order to get a representa-
tive reading. If the average of the readings is below the minimum hardness, the part
must be replaced. Take all measurements in an area free from paint.
Hardness Checks
Figure 104
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32--43--14 Sep 27/04
DISASSEMBLY
1. Disassembly Equipment and Materials
MATERIAL* POSSIBLE SOURCE⊕
Arbor Press J S J Corporation/Dake Corporation

Capacity: 1000 pound (453 kg) minimum 724 Robbins Road
Grand Haven, MI 49417
Ph: 800--937--3253
Fax: 800--846--3253
Retaining Ring Installation/Removal Tool, See the SPECIAL TOOLS, FIXTURES AND
No. P--102L EQUIPMENT section
Compression Spring Tool See the SPECIAL TOOLS, FIXTURES AND
EQUIPMENT section
Cylinder Sleeve Wrench 2--6068 See the SPECIAL TOOLS, FIXTURES AND
EQUIPMENT section
Sockets/Wrenches See the FITS AND CLEARANCES section
(General use)
* Equivalent replacements can be used for the items given.
⊕ Other sources could be available.
2. General (See Figure 1 and IPL Figure 1)
CAUTION: ♦ BE CAREFUL WITH ALL PARTS AND KEEP ALL PARTS CLEAN.
♦ IF THE BRAKE ASSEMBLY IS NOT ASSEMBLED IN LESS THAN 24 HOURS,

THE PROTECTION OF ALL PARTS AGAINST CORROSION AND DAMAGE IS
MANDATORY.
♦ DO NOT USE POWER WRENCHES TO REMOVE ANY PARTS THAT HAVE

THREADS FROM MATERIAL THAT IS NOT FERROUS AND HAS THREADS.
♦ THE USE OF POWER WRENCHES TO REMOVE FERROUS BOLTS, NUTS

OR SCREWS FROM FERROUS MATERIALS WILL DECREASE THE LIFE OF
THE BOLTS, NUTS OR SCREWS.
A. Disassemble the brake assembly to do the necessary maintenance procedures found in the
TESTING AND FAULT ISOLATION section. Disassemble the brake assembly as told in the
procedures given.
B. DO NOT use power wrenches to disassemble or assemble the brake assembly or its com-
ponents.
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3. Disassembly Procedures for the Brake Assembly

A. Put the brake assembly on a clean, flat surface with the backplate and torque tube subas-
sembly (100) down.
CAUTION: ♦ REPLACE BOTH THE NUT AND BOLT IF THE NUT OR THE BOLT IS TIGHT-
ENED TO MORE THAN 110 PERCENT OF THE RECOMMENDED TORQUE
VALUE.
B. Remove five self--locking nuts (10), recessed washers (20), and tie bolts (30); then, lift the
brake housing subassembly (530 or 530A) and pressure plate subassembly (190) off the
disk stack as a unit.
C. Remove the torque tube spacer (40), the two rotating disks (50 or 50A), and stationary disk
subassembly (60 or 60A) from the backplate and torque tube subassembly(100).
D. Put the brake housing subassembly (530 or 530A) on a clean, flat surface with the pressure
plate subassembly (190) down and remove the spring return mechanism as follows:
(1) Remove the self--locking nut (140) from the spring return mechanism.
(2) Remove the swage tube subassembly (150) from the return pins (180).
(3) Lift the brake housing subassembly (530 or 530A) off of the pressure plate subassem-
bly (190) and put it on clean surface with the pistons facing up.
(4) Remove the return pins (180) from the slots in the pressure plate.
(5) Remove the retaining ring (280) from each return spring housing and remove the re-
turn spring holder subassemblies (230A) from brake housing subassembly (530 or
530A).
(6) Disassemble each swage tube subassembly (150) as follows:
(a) Push the adjuster swage (160) through the larger end of the self--adjusting
swage tube (170 or 170A) with a steel pin and an arbor press.
NOTE: Do not continue the swage through the tube for removal.
(b) Replace the self--adjusting swage tube (170 or 170A) with item 170A only.
NOTE: Self--adjusting swage tubes (170 or 170A) cannot be used again. The
adjuster swage (160) can be used again if it does not have damage
(See the CHECK section). ARKAS S.A.
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E. Disassemble each return spring holder subassembly (230A).
NOTE: It is not necessary to disassemble spring holder subassembly (230A) unless

parts are to be replaced or checked as told in the CHECK section.
(1) If Retaining Ring 7200--66STZD (240) shows signs of wear, replace it at each over-
haul, which would require disassembly of the spring holder subassembly (230A) as
follows:
(2) Place the spring holder (250) on the base of the arbor press with the retaining ring
(240) facing up, and put the spring compression tool as shown in Figure 906 on top
of return spring housing (270A) flange with the open slot of the tool forward for access
to the end of the retaining ring (240).
NOTE: An old or discarded spring housing can be used to compress the spring
holder subassembly in place of the tool. Cut one quarter of the cylinder
away to provide access to the retaining ring.
(3) Depress the return spring housing (270A) with the arbor press and use Installation/Re-
moval Tool No. P--102L to remove the retaining ring (240) from the groove in the return
spring housing (270A). Release the arbor press slowly to release spring pressure.
NOTE: DO NOT force the retaining ring to open further than needed.
Over--extending the retaining ring can lead to a retaining ring failure.
(4) Remove the return spring housing (270A) from the spring (260) and spring holder
(250).
(5) Remove the spring (260) from the sleeve of the spring holder (250).
WARNING: ♦ KEEP HYDRAULIC FLUID AWAY FROM EYES OR SKIN.

♦ REFER TO THE MATERIAL SAFETY DATA SHEET BEFORE HYDRAULIC
FLUID IS USED.
F. Use the Cylinder Sleeve Wrench 2--6068 to remove each cylinder sleeve (290) from the
brake housing subassembly (530 or 530A).
G. Remove the preformed packing (330, 330A or 330B) and packing backup retainers (340)
from the cylinder sleeves (290).
H. Push the piston (300) out of the cylinder sleeve and use a sharp object to remove the wiper
ring (350) from each cylinder sleeve (290).
NOTE: If the wiper ring (350) is removed from the cylinder sleeve it must be replaced with
a new wiper ring at assembly.
ARKAS S.A.
I. Remove the preformed packing (360, 360A or 360B) and packing backup retainer (370)
from each piston (300).
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Sep 27/04
J. Remove the machine bleeder screws (380), bleeder washers (390), bleeder valves (400
or 400A), hydraulic bleeder valve adapters (420) and preformed packing (430, 430A or
430B) from brake housing subassembly (530 or 530A).
K. Remove the preformed packing (410 or 410A) from each bleeder valve (400 or 400A) and
the preformed packing (430, 430A or 430B) from each bleeder valve adapter (420).
L. Remove the protective plug (460 or 460A), fitting reducer (470), and preformed packing
(480) from brake housing subassembly (530 or 530A).
M. Remove the solid plug (440) from brake housing subassembly (530 or 530A).
N. Remove the preformed packing (450) from the solid plug (440).
O. Torque takeout bushing (550), inboard and outboard housing bushings (570 and 560), and
self--locking inserts (580) should not be removed from brake housing (540 or 540A) unless
replacement is necessary. Instructions for removal and installation of these parts are given
in the REPAIR section.
P. Remove the machine bolt (520) and cover plate subassembly (490).
Q. Skydrol data plate (640) and instruction data plates (650) are the pressure sensitive type
with adhesive backing, and should not be removed unless replacement is necessary or if
paint is to be stripped or if a full check of the brake housing is desired.
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Sep 27/04
CLEANING
1. Cleaning Materials

Blue Gold (for use with a cleaning unit to Modern Chemical Incorporated
clean steel parts only) P.O. Box 368, Dept. 3
Jacksonville, AR72078
Ph: 800--366--8109
Fax: 501--988--1311
Clean Wiping Cloth Commercially available
Detergent Cleaning Unit with an Agitating Commercially available
Platform (Use a non--ozone depleting clean-
er such as a water based detergent or a sol-
vent (Blue Gold or equivalent))
Dry--Cleaning Solvent Commercially available
Type I, Stoddard Solvent
Type II, 140oF Solvent
Specification ASTM D235 or P--D--680
Paint Removal Agent: International Specialty Products
ShipShape® Resin Cleaner 1361 Alps Road
or Wayne, NJ 07470
PrepRite™ Coatings Remover Ph: 732--271--0111
Fax: 732--628--4117
International Specialty Products

ISP Europe
40 Alan Turing Road
Surrey Research Park
Guilford, Surrey
GU25YF England
Ph: 44--0483--301757
Plastic Media (Dry--Stripping Abrasive) U.S. Technology Corporation
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.
ARKAS S.A.

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Sep 27/04

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
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)
Soft Wire Brush Commercially available
Soft Bristle Brush Commercially available
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 PSI
(1,0 BAR).
2. Procedures to Clean the Brake Assembly (Refer to Figure 1 and IPL Figure 1)
A. Clean rotating disks (50 or 50A), stationary disk subassembly (60 or 60A), backplate and
torque tube subassembly (100), pressure plate subassembly (190) and the torque tube
spacer (40) with low--pressure (15 psi or 1,0 bar), filtered compressed air. Use a soft wire
brush where necessary.
B. Clean all other metal parts as follows:
WARNING: ♦ DO NOT USE DRY--CLEANING SOLVENT NEAR SPARKS OR
FLAMES.
♦ KEEP DRY--CLEANING SOLVENT AWAY FROM EYES OR SKIN.
♦ DO NOT BREATHE THE FUMES.
♦ DO NOT DRINK THE DRY--CLEANING SOLVENT.
♦ DRY--CLEANING SOLVENT IS POISONOUS AND FLAMMABLE.
♦ REFER TO THE MATERIAL SAFETY DATA SHEET (OR EQUIVALENT)
BEFORE DRY--CLEANING SOLVENT IS USED.
CAUTION: ♦ FLUSH THE SOLVENT FROM OPENINGS, HOLES THAT HAVE

THREADS AND OTHER AREAS WHERE THE SOLVENT CAN GET
CAUGHT.
(1) Clean all other metal parts with dry--cleaning solvent, Specification ASTM D235 or
equivalent.
ARKAS S.A.
NOTE: Solvent can get caught in opening and holes when the brake assembly is
put fully into the dry--cleaning solvent. This can cause the brake assembly
to operate incorrectly.
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32--43--14 Sep 27/04
(2) Use a soft bristle brush to remove grease, dust and dirt that has become hard.
(3) Dry all metal parts with low--pressure (15 psi or 1,0 bar), filtered air.
NOTE: Make sure unwanted materials have been removed from all openings,
holes that have threads and other areas.
WARNING: ♦ DO NOT USE ISOPROPYL ALCOHOL NEAR SPARKS OR FLAMES.

♦ KEEP ALCOHOL AWAY FROM EYES OR SKIN.
♦ DO NOT DRINK ISOPROPYL ALCOHOL.
♦ ISOPROPYL ALCOHOL IS POISONOUS AND FLAMMABLE.
♦ REFER TO THE MATERIAL SAFETY DATA SHEET (OR EQUIVALENT) BE-
FORE ISOPROPYL ALCOHOL IS USED.
C. Clean the preformed packings, the backup rings and the packing backup retainers with iso-
propyl alcohol, Specification TT--I--735. Dry with a clean, soft cloth.
NOTE: Install new preformed packings, backup rings and packing backup retainers be
installed at each brake overhaul.
D. Use a detergent cleaning unit with an agitating platform to remove grease from the tie bolts
(30), the flat washers (20), and the self--locking nuts (10).
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 PSI

(1,0 BAR).
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.aircraftbraking.com>.
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32--43--14 Sep 27/04
CHECK
1. Check Materials

AP--763 Nondestructive Testing Manual Aircraft Braking Systems Corporation
with Procedures for Ultrasonic Inspection, Publications Department -- D648
Eddy Current Inspection, Magnetic Particle 1204 Massillon Road
Inspection and Penetrant Inspection. Akron, OH 44306--4186
Ph: 330--796--8081
Fax: 330--796--9805
2. General (Refer to Figure 1 and IPL Figure 1)

A. Visually examine all parts for cracks, wear, structural damage, corrosion and damaged
threads. Replace all parts that have cracks, structural damage, damage to threads or that
are worn more than the limits given. Repair small scratches and corrosion. Examine each
part as told in the instructions given.
NOTE: If a brake assembly has become too hot after going through a high speed re-
jected takeoff (RTO) or equivalent high energy input, the components should be
examined for hardness as told in the TESTING AND FAULT ISOLATION section.
B. Examine each part as told in these instructions. Refer to the REPAIR section for the applica-
ble repair procedures.
3. Rotating Disk (50 or 50A)
A. Visually examine relief slot terminal holes for cracks or corrosion. Replace cracked disks.
Remove corrosion or rust pits and damage as told in the REPAIR section.
B. Check rotating disks (50 or 50A) for wear. Replace disks when thickness of base plate and
the two surface mix is 0.252 inch (6,40 mm) or less. Replace disk when mix has entirely
worn off on one side at any location.
NOTE: Up to 25 percent of the mix can be lost through chipping, provided the chipping
is scattered.
C. Measure dishing by placing the disk on a surface plate and using a feeler gage to determine
the clearance at the edge of disk (See Figure 501). Straighten the disk when dishing is
0.020 inch (0,51 mm) or more.
D. Measure the width of the keyslots on the rotating disk. Replace a disk when keyslot width
is more than 0.945 inch (24,0 mm).
E. Replace all rotating disks that have an outside diameter of 14.13 inches (358,9 mm) or less
at the narrowest point (See Figure 502).
NOTE: Measurement for width of the rotating disk is to be taken at 3 locations around
ARKAS S.A.
the disk as shown in Figure 502 but not at the lip of the keyslot.
F. Replace each rotating disk when the inside diameter is 9.05 inches (229,9 mm) or less at
the narrowest point (See Figure 502).
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SURFACE PLATE MAXIMUM ALLOWABLE DISHING
Typical Dishing Check

Figure 501
∅ 9.05 ∅ 9.05
(229,9) (229,9)
MINIMUM MINIMUM
∅ 14.13
∅ 14.13
(358,9)
(358,9)
MINIMUM
MINIMUM
ARKAS S.A.
Rotating Disk Minimum Diameter

Figure 502
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Sep 27/04
4. Stationary Disk Subassembly (60 or 60A)
A. Check the disk relief slot terminal holes for cracks and corrosion. Replace cracked disks.
Blend out corrosion pits and damage in the terminal holes as told in the REPAIR section.
B. Measure the thickness of the stationary disk subassembly (60 or 60A). Replace all the wear
pads (80) on the subassembly when the thickness of disk and pads is 0.368 inch (9,35 mm)
or less, when measured at a point midway between the wear pad rivets.
C. Check disk for condition of the rivets (70) and wear pads (80). Whenever one or more rivets
are sheared or the dimension as shown in Figure 503 is less than 1.60 inches (40,64 mm)
on 25 percent or more of the wear pads, replace all wear pads.
D. Measure dishing by placing disk on a surface plate and using a feeler gage to determine
clearance at edge of disk (See Figure 501). Straighten the disk when dishing is 0.020 inch
(0,51 mm) or greater.
E. Examine the fit of the stationary disk subassembly (60 or 60A) on the backplate and torque
tube (130). Replace a disk that has an inside diameter less than 7.84 inches (199,14 mm)
or that does not fit freely over the keys.
F. Measure the width of the keyslots. Replace a disk when the width of the keyslot is more than
0.340 inch (8,64mm).
1.60 ( 40,64 )
RIVET HOLE
WEAR MEASUREMENT
MEASURED ON CENTER
LINE BETWEEN RIVETS
EDGE CURLING (TYPICAL). WEAR PADS HAVE

A TENDENCY TO CURL AS SHOWN. CURLING
ARKAS S.A.
IS NOT A REASON FOR REPLACEMENT.

NOTE:
WEAR PADS CONTAINING HEAT CHECKS OR CRACKS MUST BE REPLACED.
Wear Pad Limits

Figure 503
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5. Backplate and Torque Tube Subassembly (100)
A. Visually examine torque tube section for nicks, cracks and other damage. Repair small
nicks and scratches as told in the REPAIR section.
B. Measure the width of the key sections. Replace the backplate and torque tube (130) when
the key width is 0.225 inch (5,70 mm) or less. Weld repair the key section with a maximum
of 0.025 inch (0,64 mm) depth of wear on the key face or if the top of the key is worn or dam-
aged beyond the limits given in Figure 505.
NOTE: Removal of more metal from the side of the key than the permitted 0.020 inch
(0,51 mm) wear limit can increase the quantity of wear on the stationary disk
keyslot and can decrease the life of the stationary disk. Sharp edges must be
removed.
C. Magnetic--particle check backplate and torque tube (130) for cracks (only if wear pads are
worn out). Replace the backplate and torque tube if there are cracks in the backplate and
the torque tube (130).
D. Visually examine the backplate section of the backplate and torque tube subassembly (100)
for cracks. Look carefully at the mounting bolt holes. Replace the backplate and torque tube
subassembly (100) if it has cracks.
E. Do a check of the wear pad mounting holes for elongation. Rivets holes can be elongated
in a circumferential direction to a maximum of 0.326 inch (8,28 mm) for the outer diameter
holes and to 0.280 inch (7,11 mm) for the inner diameter holes.
F. Check the torque tube mounting holes for elongation. Mounting holes can be elongated in
a circumferential direction to a maximum of 0.397 inch (10,08 mm). If elongation has
occurred, remove all displaced metal on the torque tube mounting faces.
G. Measure the wear pad thickness on the backplate and torque tube subassembly (100) as
shown in Figure 504. Replace wear pads when thickness of any pad is less than 0.075 inch
(1,91 mm).
H. Examine the backplate section for the condition of the rivets (110) and wear pads (120). Re-
place all wear pads whenever one or more rivets are sheared, or when the dimension shown
in Figure 503 is less than 1.60 inches (40,64 mm) on 25 percent or more of the pads.
I. Measure dishing on the backplate subassembly (See Figure 501). Straighten the plate
when dishing is 0.020 inch (0,51 mm) or more.
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Sep 27/04
MEASURE AT THIS POINT 0.075 (1,91) MINIMUM
Backplate Subassembly Wear Pad Thickness Limits

Figure 504
6. Pressure Plate Subassembly (190)
A. Measure the thickness of the pressure plate subassembly. Replace wear pads (210) when
minimum thickness of plate and pads is 0.375 inch (9,53 mm) or less, when measured at
a point midway between wear pad rivets.
B. Examine the pressure plate subassembly for the condition of rivets (200) and wear pads
(210). Replace all wear pads on the subassembly whenever one or more rivets are sheared,
or when the dimension shown in Figure 503 is less than 1.60 inches (40,6 mm) on 25
percent or more of the pads.
C. Measure dishing by placing the pressure plate subassembly on a surface plate and using
a feeler gage to determine the clearance at edge of the plate (See Figure 501). Straighten
the plate when dishing is 0.015 inch (0,38 mm) or more.
D. Measure the width of the keyslots. Replace a disk when the width is more than 0.340 inches
(8,64 mm).
ARKAS S.A.
E. Examine the fit of the pressure plate (220) on the backplate and torque tube subassembly.
Replace the disk stack if the pressure plate does not fit freely over the torque tube or if the
inside diameter is less than 7.84 inches (199,1 mm).
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Sep 27/04
0.225 (5,72)
MINIMUM
4
∅ 0.326 (8,28)
MAXIMUM
∅ 0.280 (7,11)
MAXIMUM
∅ 0.397 (10,08)
MAXIMUM
1
KEY AREA
2 SECTIONAL VIEW
NOTES:
1 EXAMINE TORQUE TUBE SECTION FOR NICKS, CRACKS AND OTHER
DAMAGE.
2 EXAMINE KEY AREA FACE FOR EXCESS ABRASION OR METAL FRETTING.
3. MEASURE FOR BACKPLATE DISHING IN EXCESS OF 0.020 (0,51).
ARKAS S.A.
4 WELD REPAIR PERMITTED ON THE BACKPLATE AND TORQUE TUBE WITH

A MAXIMUM 0.025 (0,64) DEPTH OF WEAR ON THE KEY FACE.
Backplate and Torque Tube Damage Limits

Figure 505
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Sep 27/04
7. Brake Housing Subassembly (530 or 530A)

A. Examine the threads of the cylinder sleeve holes, the inlet ports and the bleeder ports.
Replace a brake housing that has damaged threads in a cylinder sleeve hole. Repair the
inlet port holes and the bleeder port holes as told in the REPAIR section.
B. Visually examine the brake housing subassembly (530 or 530A) for corrosion and
scratches. Rub out small corrosion and scratches as told in the REPAIR section.
C. Examine the threads of the self--locking inserts (580) for damage. If the self--locking inserts
(580) have damage, repair as told in the REPAIR section.
D. Inspect the brake housing subassembly torque takeout bushing (550) and housing
bushings (560 and 570) for looseness, seating, wear and damage. If one of these conditions
are present, see the REPAIR section.
(1) Measure the inside diameter of the torque takeout bushing at three different places,
equally spaced. Replace the torque takeout bushing (550) when the inside diameter
exceeds 1.187 inches (30,15 mm) and replace the housing bushings (560 and 570)
when the inside diameter is more than 2.946 inches (74,83 mm).
(2) Examine the inner cylinder cavity diameter below the threads for 1.681 inch
(42,70 mm) maximum.
E. Do a penetrant inspection of the brake housing subassembly (530 or 530A) for cracks.
Replace the brake housing subassembly if it has cracks. Refer to AP--763 Nondestructive
Testing Manual (32--42--07) for penetrant inspection procedures.
NOTE: If the brake housing subassembly (530 or 530A) had the paint removed by the
dry stripping method, it is recommended that an alternate crack inspection
procedure, such as an eddy current inspection or equivalent, be done on the
brake housing subassembly. Refer to AP--763 Nondestructive Testing Manual
(32--42--05) for eddy current inspection procedures.
F. Examine the passage plugs in the brake housing for leaks and damage.
(1) If the ball plugs (590) in housing (530) show signs of leakage or have damage, repair
as told in REPAIR No.1.
(2) If the expander plugs (610 or 610A) in housing (530A) show signs of leakage or have
damage, repair as told in REPAIR No. 4.
G. Measure the outside diameter of the cylinder sleeve at the gland seal area. Replace a
cylinder sleeve when the outside diameter at the gland seal area is less than 1.497 inches
(38,02 mm). See Figure 506.
H. Measure the outside diameter of the cylinder sleeve at the thin end. Replace a cylinder
sleeve when the outside diameter at the thin end is less than 1.409 inches (35,79 mm). See
Figure 506.
I. Examine the cylinder sleeve for damage to the threads. Replace a damaged cylinder
sleeve.
ARKAS S.A.
J. Visually examine the packing grooves of the cylinder sleeve for burrs, sharp edges and
scratches. Remove small burrs, sharp edges and scratches as told in the REPAIR section.
CO: 5668
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Page 507
Sep 27/04
NO SHARP EDGES PERMITTED 0.002 (0,05) DEEP PITS

THESE CORNERS ACCEPTABLE THIS SURFACE
RAISED OR
∅1.306 (33,17)
∅1.665 (42,29)
∅1.497 (38,02)
∅1.409 (35,79)
DISPLACED MATERIAL
MAXIMUM
MINIMUM
MINIMUM
MINIMUM
NOT PERMITTED
THESE CORNERS
SCRATCHES,
CORROSION
ACCEPTABLE TO
0.003 (0,08)
DEPTH THIS
SURFACE
INSPECT FOR SCRATCHES AND CORROSION.

REWORK TO DIMENSIONS SHOWN TO
REMOVE SCRATCHES AND CORROSION
EXCEEDING 0.005 (0,13) DEEP
Cylinder Sleeve Wear and Check Limits

Figure 506
8. Cylinder Sleeve (290)
A. Measure the inside diameter of the cylinder sleeve. Replace a cylinder sleeve when the
inside diameter is 1.306 inches (33,17 mm) or more. See Figure 506.
B. Measure the outside diameter of the cylinder sleeve. Replace a cylinder sleeve when the
outside diameter is less than1.665 inches (42,29 mm). See Figure 506.
ARKAS S.A.
CO: 5668
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Page 508
Sep 27/04
9. Piston Subassembly (300)

A. Measure the length of the piston subassembly (300). Replace the piston subassembly if the
length is less that 1.398 inches (35,51 mm). See Figure 507.
B. Measure the outside diameter of the piston (320) at six locations. Replace the piston subas-
sembly if the diameter is less than 1.299 inches (32,99 mm) at one or more locations.
C. Visually examine the piston subassembly (300) for wear, burrs, sharp edges, scratches and
corrosion.
(1) Replace the piston subassembly if the corrosion holes or scratches are more than
0.006 inch (0,15 mm) deep in the seal gland area.
(2) Repair the piston if the corrosion holes and scratches are less than 0.006 inch (0,15
mm) deep as told in the REPAIR section.
(3) Sharp edges on the leading or trailing edge of the piston land are not permitted.
(4) Replace the piston subassembly if the insulator has scratches and corrosion more
than 0.020 inch (0,51 mm) deep. Repair scratches and corrosion less than 0.020 inch
(0,51 mm) deep as told in the REPAIR section.
D. Visually examine the insulator for cracks, nicks, and blisters.
(1) Examine for a tight fit of the piston insulator on the piston.
(2) Measure for a gap between the piston and the insulator. Replace the piston subas-
sembly if there is a loose fit or if the measured gap is greater than 0.005 inch (0,13
mm).
NO SHARP EDGES
PERMITTED 2
THESE CORNERS.
∅ 1.299 (32,99)
MINIMUM
0.005 (0,13) GAP

1
ACCEPTABLE
1.398 (35,51)
NOTES: MINIMUM
1 REPAIR WEAR SCRATCHES AND CORROSION LESS THAN 0.006 (0,15) DEEP IN
THE SEAL GLAND AREA.
2 REPAIR WEAR SCRATCHES AND CORROSION LESS THAN 0.020 (0,51) DEEP IN
ARKAS S.A.
THE PISTON INSULATOR.

Piston Subassembly Wear and Check Limits
Figure 507
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Page 509
Sep 27/04
10. Return Spring Housing (270A)

A. Examine the return spring housing for nicks, distortion or damage. Replace the return
spring housing with scratches more than 0.025 inch (0,64 mm) deep on the outside and
more than 0.010 inch (0,25 mm) on the inside lip. See Figure 508.
B. Measure the outside diameter and the inside diameter as shown in Figure 508. Replace the
return spring housing if the inside diameter is more than 1.067 (27,10 mm) or if the outside
diameter is less than 1.271 inch (32,28 mm).
C. Inspect the return spring housing for damage. Clean superficial damage on the spring
housing inner surface in the area indicated and displaced metal on spring housing flange
surface abutting the brake housing. Replace spring housings damaged beyond limits
indicated in Figure 508.
D. Measure the thickness of the spring retaining flange shoulder. Replace the return spring
holder if the spring retaining lip is less than 0.055 inch (1,40 mm) thick or if the flange
shoulder is less than 0.055 inch (1,40 mm) thick.
E. Examine the return spring housing for damage or debris in the retaining ring groove.
11. Retaining Rings (240 and 280)
A. Examine the retaining rings for cracks, distortion or other damage. Replace a retaining ring
that has cracks, distortion or other damage, or is loose.
NOTE: If problems with retaining rings (240) have been found, replace all at each over-
haul per Service Bulletin ATR42--500--32--5.
CHECK RING GROOVE FOR
CHECK FOR ANY DISPLACED RESIDUE AND DAMAGE TO
METAL, THESE SURFACES ONLY OUTSIDE CORNERS
0.055 (1,40)
MINIMUM
∅ 1.067 (27,10)
MAXIMUM ∅ 0.689 (17,50)
MAXIMUM
CHECK FOR DISPLACED ∅ 1.271 (32,28)
METAL THIS SURFACE MINIMUM
WEAR, NICKS, AND

GOUGES ACCEPTABLE TO
0.010 (0,25) THIS SURFACE
0.030 ( 0,76 )
MAXIMUM BOW
NICKS AND GOUGES TO A MAXIMUM
DEPTH OF 0.025 (0,64) ACCEPTABLE OVER
THE ENTIRE AREA SURFACE
0.055 (1,40) MINIMUM
ARKAS S.A.
Return Spring Housing Damage Limits

Figure 508
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Sep 27/04
12. Spring Holder (250)

A. Examine the spring holder for cracks or damage. Polish out permissible damage as told in
the REPAIR section. Replace the spring holder if it has cracks or if it is damaged.
B. Measure the spring holder flange for a minimum diameter of 1.130 inches (28,70 mm) and
measure the barrel for a minimum diameter of 0.659 inch (16,74 mm) as shown in NO TAG.
Replace the spring holder if the diameter is less than the minimum permitted.
C. Measure the swage tube through hole for a maximum diameter of 0.368 inch (9,35 mm) as
shown in Figure 509. Replace the spring holder if the diameter is greater than the maximum
permitted.
D. Measure the spring holder flange for a minimum thickness of 0.068 inch (1,73 mm) and the
swage tube through hole for a minimum thickness of 0.062 inch (1,57 mm). Replace the
spring holder if the thickness is less than the minimum permitted.
E. Inspect for a maximum bow of the spring holder flange of 0.010 inch (0,25 mm).
F. Examine for nicks and gouges to a maximum depth of 0.025 inch (0,64 mm) on the surfaces
shown in Figure 509 except 0.2 inch (5,1) on the inside of the retaining ring groove check
to a maximum depth of 0.035 inch (0,89 mm).
(1) If burr is evident on either edge of the flange, remove the burr by using a file or grinder.
0.068 (1,73) MINIMUM NICKS AND GOUGES TO A MAXIMUM DEPTH

OF 0.025 (0,64) ACCEPTABLE THESE SURFACES
CHECK FOR ANY DISPLACED
NICKS AND GOUGES TO A
METAL, THESE SURFACES ONLY
MAXIMUM DEPTH OF 0.035 (0,89)
ACCEPTABLE THIS SURFACE,
CHECK MINIMUM DIAMETER
0.2 (5,1)
∅ 1.13 (28,70) 0.062 (1,57)

MINIMUM MINIMUM ∅ 0.368 (9,35)
∅ 0.562 (14,27) MAXIMUM ∅ 0.659 (16,74)
MAXIMUM MINIMUM *
CHECK RING GROOVE FOR RESIDUE

AND DAMAGE TO OUTSIDE CORNERS
ARKAS S.A.
0.010 (0,25) MAXIMUM BOW
Spring Holder Damage Limits

Figure 509
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Sep 27/04
13. Return Compression Spring (260)
A. Examine the compression spring for nicks, distortion or damage. Replace the spring if it is
damaged.
B. Use a spring tester to measure the force necessary to compress the spring to a height of
0.699 inches (17,75 mm). Replace a spring when the compression force is less than
92 (41,7 kg) or more than 112 pounds (50,8 kg).
C. Use a spring tester to measure the force necessary to compress the spring to a height of
0.586 inches (14,88 mm). Replace a spring when the compression force is less than
132 pounds (59,9 kg) or more than 152 pounds (68,9 kg).
14. Straight Headed Return Pin (180)
A. Examine the return pin (180) for damaged threads and for bends. Replace a return pin that
is bent or that has damaged threads.
B. Do a magnetic--particle inspection per AP--763 (32--42--06) of the return pins for cracks.
Carefully inspect under the head of the return pin and in the threads adjacent to the shank.
Replace a return pin that has cracks.
15. Adjuster Swage (160)
NOTE: The square adjuster swages, which are made from case hardened steel, can be used
again with no decrease in performance. However, in operation, environmental
conditions can cause wear and decrease the life of the adjuster swage.
A. Visually examine the adjuster swage (160) for damage. Carefully examine the adjuster
swage corners for cracks, grooves, scoring, burrs and holes. Replace a damaged adjuster
swage.
B. Measure the dimension across the adjuster swage corners. Replace an adjuster swage that
is less than 0.420 inch (10,67 mm) across the corners.
16. Bleeder Valve (400 or 400A) and Bleeder Valve Hydraulic Adapter (420)
A. Examine bleeder valve (400 or 400A), bleeder valve hydraulic adapter (420) for broken
threads or other damage. Replace damaged parts.
17. Self--Locking Insert (580)
A. Examine the self--locking insert (580) for broken threads or other damage. Replace all in-
serts that have broken threads or other damage.
18. Preformed Packings (330 or 330B, 360 or 360B, 410 or 410B, 430 or 430B, 450 and 480), Backup
Retainers (340 and 370), and Wiper Ring (350)
ARKAS S.A.
A. Install new preformed packings, backup retainers and wiper rings be installed each time the
brake is assembled. If it is necessary to use a preformed packing or a backup retainer again,
CO: 5668
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Page 512
Sep 27/04
examine the preformed packing or the backup retainer for scores, permanent distortion,
permanent extension and other damage. Do not re--use damaged parts.
19. Bolts (30 and 520) and Self--Locking Nuts (10 and 140)
A. Visually examine all bolts and self--locking nuts to see if the threads are worn or if the
threads are broken or have damage. Replace all bolts and nuts that have threads that are
worn, threads that are broken or threads that have damage.
B. Measure the self--locking torque of each self--locking nut as follows:

(1) Remove all grease from the self--locking nut.
(2) Put the self--locking nut on a bolt that is not lubricated.

(3) Turn the nut on the bolt to get a minimum of three threads through the locking feature
of the nut and measure the torque.
NOTE: The accuracy of the torque measurement equipment must be less than 5%
of the full scale value and the full scale value must be less than 50 pound--
inches (5,6 N--m).
(a) Replace a self--locking nut (10) for the brake tie bolts when the torque value is
less than 7.0 pound--inches (0,80 N--m).
(b) Replace a self--locking nut (140) for the return pin when the torque value is less
than 2.0 pound--inches (0,23 N--m).
C. Do an ultrasonic inspection or a magnetic--particle inspection of all bolts (30 and 520) for
cracks. Carefully inspect under the bolt head and in threads adjacent to the shank. Replace
all bolts with cracks. Repair of bolts is not permitted.
Refer to AP--763 (32--42--04 or 32--42--06) Nondestructive Testing Manual for ultrasonic

inspection or magnetic particle inspection procedures.
20. Machine Bleeder Screws (380)
A. Examine the machine bleeder screws (380) for damage and for threads that are broken.
Replace all damaged parts.
21. Washer (20 and 390)

A. Examine the washers for cracks, distortion or other damage. Replace all damaged parts.
22. Torque Tube Spacer (40)
A. Do an inspection of the torque tube spacer (40) for nicks, scratches, cracks or other dam-
age. Replace the torque tube spacer (40) if it has cracks or bad damage. Rub out all nicks
and scratches as told in the REPAIR section.
ARKAS S.A.
23. Protective Storage and Shipping Plug (460 or 460A)

A. Check plug for stripped threads or other damage. Replace defective part.
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Sep 27/04
THIS PAGE
KEPT
BLANK
ARKAS S.A.
CO: 5668
32--43--14
Page 514
Sep 27/04
REPAIR
1. Repair Materials
Acetone Commercially available

Specification ASTM D329
High Solids Polyurethane Topcoat Courtaulds Aerospace, Inc. Int.
per Specification MIL--PRF--85285 5454 San Fernando Road
(FA 16473) Light Gray Glendale, CA 91203
Ph.: 818--247--7140
Fax: 818--549--7606
High Solids Epoxy Polyamide Primer Dexter Aerospace
per Specification MIL--PRF--23377, Type I 1 East Water Street
Waukegan, IL 60085
Ph.: 847--623--4200
Fax: 847--623--9011
Aluminum Oxide Cloth Commercially available
(Wet--or--dry, 320 to 400 grit)
AP--763 Nondestructive Testing Manual with Aircraft Braking Systems Corporation
Procedures for Ultrasonic Inspection, Eddy Cur- Publications Department -- D648
rent Inspection, Magnetic Particle Inspection 1204 Massillon Road
and Penetrant Inspection. Akron, OH 44306--4186
Ph: 330--796--8081
Fax: 330--796--9805
Capacity: 1000 lb (454 kg) minimum 724 Robbins Road
Ph: 800--937--3253
Fax: 800--846--3253
Anvils See the SPECIAL TOOLS, FIXTURES
2--25309, 1--10066 and 1--10067 AND EQUIPMENT section
Brush (for application of epoxy polyamide Commercially available
primer)
ARKAS S.A.
CO: 5668
32--43--14
Page 601
Sep 27/04
Chemical Film Solution

Specification SAE AMS 2473 or MIL--C--5541
Alodine 1200 Henkel Surface Technologies
32100 Stephenson Hwy.
Madison Heights, MI 48071
Ph: 248--583--9300
Fax: 248--0589--4629
Turcoat Alumnigold/4178 Elf Atochem N. A. Inc. /Turco Products
2000 Market Street
Philadelphia, PA 19103--3222
Ph: 215--419--7000
Fax: 215--419--7343
Iridite 14--2 MacDermid, Incorporated
245 Freight Street
Waterbury, CT 06702
Ph: 203--575--5700
Fax: 203--575--5630
Drill Bits (High Speed Carbon Steel) Commercially available
Diameters: 7/32 , 0.219 inch
Expander Plug Installation Tools: See the SPECIAL TOOLS, FIXTURES
HKW010108 (Nosepiece) AND EQUIPMENT section
HKW010308 (Jaw Case)
HKW014208 (Jaws)
HKW01508 (Jaw Pusher)
or
Mobil Aviation Grease SHC100)
Hand Grinder Commercially available
High Temperature Paint
Aluminum Color
Silver Brite The Sherwin Williams Company
Hi Heat Silicon Alkyd 479 North Main Street
Akron, OH 44301
Ph: 330--376--2126
Hi Temperature Aluminum Sikkens Aerospace Finishes
Paint 521--8 Holland
ARKAS S.A.
CO: 5668
32--43--14 Page 602

Sep 27/04
Hydraulic Fluid, Commercially available

Phosphate Ester, Type 4
Lockwire MS20995C32 Commercially available
Lubribond 220 per Specification E/M Corporation
MIl--L--23398 or MIL--L--46147 100 Cooper Circle
P.O. Box 3969
Peachtree City, GA 30169
Ph: 800--428--7802
Fax: 770--261--4805
Orbital (Spin) Riveter See the SPECIAL TOOLS, FIXTURES
Model T320 or T500 AND EQUIPMENT section
Oven (Industrial Furnace) Commercially available
Temperature Stability:
1075° F + 25° F (579°C + 18° C)
1150° F + 25° F (621°C + 18° C)
Minimum Inside Dimensions:
3 ft x 3 ft x 3 ft (0,9 m x 0,9 m x 0,9 m)
Paint Cabinet Commercially available
Temperature Range:
60° to 95° F
(15,6° to 35° C)
Humidity Range:
55 to 85%
Peens See the SPECIAL TOOLS, FIXTURES
1--25311, 1--25807, 1--26126 and 1--26170 AND EQUIPMENT section
Pneumatic Pop Rivet Gun Crawford Products
Model No. PRG540 3637 Corporate Drive
with a 90° Head No. PRH850 Dept SS
Columbus, OH 43231--4965
Ph: 800--666--3424 ext 245
Fax: 614--890--1876
Profilometer (for surface finish measurement) Commercially available
32 to 500 RHR
Rust Veto 4214 Houghton International
Specification MIL--C--16173, Class 3 Madison and Van Buren Avenue
Valley Forge, PA 19482--0930
Ph.: 610--666--4058
ARKAS S.A.

CO: 5668
32--43--14
Page 603
Sep 27/04
Slide Puller Hammer Commercially available

Bore Clearance: 1.875 inch (47,62 mm)
Foot Thickness: 0.150 inch (3,81 mm)
Slimsert Installation Tools See the SPECIAL TOOLS, FIXTURES
(See Repair No. 3) AND EQUIPMENT section
SR19R--(Removal Tool)
SR19W--A (Drive Wrench)
SRW19S--A (Swage Tool)
(General use)
Soft Wire Brush Commercially available
Spray Gun (Air Atomizing) Commercially available
(For use with lacquers, enamels, catalyzed
paints and primers. Must be able to control the
thickness as given in this CMM)
Thimble or Thin--Walled Tubing Commercially available
Tumble Polisher Commercially available
2. General (See IPL Figure 1)

A. Only the repairs and replace parts as given in this section.
Do not repair parts that have cracks, bad corrosion or damage. Replace all cracked parts
and all parts that cannot be repaired within the limits given in this section.
3. Straightening Base Plates and Disks
A. Cold Straightening
(1) Excessively dished backplate and torque tube subassembly (100), pressure plate
subassembly (190), rotating disk (50 or 50A) and stationary disk subassembly (60 or
60A) can be straightened according to the following instructions:
(a) Remove the wear pads from the base plates.
(b) Fabricate upper and lower register plates of straightening fixture (See
Figure 901) as told in SPECIAL TOOLS, FIXTURES AND EQUIPMENT.
(c) Mount the upper and lower register plates in an arbor press.
(d) Place the dished plate or disk in the lower register plate with the domed side up.
ARKAS S.A.
(e) Apply sufficient pressure with the arbor press to straighten the plate or disk. Base
plates must be flat to within 0.010 inch (0,25 mm).
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Sep 27/04
B. Draw Flattening
(1) The pressure plate, stationary disk base plate and rotating disks can be draw flattened
as follows:
(a) Remove the wear pads from the base plates.
(b) Stack the base plates back--to--back between two--inch (50,8 mm) boiler plates
with long bolts through center of the stack and boiler plates.
NOTE: When draw flattening rotating disks, they must be separated by

stationary base plates.
(c) Put the plates 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.
(d) Remove the plates from the oven and retighten the bolt.
(e) Put again in an oven for two to three more hours.
(f) Remove the plates from the oven and air--cool to room temperature; then remove
the bolt and separate parts.
4. Replacing Wear Pads (80, 120 and 210)
A. Replace the wear pads on the backplate and torque tube subassembly (100), stationary
disk subassembly (60 or 60A) and pressure plate subassembly (190) as follows:
NOTE: Replace all wear pads on a stationary disk, backplate or pressure plate whenever
25 percent or more wear pads require replacing.
CAUTION: ♦ DO NOT DAMAGE OR ENLARGE THE RIVET HOLES IN THE BASE

PLATES.
(1) Use a 7/32 (0.219) inch (5,6 mm) diameter drill bit to drill out the shop heads of the
rivets. Then punch out the rivets and remove the wear pads.
NOTE: The maximum allowable diameter for the rivet holes in the base plates is
0.276 inch (7,01 mm) for those nearest the inside diameter and 0.322 inch
(8,18 mm) for those nearest the outside diameter.
B. Magnetic particle check the base plates (90, 130 and 220). Replace a base plate that has
cracks.
C. Do a hardness check to determine if the base plates are acceptable for repadding on all
base plates that are suspected of having been overheated. Do a hardness check as told
in the TESTING AND FAULT ISOLATION section.
ARKAS S.A.
NOTE: Hardness checks do not have to be done on every base plate that is overhauled,
but only on those that are suspected of having been overheated.
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Sep 27/04
D. Straighten the base plates as given in paragraph 3. Base plates must be flat within
0.020 inch (0,51 mm).
E. Repair the base plates as given in paragraph 6., paragraph 7., or paragraph 8. as required.
(1) Grit blast the base plate to remove all rust, paint, scale or brake residue.
CAUTION: ♦ GRINDING IS NOT AN ACCEPTED METHOD OF FLATTENING DISKS,

EXCEPT FOR LOCAL BULGING, RAISED METAL, BURRS OR EX-
CESS WELD.
(2) Visually examine each face of the base plates for burrs and raised metal that would
prevent seating of new wear pads or linings. Remove all excess weld, burrs or raised
metal by localized grinding or by surface grinding the entire base plate.
F. Clean the new wear pads or linings as told in the CLEANING section for metal parts to re-
move any protective coating, grease, dust and grit.
G. Remove all burrs or raised metal on the bottom of the wear pads or linings.
H. Rivet the wear pads to the base plates as given in the following instructions, with the rivet
tools listed in SPECIAL TOOLS, FIXTURES AND EQUIPMENT.
CAUTION: ♦ TWO CRACKS ARE PERMITTED IN THE SHOP HEAD OF A RIVET,

PROVIDED THE CRACKS DO NOT EXTEND INTO THE RIVET SHANK.
♦ REMOVED AREAS OF RIVET HEADS MUST NOT BE MORE THAN
25 PERCENT OF THE RIVET HEAD.
(1) The compression method of installing rivets, using the tools shown in Figure 902 is
preferred. However, the spin riveting method, using the tools listed in Figure 903 for
the Bracker Riveter or Figure 904 for the Taumel Riveter can be used if desired.
NOTE: These wear--padded assemblies are designed to maintain the rivet heads
flush or below the pad surface. If the rivet heads protrude above the wear
pad or lining surface, grind off as shown in Figure 601 until flush.
CAUTION: ♦ PRODUCE THE CORRECT RIVET SQUEEZE WHEN ADJUSTING THE

RIVET MACHINES. EXCESSIVE SQUEEZE PRESSURE WILL RESULT
IN THE WEAR PAD OR LINING CORNER “LIFT--UP”, WHILE INSUFFI-
CIENT SQUEEZE PRESSURE WILL RESULT IN LOOSE PADS OR LIN-
INGS AND INCORRECTLY FORMED HEADS.
(2) Rivets must be snug. Installation procedures require that a minimum force of 2 pounds
(0,91 kg) and a maximum force of 100 pounds (45 kg) are required to move a pad or
lining.
ARKAS S.A.
NOTE: On the pressure plate, rotating disk and stationary disk, check seating of
wear pads or linings by attempting to insert a 0.0015 inch (0,038 mm) feeler
gauge between the wear pad and the base plate.
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Sep 27/04
SHADED PORTION INDICATES AREA

GROUND FROM RIVET HEAD
( MAXIMUM ALLOWABLE 25% )
TOTAL RIVET HEAD AREA
Grinding Rivet Heads

Figure 601
(3) Assembled subassemblies must be flat within 0.020 inch (0,51 mm). The thickness
of newly repadded subassemblies must be as shown in Figure 602.
NOTE: Newly assembled stationary, backplate and torque tube, and pressure
plate subassemblies that are not put into service immediately must be
treated for storage as told in ASSEMBLY AND STORAGE.
(4) After each repadding of the backplate and torque tube, pressure plate and stationary
disk subassemblies, re--identify the disk base plates that a visual check can determine
the number of times the base plates have been repadded.
NOTE: The recommended method of identification is to notch a groove across the

thickness or outer edge of the base plate above the part number 0.063 inch
(1,6 mm) deep.
ARKAS S.A.
CO: 5668
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Page 607
Sep 27/04
0.408 (10,36) 0.426 (10,82) 0.101 (2,56)

MAXIMUM MAXIMUM MAXIMUM
WEAR PAD (210)
GY18B8 GYR8A20
RIVET GY18B11
RIVET RIVET
WEAR PAD (120)
WEAR PAD (80)
PRESSURE STATIONARY
PLATE DISK BACKPLATE
BACKPLATE AND
PRESSURE PLATE STATIONARY DISK TORQUE TUBE
SUBASSEMBLY (190) SUBASSEMBLY (60 or 60A) SUBASSEMBLY (100)
5009841 5012608 or 5013656 5006971
NOTES:
1. ALL SUBASSEMBLIES MUST BE FLAT WITHIN 0.020 (0,51).
2. ALL SUBASSEMBLIES MUST BE WITHIN THE INDICATED
LIMITS AFTER REPADDING.
ARKAS S.A.
Acceptable Limits for Newly Repadded Subassemblies

Figure 602
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Sep 27/04
5. Repair of Rotating Disk (50 or 50A)

A. Remove rust pits, corrosion, tool marks and nicks from relief slot terminal holes.
NOTE: Paragraphs 5.A.(1) through (4) apply to rotating disks (50) only.
(1) Terminal holes can be enlarged to the maximum diameter of 0.544 inch (13,82 mm).
(2) After enlarging the holes in the rotating disk, radius both sides of the terminal holes
0.04 to 0.07 inch (1,02 to 1,78 mm).
(3) The surface finish must not exceed 250 RHR as shown in Figure 603 when measured
on lines which are in the same plane as the center of terminal hole. The surface finish
must not exceed 125 RHR as indicated on any circle concentric to the center of the
hole.
(4) Replace the rotating disk if pits or nicks remain in terminal holes after machining to
maximum diameter.
CAUTION: DO NOT PAINT ROTATING DISKS WITH KIDNEY SHAPED TERMINAL

HOLES (SEE FIGURE 606).
(5) Apply high temperature paint to the round or anchor shaped relief slot terminal holes
on the rotating disks as follows:
NOTE: Keep paint overspray on friction material to a minimum.
(a) Mask the friction mix terminal hole pocket area around the center of each round
or anchor shaped relief slot terminal hole on the rotating disks (50 or 50A) and
apply a coat of high temperature paint as shown in Figure 604 and Figure 605.
Do not paint rotating disks (50A) with kidney shaped relief slots!
Apply the paint spray at an angle to fully coat the inner cut out and protect the
area from corrosive moisture and contaminants.
(b) Permit the paint to dry as told in the manufacturer instructions.
B. Identify all Brake Assemblies 5012609 with disk stacks containing anchor or kidney shaped
rotating disks (50A) and stationary disks (90A), or stationary disk subassemblies (60A) by
metal stamping “REV K” in 0.12 inch (3,0 mm) high characters on the raised pad of the brake
housing after the brake assembly number, to read “ASSY 5012609 REV K”.
ARKAS S.A.
CO: 5668
32--43--14
Page 609
Sep 27/04
DIRECTION OF
250 RHR FINISH
A
3
DIRECTION OF
125 RHR FINISH
90° 2
CRITICAL
AREA
CRITICAL AREA
ROTATING DISK
R 0.04 TO 0.07
(1,02 TO 1,78)
SECTION A -- A
NOTES:
1. THE SURFACE FINISH REQUIREMENTS ARE APPLICABLE ONLY IN THE CRITICAL

AREA WITHIN THE INCLUDED ANGLE OF 90° OPPOSITE THE RELIEF SLOT.
2 CRITICAL AREA MUST HAVE A FINISH NOT TO BE MORE THAN 125 RHR ON ANY
CIRCLE CONCENTRIC TO THE CENTER OF THE TERMINAL HOLE.
3 CRITICAL AREA MUST HAVE A FINISH NOT TO BE MORE THAN 250 RHR WHEN
MEASURED ON LINES WHICH ARE IN THE SAME PLANE AS THE CENTER OF THE
TERMINAL HOLE.
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.
ARKAS S.A.
Rotating Disk Terminal Hole Surface Finish Requirements

Figure 603
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Sep 27/04
∅ 0.72 (18,3)
1
ROTATING DISK
NOTES:
1 MASK THE AREA AROUND EACH RELIEF SLOT TERMINAL HOLE TO THE
DIAMETER SPECIFIED.
2. APPLY PAINT SPRAY AT AN ANGLE TO FULLY COAT THE INNER CUT OUT.
Relief Slot Terminal Hole Painting -- Rotating Disk

Figure 604
ARKAS S.A.
CO: 5668
32--43--14
Page 611
Sep 27/04
6 PLACES BOTH SIDES

2
ROTATING DISK
NOTES:
1. PAINT ROTATING DISKS AND STATIONARY DISK CORES WITH ANCHOR SHAPED
TERMINAL HOLES
2 MASK THE AREA AROUND EACH RELIEF SLOT TERMINAL HOLE TO THE AREA
SPECIFIED, NO PAINT PERMITTED OUTSIDE THE AREA
3. APPLY PAINT SPRAY AT AN ANGLE TO FULLY COAT THE INNER CUT OUT
Painting Instructions, Rotating Disk with Anchor Shaped Relief Slots

Figure 605
ROTATING DISK
ARKAS S.A.
NOTES:
1. DO NOT PAINT ROTATING DISKS WITH KIDNEY SHAPED TERMINAL HOLES
No Painting of Rotating Disk with Kidney Shaped Relief Slots

Figure 606
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Sep 27/04
6. Repair of Stationary Disk (90 or 90A)
A. Remove the wear pads (80) according to Replacing Wear Pads.
B. Magnetic particle check the base plate. Replace a cracked base plate.
(1) Cleanup must not be done by drilling, but reamed or hand polished with emery cloth
on a split spindle in an air motor.
C. Remove rust pits, corrosion and tool marks from the relief slot terminal holes.
NOTE: Paragraphs 6.C.(1) through (4) apply to stationary disk (90) only.
(1) Terminal holes can be enlarged to a maximum diameter of 0.566 inch (14,38 mm).
(2) After enlarging the terminal holes in stationary disk, radius the corners on both sides
of the terminal holes 0.04 to 0.07 inch (1,02 to 1,78 mm).
(3) The surface finish must be more than 250 RHR as shown in Figure 607 when
measured on lines which are in the same plane as the center of terminal hole .The
surface finish shall be more than 125 RHR as indicated on any circle concentric to the
center of the hole.
(4) Replace the stationary disk if pits or nicks remain in a terminal hole after machining
to the maximum diameter.
(5) Apply high temperature paint to all, round, anchor, or kidney shaped relief slot terminal
holes on the stationary disk core as follows:
(a) Mask a 1.2 inch (30,5 mm) diameter area around the center of each relief slot
terminal holes on stationary disk (90) and apply a coat of high temperature paint
as shown in Figure 608. Apply the paint spray at an angle to fully coat the inner
cut out and protect the area from corrosive moisture and contaminants.
(b) Mask an area around each relief slot terminal hole on stationary disk for anchor
or kidney slotted stator (90A) and apply a coat of high temperature paint as
shown in Figure 608. Apply the paint spray at an angle to fully coat the inner cut
out and protect the area from corrosive moisture and contaminants.
NOTE: The stationary disk wear pads must be removed before the paint is ap-
plied.
D. Identify all Brake Assemblies 5012609 with disk stacks containing anchor or kidney shaped
rotating disks (50A) and stationary disks (90A), or stationary disk subassemblies (60A) by
metal stamping “REV K” in 0.12 inch (3,0 mm) high characters on the raised pad of the brake
housing after the brake assembly number, to read “ASSY 5012609 REV K”.
ARKAS S.A.
CO: 5668
32--43--14
Page 613
Sep 27/04
DIRECTION OF
250 RHR FINISH
DIRECTION OF 3
125 RHR FINISH
2
90°
CRITICAL
A AREA
A CRITICAL AREA
STATIONARY DISK
R 0.04 TO 0.07
(1,02 TO 1,78)
NOTES: SECTION A -- A
1. THE SURFACE FINISH REQUIREMENTS ARE APPLICABLE ONLY IN THE CRITICAL AREA
WITHIN THE INCLUDED ANGLE OF 90° OPPOSITE THE RELIEF SLOT.
2 CRITICAL AREA SHALL HAVE A FINISH MUST NOT BE MORE THAN 125 RHR ON ANY
CIRCLE CONCENTRIC TO THE CENTER OF THE TERMINAL HOLE.
3 CRITICAL AREA SHALL HAVE A FINISH MUST NOT BE MORE THAN 250 RHR WHEN
MEASURED ON LINES WHICH ARE IN THE SAME PLANE AS THE CENTER OF THE
TERMINAL HOLE.
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.
ARKAS S.A.
Stationary Disk Terminal Hole Surface Finish Requirements

Figure 607
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Sep 27/04
∅ 1.2 (30,5)
1
2 X 0.40 (10,16) R
0.80
(20,32)
STATIONARY DISK (90)
0.99
(25,14)
(REF)
STATIONARY DISK (90A) 6 PLACES

(Anchor Slotted Stator) BOTH SIDES
1
0.99 (25,0)
6 PLACES BOTH SIDES 0.80 ±0.040 (20,3 ±1,0)
1
R 0.40 (10,1)
STATIONARY DISK (90A)

NOTES:
1 MASK THE AREA AROUND EACH RELIEF SLOT TERMINAL HOLE TO THE DIAMETER SPECIFIED.
ARKAS S.A.
2. APPLY PAINT SPRAY AT AN ANGLE TO FULLY COAT THE INNER CUT OUT.
Relief Slot Terminal Hole Painting -- Stationary Disk

Figure 608
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Page 615
Sep 27/04
E. Repair any damaged rivet holes as follows:
(1) Weld the damaged rivet holes closed as given in paragraph 7.H.
Acceptable methods of welding are listed in order of preference in Figure 609.
Method Material
(Order of Preference) (Order of Preference)
Gas Tungsten Arc Weld (G.T.A.W.) 17--22A Steel Wire per AMS6458
4130 Steel per AMS6457

Gas Metal Arc Weld (G.M.A.W.) 17--22A Steel Wire per AMS6458
4130 Steel per AMS6457

Weld Data List
Figure 609
CAUTION: ♦ DO NOT REPAIR MORE THAN ONE--THIRD OF THE RIVET HOLES IN
ANY BASE PLATE.
(2) Drill new rivet holes the same size as original rivet holes. Use a new wear pad as a
template to locate the new holes as shown in Figure 610.
F. Straighten the base plates according to Straightening Base Plates and Disks. Base plates
must be flat within 0.020 inch (0,51 mm).
∅ 0.315 +0.005
A (8,00 +0,12)
THRU HOLE
∅ 0.269 + 0.005
(6,83 +0,12)
THRU HOLE
SECTION A -- A
A
STATIONARY DISK 5012601

ARKAS S.A.
Stationary Disk Machining after Rivet Hole Welding

Figure 610
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Sep 27/04
G. Grit blast the base plate to remove all rust, paint, scale or brake residue.
H. Visually examine each face of the base plate for burrs and raised metal which would prevent
seating of newer wear pads. Remove all excess weld, burrs or raised metal by localized
grinding or by surface grinding the entire base plate. Surface grinding can be done as fol-
lows:
CAUTION: ♦ GRINDING IS NOT AN ACCEPTED METHOD OF FLATTENING DISKS,

EXCEPT FOR LOCAL BULGING, RAISED METAL, BURRS OR EX-
CESS WELD.
(1) Using a grinder with a magnetic chuck, float the base plate on shims until original sur-
face is level.
(2) Grind the raised areas or high spots until parallel to, and almost even with the sur-
rounding surfaces.
(3) Turn the plate over and repeat the grinding on opposite side without the use of shims.
(4) Turn plate over again and grind the surface flat. Repeat the grinding on the opposite
side until both sides are parallel and flat to within 0.010 inch (0,25 mm).
(5) Minimum thickness of the stationary disk base plate after grinding not to be less than
0.216 inch (5,49 mm).
I. Repad the stationary disk (90 or 90A) as given in paragraph 4.
7. Repair of Backplate and Torque Tube (130)
CAUTION: ♦ KEEP THE REMOVAL OF MATERIAL TO A MINIMUM.
♦ REMOVAL OF MATERIAL CAN DECREASE THE LIFE OF THE TORQUE

TUBE.
♦ REMOVE MATERIAL ONLY IN THE AREAS WHERE THERE IS CORROSION

OR SURFACE DAMAGE TO GIVE A SMOOTH CONTOUR.
A. Remove the wear pads (120) as given in paragraph 4.

B. Do a magnetic particle inspection of the backplate and torque tube (130). Weld repair a
backplate and torque tube that has small cracks as told in paragraph 7.H.
Refer to AP--763 (32--42--06) Nondestructive Testing Manual for magnetic particle inspec-
tion procedures.
C. Repair the torque tube keys that are worn by blending out indentations along the sides of
the keys (See Figure 611). Torque tube keys that have minor cracks or indentations can be
weld repaired as told in paragraph 7.H. The torque tube keys must not be less than the mini-
mum thickness as told in the CHECK section.
ARKAS S.A.
D. If the brake assembly became too hot, do a hardness test on the backplate and torque tube
(130) to find out if the torque tube can be used. Refer to the TESTING AND FAULT ISOLA-
TION section.
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Page 617
Sep 27/04
6 3
4
8
A
4 ( REF. ) 6
HEAT CHECK AREA
2 2
1
9
6
KEY AREA SECTIONAL VIEW SECTION A--A

ARKAS S.A.
Torque Tube Repair

Figure 611
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Sep 27/04
General: Repairs are limited in each marked area to the following limits. The material re-
moved by blending is limited to the minimum required for removing corrosion or
surface damage.
Area 1: 0.004 inch (0,10 mm) deep maximum blending or rework of damaged area on key
top is acceptable, when key corners have not been repaired previously, as stated
in Area 2 for key corner cracking.
Area 2: Key corner cracks or damage can be blended or ‘‘V” notched to a maximum of
0.08 inch (2,03 mm) wide times 0.08 inch (2,03 mm) deep with a minimum of
0.02 inch (0,5 mm) radius at the bottom of the notch, maximum face area/repair
0.007 inch2 (0,04 mm2) when key top rework or blending has not been previously
accomplished as stated in Area 1. Minimum space between repair areas on the key
corners shall be 0.050 inch (1,27 mm).
Area 3: 0.06 inch (1,52 inch) deep maximum damage clean up in the rib area.
Area 4: 0.015 inch (0,381 mm) depth maximum clean up. Pad surface must be flat within
0.010 inch (0,25 mm). Repair is limited to one inch2 (6,45 mm2) maximum per
30 degree sector (2 pads widths) not more than two inches (50,8 mm) in length.
Weld repair is acceptable if rivet holes have not been previously welded.
Heat check damage of the pad face side of the backplate must not more than
0.015 inch (0,381 mm) deep. Heat check damage can be ground or turned. Alter-
nate method (not preferred) is to grind the local area not more than 1/3 of the area
of a wear pad at each location. minimum cross sectional thickness at rivet is
0.165 inch (4,19 mm).
NOTE: Heat check around the rivet holes can be removed.

Area 5: Damage in the rivet area can be cleaned up to a minimum thickness of 0.165 inch
(4,19 mm) on outer surface only.
Area 6: Corrosion clean up by blending is not to exceed 0.05 inch (1,27 mm) deep. Dings,
gouges and similar damage should have displaced metal removed but not more
than a depth of 0.06 inch (1,524 mm) and limited to one inch2 (6,45 mm2) area with
a minimum spacing of one inch (25,4 mm) between repairs of the surfaces.
Area 7: 0.020 inch (0,51 mm) maximum depth of blending clean up for corrosion and dam-
age in bolt holes. Remove all displaced metal.
Area 8: 0.015 inch (0,38 mm) maximum blending of damage areas.
Area 9: 0.015 inch (0,38 mm) maximum clean up of damaged areas on the key sides.
Remove all displaced metal. ARKAS S.A.
Key to Figure 611

CO: 5668
32--43--14
Page 619
Sep 27/04
E. Remove nicks, burrs, scratches and corrosion from the backplate and torque tube (130)
with a file or hand grinder. Blend out grooves and nicks to 0.015 inch (0,38 mm) deep on
sides of the keys with a hand grinder. Remove corrosion and blend out scratches up to
0.015 inch (0,38 mm) deep in the tube mounting flange (See Figure 611).
NOTE: Removal of corrosion and surface damage can prevent stress concentrations.
F. Remove small cracks radially around the lightening holes. Small imperfections, up to
0.06 inch (1,52 mm) long, must be blended out and polished within a minimum of 0.020 to
0.05 inch (0,508 to 1,27 mm) radius at the edges.
G. Damaged rivet holes or rivet holes that exceed the limits of elongation can be weld repaired
as told in paragraph 7.H.
H. Weld repair damaged rivet holes, key sections, or small cracks in the backplate and torque
tube as follows:
NOTE: Backplate and torque tube weld repairs can be made as needed providing the
following procedures are used.
CAUTION: ♦ BACKPLATE AND TORQUE TUBE MUST NOT EXCEED 800°F (427°C)
DURING WELD REPAIRS.
(1) Prepare the weld area(s) by removing all indications of cracks or displaced metal by
grinding or minimal machining.
(2) Magnetic particle inspect the area to make sure cracks are fully removed.
(3) Preheat backplate and torque tube to 600°F (316°C).
(4) Use the welding methods and materials listed in order of preference in Figure 609.
(5) Weld in a criss cross pattern to fill the damaged hole or area of the backplate and
torque tube to avoid heat buildup. Do not weld adjacent holes consecutively.
NOTE: Keep the weld time and heat penetration to an absolute minimum. Avoid ex-
cessive heat build up in localized areas of the backplate and torque tube by
alternately welding in remote locations and not adjacent locations.
(6) Use 800°F (427°C) Templistik or Tempilaq on the plate to prevent overheating.
(7) Post--heat the plate to 700°F (370°C) and slow cool to room temperature. Use of an
insulating blanket will slow the cooling process and reduce the possibility of excessive
distortion.
(8) Grind, machine, or drill the weld area to the original backplate and torque tube con-
ARKAS S.A.
tours (Refer to Figure 612 for the location and dimension of the original wear pad rivet
holes. Drill and counter bore new rivet holes the same size as the original rivet holes.
Use a new wear pad as a template to locate the new holes.)
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Sep 27/04
BASE THICKNESS
0.188 +0.010 (4,78 +0,25)
∅ 0.266 +0.006 / --0.001 (6,75 +0,15 / --0,025) THRU HOLE

COUNTERSINK ∅ 0.33 (8,38) x 90_ OR BREAK EDGES
0.03 +0.01 (0,76 +0,25)
∅ 0.312 +0.006 / --0.001

SECTION A -- A (7,92 +0,15 / --0,025) THRU HOLE
BACKPLATE AND TORQUE TUBE 5006972

ARKAS S.A.
Backplate Machining after Rivet Hole Welding

Figure 612
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Page 621
Sep 27/04
I. Grit blast the backplate and torque tube to remove all rust, paint, scale or brake residue.
J. The surface finish of surfaces that were repaired must not be irregular more than 250 micro-
inches RHR unless told differently (use a profilometer or equivalent to measure the surface
finish). Clean and apply protective coating Rust Veto 4214, or Lubribond 220 per Specifica-
tion MIL--L--23398 and MIL--L--46147, to all surfaces that were repaired. Apply Rust Veto
4214 coating as told in Specification MIL--C--16173.
K. Visually examine the face of base plate for burrs and raised metal which would prevent flush
seating of new wear pads. Remove any excess weld, burrs or raised metal by localized
grinding or by surface grinding entire base plate.
L. Repad the backplate as given in paragraph 4..
8. Repair of Pressure Plate (220)
A. Remove wear pads (210) as given in paragraph 4.
B. Magnetic particle check the base plate. Replace a pressure plate (220) that has cracks.
C. Repair all damaged rivet holes as follows:
CAUTION: ♦ DO NOT REPAIR MORE THAN ONE--THIRD OF THE RIVET HOLES IN

A BASE PLATE.
(1) Weld damaged rivet holes closed as given in paragraph 7.H. Acceptable methods of
welding are listed in order of preference in Figure 609.
(2) Drill new rivet holes in the same location and size as original the rivet holes as shown
in Figure 613. Use a new wear pad as a template to locate new holes.
(3) When the pressure plate rivet holes are welded, counterbore must be as shown in
Figure 613.
D. Straighten the base plates according to Straightening Base Plates and Disks. Base plates
must be flat within 0.010 inch (0,25 mm).
E. Grit blast the base plate to remove any rust, paint, scale or brake residue.
F. Visually examine the face of the pressure plate for burrs and raised metal which would im-
pair seating of new wear pads. Remove all excess weld, burrs or raised metal by localized
grinding to be flush with the adjacent surfaces or by surface grinding the entire base plate
to not more than the limits permit as told in the CHECK section. Surface grind as follows:
(1) Machine the seating surface to be flat to within 0.010 inch (0,25 mm).
(2) The minimum thickness is 0.285 inch (7,24 mm) measured between rivet holes for a
ARKAS S.A.
worn pressure plate or 0.295 inch (7,49 mm) for a new pressure plate. See Figure 613.
G. Repad the pressure plate (220) as given in paragraph 4.

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Sep 27/04
∅ 0.312 +0.006 / --0.001

(7,92 +0,15 / --0,025) THRU 0.185 +0.005 (4,70 +0,12)
∅ 0.68 ( 17,27 ) HOLE, BREAK CORNERS MINIMUM
COUNTERBORE
TO DEPTH SHOWN 0.100 +0.005 (2,54 +0,12)
A
0.03 (0,76)
CORNER RADIUS
0.295 +0.05 (7,49 +1,27)

MINIMUM NEW
0.285 +0.05 (7,24 +1,27)
MINIMUM WORN
∅ 0.266 + 0.006 / -- 0.001 (6,75 +0,15 / --0,025) THRU

HOLE, COUNTERSINK TO ∅ 0.33 (8,38) x 90° SECTION A -- A
PRESSURE PLATE 5009840
Pressure Plate Machining after Rivet Hole Welding

Figure 613
9. Repair of Brake Housing Subassembly (530 or 530A)
CAUTION: ♦ KEEP THE REMOVAL OF MATERIAL TO A MINIMUM. REMOVAL OF MATERI-
AL CAN DECREASE THE LIFE OF THE BRAKE HOUSING SUBASSEMBLY.
♦ REMOVE MATERIAL ONLY IN THE AREAS WHERE THERE IS CORROSION

OR SURFACE DAMAGE TO GIVE A SMOOTH CONTOUR.
A. If the brake assembly became too hot, do a hardness test on brake housing to find out if
brake housing can be used again. Refer to the TESTING AND FAULT ISOLATION section.
B. Use a file or a hand grinder to remove scratches, nicks, burrs and corrosion from the outside
surfaces of the brake housing to the limits given in Figure 614. Remove all corrosion from
the threads with a soft wire brush. The surface finish of surfaces that were repaired must
not be irregular more than 150 microinches RHR unless told differently (use a profilometer
or equivalent to measure the surface finish).
(1) If a brake housing has more damage than these limits permit, the brake housing
subassembly (530 or 530A) must be replaced.
(2) Clean all surfaces that were repaired as told in the CLEANING section.
(3) Apply chemical film solution, Specification SAE AMS 2473 or equivalent, and paint to
all surfaces that were repaired as told in the Surface Treatment and Paint paragraph.
ARKAS S.A.
NOTE: Removal of corrosion and surface damage can prevent stress

concentrations.
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32--43--14
Page 623
Sep 27/04
9
A
8 8
6 4
3
7
2 2
1
9
2 1 1
10 2
SECTION A--A
ARKAS S.A.
Brake Housing Repair Limits

Figure 614
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Sep 27/04
General: Repairs are to be done to the limits given for each area identified. Keep the removal
of material to a minimum. Rub only the area where there is corrosion or surface dam-
age to remove material. When the depth of the damage is less than 0.015 inch
(0,38 mm), rub the damaged area to get a width--to--depth ratio of 100:1. When this
does not apply, use as large a width--to--depth ratio as possible for the area that must
be repaired.
Area 1: Damaged areas can be repaired to a maximum of 0.015 inch (0,51 mm) in each
60 degree sector when the damage is not more than 50 percent of the area. The
bushing seating and retention must not be affected.
Area 2: Damaged areas can be repaired to a maximum depth of 0.015 inch (0,38 mm) and
0.5 in2 (322,6 mm2) in surface area. For each bolt hole location, only one repair is
permitted.
Area 3: Damaged areas can be repaired to a maximum of 0.030 inch (0,76 mm). The mini-
mum cross section permitted on the cylinder sleeve bore base is 0.165 inch
(4,19 mm).
Area 4: Damaged areas can be repaired to a maximum of 0.015 inch (0,38 mm). Damage
must not be continuous across the face of the cylinder sleeve hole or affect the cyl-
inder sleeve installation.
Area 5: Damage areas can be repaired to a maximum depth of 0.015 inch (0,38 mm) in
small local areas in the bushing bore area, as long as the bushing retention and
seating is not affected.
Area 6: Corrosion (damage) can be removed (repaired) in the seal bore to a maximum
depth of 0.002 inch (0,05 mm). The surface finish in this area must be 32 microin-
ches RHR.
Area 7: Damaged areas can be repaired to a maximum of 0.010 inch (0,25 mm). If the op-
posite side of the cylinder sleeve bore base has been repaired, a minimum cross
section of 0.165 inch (4,19 mm) must be kept.
Area 8: Damaged areas on the front and back sides of the brake housing between the cyl-
inder sleeve bores can be repaired to a maximum of 0.030 inch (0,76 mm).
Area 9: Damaged areas in the return spring housing bosses can be repaired to a maximum
depth of 0.010 inch (0,25 mm) and 0.5 in2 (322,6 mm2).
Area 10: Damaged areas in the lightening holes can be repaired to a maximum depth of
0.015 inch (0,38 mm).
ARKAS S.A.
Key to Figure 614

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Page 625
Sep 27/04
C. If there are leaks around the passage ball plugs (590), repair the ball plug holes as told in
REPAIR No. 1 -- Passage Ball Plug Hole Repair.
If there are leaks around the passage expander plugs (610 or 610A), repair the expander
plug holes as told in REPAIR No. 4 -- Passage Expander Plug Hole Repair.
D. Replace damaged bushings (550, 560 or 570) as follows:
NOTE: Migration of bushing from a housing is not grounds for replacement. The bushing
flange can be reseated in the brake housing. Do not remove bushing from the
brake housing except for replacement or special inspection requirements.
(1) Using a slide hammer puller, carefully remove a damaged bushing and examine the
housing and bushing bores for wear and damage. Measure the inside diameter of
bushing bores at three places, equally spaced.
NOTE: Removal of the inboard housing bushing (570) and the outboard housing
bushing (560) could require cutting the bushing or welding attachments to
the bushing if it is not loose. Do not damage the brake housing or bushing
bore during removal.
(a) Replace the housing if the bore diameter exceeds 3.1190 inches (79,223 mm)
for the housing bushing (560 or 570).
(b) Replace the housing if bore diameter is more than 1.3350 inches (33,909 mm)
for torque takeout bushing (550).
(2) Machine the inside diameter of the replacement bushings to the dimensions shown
in Figure 615.
(3) Heat the housing subassembly to 210° F (99° C) in an oven.
(4) Carefully install replacement bushings into brake housing (Refer to Figure 615). Be-
fore installation, coat both faces of bushing and mating surfaces with one coat of epoxy
polyamide primer or paste.
E. Examine the threaded areas of brake housing subassembly (530 or 530A) for damage.
(1) If the ball plugs (590) are leaking, refer to REPAIR No.1.
(2) If the expander plugs (610 or 610A) are leaking, refer to REPAIR No. 4.
(3) If the threads in a bleeder valve hole are damaged, refer to REPAIR No. 2.
(4) If a threaded insert (580) has damage, refer to REPAIR No. 3.

ARKAS S.A.
(5) If cylinder sleeve holes have damage, or any of the areas above are badly damaged,
replace the brake housing subassembly (530 or 530A).
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Sep 27/04
6.500 ( 165,1 ) RADIUS -- E --
1.182 +
-- 0.001 ( 30,02 +
-- 0,085 ) DIAMETER
0.008 (0,203) M A B M E M
0.004 (0,102) M A 1
√
150
5006956
0.750 +
-- 0.025 REFERENCE
( 19,05 +
-- 0,635 ) 1.180+
150 -- 0.015
√ ( 29,97+
-- 0,381 )
150
√
-- A --
5006955
REFERENCE
√
150
+ 0.003 + 0,076
5006957 2.938 -- ( 74,62 -- ) DIA.
0.000 0,000
REFERENCE
5.292 ( 134,4 ) 0.010 (0,254) M A C M E M
SECTION A -- A DIAMETER
0.003 (0,076) M A 1
REFERENCE
-- C -- -- B --
NOTE:
ARKAS S.A.
1 DIMENSIONS INDICATED MUST BE MET AFTER MACHINING.
Installation of Brake Housing Bushings

Figure 615
CO: 5668
32--43--14
Page 627
Sep 27/04
10. Repair of Cylinder Sleeve (290)
A. Remove corrosion to a maximum depth of 0.00 inch (0,05 mm) in the preformed packing
groove and remove burrs or sharp edges around the sleeve openings of the cylinder sleeve
(290). See Figure 616. Remove corrosion from the threads with a soft wire brush.
B. Polish out scratches, corrosion or other damage to a maximum depth of 0.003 inch
(0,08 mm) on the inside diameter and to a depth of 0.005 inch (0,13 mm) on the outside
diameter of the cylinder sleeve (290) with aluminum oxide cloth, 320 to 400 grit.
WARNING: ♦ KEEP CHEMICAL FILM SOLUTION AWAY FROM EYES OR SKIN.

♦ DO NOT DRINK CHEMICAL FILM SOLUTION.
♦ CHEMICAL FILM SOLUTION CONTAINS CHROMIC ACID, IS CAUSTIC AND
IS POISONOUS.
FORE CHEMICAL FILM SOLUTION IS USED.
C. Apply chemical film solution, Specification SAE AMS 2473 or equivalent, to all areas that
were repaired and to all bare metal. Refer to the Surface Treatment and Paint paragraph.
BLEND OUT CORROSION TO

BLEND OUT SHARP EDGES, 0.002 (0,05) MAXIMUM, NO
RAISED MATERIAL TO SHARP EDGES PERMITTED
MAXIMUM RADIUS 0.015 (0,38)
REMOVE RAISED OR
DISPLACED MATERIAL,
SMOOTH CORNERS TO
0.050 ( 1,27 ) MAXIMUM
BLEND OUT SCRATCHES, RADIUS
CORROSION TO 0.003 (0,08)
DEPTH MAXIMUM
BLEND OUT SCRATCHES, CORROSION

TO 0.005 (0,13) DEPTH MAXIMUM
ARKAS S.A.
Cylinder Sleeve Repair

Figure 616
CO: 5668
32--43--14 Page 628

Sep 27/04
11. Repair of Pistons (320)
A. Polish out the scratches that have a depth less than 0.002 inch (0,05 mm) to a surface finish
of 32 microinches RHR with aluminum oxide cloth, 320 to 400 grit.

♦ CHEMICAL FILM SOLUTION CONTAINS CHROMIC ACID, IS CAUSTIC AND
IS POISONOUS.
FORE CHEMICAL FILM SOLUTION IS USED.
B. Apply chemical film solution, Specification or equivalent, to all areas that were repaired and
to all bare metal. Refer to paragraph 15.
12. Repair of Spring Holder (250)
A. Remove nicks or gouges to a maximum depth of 0.025 inch ( 0,635 mm) within 0.2 inches
( 5,0 mm) area of the retaining ring groove as shown in Figure 617.
B. Remove raised or displaced material on the flange and barrel of the spring holder (250).
C. Remove material from the retaining ring groove that would prevent correct seating of the
retaining ring. See Figure 617.
13. Repair of Return Spring Housing (270A)
A. Polish out scratches on the inside of the return spring housing and remove displaced metal
on the underside of the flange as shown in Figure 618.
B. Remove raised or displaced material in the corners and on the surfaces shown in
Figure 618.
C. Remove material from the retaining ring groove that would prevent correct seating of the
retaining ring. See Figure 618.
ARKAS S.A.
CO: 5668
32--43--14
Page 629
Sep 27/04
REMOVE RAISED OR DISPLACED

MATERIAL, THESE SURFACES
0.2 ( 5,0 ) 1
REMOVE DISPLACED
MATERIAL THESE CORNERS
NOTES:
1 NICKS AND GOUGES ACCEPTABLE TO A MAXIMUM DEPTH OF 0.025 (0,635). REMOVE
RAISED OR DISPLACED MATERIAL IN THIS AREA.
2 REMOVE RAISED MATERIAL THAT WOULD PREVENT PROPER INSTALLATION OF LOCK
RING INTO GROOVE. THIS CORNER MUST BE SHARP, BREAK EDGE ONLY.
Spring Holder Repair

Figure 617
REMOVE RAISED OR DISPLACED

1 MATERIALS THESE SURFACES WHICH
CONTACT RETAINING RING (240)
NOTES: 2
1 NICKS AND GOUGES ACCEPTABLE TO A MAXIMUM DEPTH OF 0.010 (0,25). REMOVE
RAISED OR DISPLACED MATERIAL IN THIS AREA.
ARKAS S.A.
2 REMOVE DISPLACED MATERIAL THIS SURFACE AND AT THE CORNERS.

3 REMOVE RAISED MATERIAL THAT WOULD PREVENT PROPER INSTALLATION OF LOCK
RING INTO GROOVE. THIS CORNER MUST BE SHARP, BREAK EDGE ONLY.
Return Spring Housing Repair

Figure 618
CO: 5668
32--43--14 Page 630

Sep 27/04
14. Repair of Torque Tube Spacer (40)
A. Use aluminum oxide cloth to rub out scratches in the torque tube spacer (40) to a maximum
depth of 0.030 inch (0,76 mm) and 1.0 inch2 (6,45 cm2). A minimum of 120 degrees is per-
mitted between areas that are repaired.
B. Replace the torque tube spacer (40) if it has cracks.
15. Surface Treatment and Paint (See Figure 619)
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.aircraftbraking.com>.
CAUTION: DO NOT PAINT ROTATING DISKS WITH KIDNEY SHAPED TERMINAL

HOLES (SEE FIGURE 606).
A. Repaired areas of the brake housing (540 or 540A) and those areas that have the paint and
chemical film solution removed must have chemical film solution and paint applied as
shown in Figure 619 and as follows:
B. Re--Treating
WARNING: ♦ DO NOT USE ACETONE NEAR SPARKS OR FLAMES.

♦ KEEP ACETONE AWAY FROM EYES OR SKIN.
♦ DO NOT DRINK ACETONE.
♦ ACETONE IS POISONOUS.
BEFORE ACETONE IS USED.
(1) Clean the surface that must have chemical film solution and/or paint applied with ace-
tone, Specification ASTM D329, or with hot water and dry fully with low--pressure, fil-
tered air.

♦ CHEMICAL FILM SOLUTION CONTAINS CHROMIC ACID, IS CAUSTIC
AND IS POISONOUS.
BEFORE CHEMICAL FILM SOLUTION IS USED.
ARKAS S.A.
(2) Apply chemical film solution, Specification SAE AMS 2473 or equivalent, to all bare
aluminum surfaces as told in the instruction of the manufacturer. Refer to the Repair
Materials paragraph for the recommended solution.
CO: 5668
32--43--14
Page 631
Sep 27/04
1 5 PLACES
2.31 (58,7)
2
B
1
4
PLACES
A SECTION B -- B
B 1
2 2
3 3
1
2
5 PLACES
2
1.64 (41,7) 1
3 3
2
NOTES: A SECTION A -- A
1 COAT SURFACES INDICATED WITH ONE COAT OF HIGH SOLIDS EPOXY POLYAMIDE
PRIMER ONLY. MASK THIS AREA BEFORE APPLYING TOPCOAT
2 COAT SURFACES INDICATED WITH PRIMER AND TOPCOAT.
3 NO PRIMER OR TOP COAT ON BUSHING SURFACES, BORES OR CHAMFERS.

4 NO PAINT OR PRIMER IN PISTON CAVITIES, FLUID PASSAGES, INLET THREADS OR
BLEEDER THREADS.
ARKAS S.A.
Painting Diagram for Housing Subassembly

Figure 619
CO: 5668
32--43--14 Page 632

Sep 27/04
C. Do repair and touchup painting as follows:
(1) The part or area requiring touchup painting must be thoroughly clean and free of all
contaminants.
(2) Prepare the area to be painted by removing all scratches, nicks and chipped paint and
then by sanding lightly to feather out all edges of adjacent finish, using 320--400 grit,
wet--or--dry, aluminum oxide cloth. Wet sanding is preferred. Avoid removing more
primer than is absolutely necessary from the damaged area.

(3) Wipe the repaired surface with a cloth moistened with acetone, Specification ASTM
D329, and wipe surface dry with a clean cloth. If the conversion coat or anodize has
been removed, re--treat using chemical film solution, Specification SAE AMS 2473 or
equivalent.
CAUTION: ♦ DO NOT PERMIT METAL TO BE BARE.
♦ IF METAL IS BARE, APPLY CHEMICAL FILM SOLUTION BEFORE THE

HIGH SOLIDS POLYURETHANE TOPCOAT/PRIMER COMBINATION
IS APPLIED.
(4) Starting with the last intact paint layer, reapply paint coats in accordance with Repaint
Brake Housing Subassembly.
NOTE: The gloss must be removed in the area to be touched up with an abrasive
material, the defective area smoothed and the edges feathered. The area
must then be cleaned removing all loose and foreign material.
ARKAS S.A.
CO: 5668
32--43--14
Page 633
Sep 27/04
D. Repaint Brake Housing Subassembly as follows:

(1) Use a cloth moist with acetone, Specification ASTM D329, to clean the surface that
was repaired. Dry the surface with clean cheesecloth. If the chemical film solution or
anodize was removed, apply chemical film solution, Specification SAE AMS 2473 or
equivalent, to the area.

♦ CHEMICAL FILM SOLUTION CONTAINS CHROMIC ACID, IS CAUSTIC
AND IS POISONOUS.
(2) Apply chemical film solution, Specification SAE AMS 2473 or equivalent, to all bare
aluminum surfaces as told in the manufacturer’s instructions. Refer to paragraph 1.
for the recommended solution.
CAUTION: ♦ DO NOT PAINT THE INTERIOR OF CYLINDER SLEEVE CAVITIES, IN-
LET OR BLEEDER OPENINGS OR FLUSH PORTS.
(3) Mask all cylinder sleeve cavities and all threaded holes to avoid getting paint on these
surfaces.
E. Repaint the brake housing with two coats of High Solids Polyurethane Topcoat, Specifica-
tion MIL--PRF--85285, in accordance with Figure 619 as follows:
(1) Surface Preparation
(a) Parts must be clean and have received the surface treatment required before the
application of paint.
NOTE: It is acceptable to overcoat areas previously painted with acrylic

enamel, with high solids polyurethane.
(b) It is not necessary to apply High Solids Epoxy Polyamide Primer, Specification
ARKAS S.A.
MIL--PRF--23377, to small areas such as scratches, dings, impression stamping,

etc. If required, use a high volume, low pressure spray gun (refer to General Ser-
vice Letter GS--SL--46).
CO: 5668
32--43--14 Page 634

Sep 27/04
(2) Thinning
(a) Thinning is not required, as long as the admix viscosity does not exceed 35 sec-
onds using a #2 Zahn or #4 Ford cup (normally the viscosity to be between 16
and 25 seconds using a #2 Zahn or #4 Ford cup).
CAUTION: ♦ APPLY ONLY ONE COAT OF HIGH SOLIDS EPOXY POLYAMIDE PRIM-
ER TO THE REGISTER SURFACES AND BOLT BOSSES. EXCESSIVE
PRIMER ON THESE SURFACES CAN CONTRIBUTE OR RESULT IN
LOSS OF BOLT PRELOAD.
(3) Application
(a) Spray a thin, wet cross coat to a dry film thickness of approximately 0.0004 to
0.0006 inch (0,010 to 0,015 mm).
(b) Air dry for a minimum of 45 minutes before applying a second coat.
(c) Spray a second wet, full cross coat (if required) in accordance with Figure 619
to a total dry film thickness of approximately 0.0016 to 0.0023 inch (0,04 to
0,06 mm).
(d) Air dry 45 minutes before handling. Paint will reach full cure in 72 hours.
16. Approved Repairs
A. The repairs shown in Figure 620 are approved repairs to be done as necessary. When each
repair is done, make sure the repaired part is correctly identified as told.
Manual Repair No. Repair Identification No. Repair

1 R1--1 Passage Ball Plug Repair
2 R2--1 Brake Housing Bleeder Valve
3 R3--1 Self--Locking Insert (Sensor Cover)
4 R4--1 Passage Expander Plug Repair
N/A -- The repair was not available at the publication release date.
Approved Repairs
Figure 620 (Sheet 1 of 2) ARKAS S.A.
CO: 5668
32--43--14
Page 635
Sep 27/04
R2--1
BRAKE HOUSING
BLEEDER VALVE
REPAIR
R3--1
SELF--LOCKING INSERT
(SENSOR COVER)
REPAIR
(2 LOCATIONS) R1--1 or R4--1
PASSAGE PLUG
REPAIR
(6 LOCATIONS)
ARKAS S.A.
Approved Repairs
CO: 5668
32--43--14 Page 636

Sep 27/04
REPAIR NO. 1 -- PASSAGE BALL PLUG REPAIR
A. The procedure given is used to repair damaged or leaking Passage Ball Plugs GYP00 (590)
in brake housing subassembly (530 or 530A).
NOTE: This repair is not applicable to the expander plugs (610 or 610A).
B. This repair gives instructions to remove the damaged or leaking passage ball plug, machine
the passage ball plug hole and install oversized Passage Ball Plug GYP1 (600).
C. Disassemble as specified in DISASSEMBLY.
2. R1--1 -- Repair of Damaged Passage Ball Plug
A. Remove passage ball plug (590) as shown in Repair Figure 601 and as follows:
(1) Machine passage ball plug hole as specified in Repair Figure 601, Ball Removal De-
tail.
(2) Use a T--Bar Hand Tapping Tool to cut threads into the passage ball plug.
(3) Hit the handle of the T--Bar Hand Tapping Tool to force the passage ball plug out. Dis-
card the passage ball plug.
B. Machine the passage ball plug hole as specified in Repair Figure 601, Machining Detail,
and as follows:
(1) Treat all bare and machined surfaces with chemical film solution, Specification
SAE AMS 2473 or MIL--C--5541, as specified in the Surface Treatment and Paint para-
graph.
C. Install oversized passage ball plug (600) as specified in Repair Figure 601, Ball Installation
Detail, and as follows:
(1) Put the brake housing in a position so that the staking force will not cause damage to
the brake housing.
(2) Apply hydraulic assembly fluid MCS--352 to the passage ball plug and to the staking
end of Staking Tool 2--10240--1.
(3) Install the passage ball plug into the countersink.
(4) Put the staking end of Staking Tool 2--10240--1 in the center of the passage ball plug.
The staking tool axis must be parallel within +5 degrees with the axis of the fluid pas-
sage hole.
ARKAS S.A.
(5) Hit the staking tool (and passage ball plug) until the shoulder of the staking tool
touches the surface of the brake housing.
REPAIR
Repair No. 1
CO: 5668
Page 601
32--43--14 Sep 27/04
3 C
L PASSAGE HOLE
2
B
125 BALL REMOVAL DETAIL

√ 125
√
C 5 CL
PASSAGE HOLE
4 METAL STAMP ‘‘R”
MACHINING DETAIL
CL
PASSAGE HOLE
2--10240--1 STAKING TOOL GYP1 PASSAGE BALL PLUG
STAKING TOOL SHOULDER
BALL INSTALLATION DETAIL
SEQUENTIAL
DIAMETER DEPTH ANGLE REMARKS
OPERATION
C’BORE 0.218+0.005--0.005 0.069+0.020--0.000 0.000--0.010 (0,00--0,25) COR RAD &

1 A
EXISTING C’SK (5,54+0,13--0,13) (1,75+0,51--0,00) CENTERED ON C’SK
0.110+0.004--0.001 CENTER PUNCH AS NEAR TO

2 TAP DRILL -- THRU
(2,79+0,10--0,03) CENTER AS POSSIBLE
USE A T--BAR HAND TAPPING

3 TAP THREADS 0.138--32UNC -- THRU
TOOL
ENLARGE SURFACE MUST NOT HAVE ANY

EXISTING 0.236+0.006--0.006 0.280+0.020--0.000 MACHINING MARKS, GOUGES,
4 B
(5,99+0,15--0,15) (7,11+0,51--0,00)
HOLE SPIRAL MARKS, SCRATCHES, ETC.
CENTERLINE OF C’SK CAN BE

ARKAS S.A.
ENLARGE 0.260+0.010--0.010
5 C -- 19+1° WITHIN +5° FROM THE
EXISTING C’SK (6,60+0,25--0,25)
CENTERLINE OF PASSAGE HOLE
COUNTERSINK & DRILLED HOLE MUST BE CONCENTRIC WITHIN 0.030 (0,76) TIR
Passage Ball Plug Repair

Figure 601 REPAIR
Repair No. 1
CO: 5668
32--43--14 Page 602

Sep 27/04
D. To make sure the passage ball plug is correctly installed, examine the passage ball plug as
follows:
(1) The passage ball plug must be 0.000 to 0.030 inch (0,76 mm) below the surface
around the passage opening.
(2) The inside diameter of the stake--formed rim must be a maximum of 80 percent of the
diameter of the passage ball plug and a minimum of 300 degrees around the passage
ball plug.
(3) Small cracks, burrs or staked surfaces that are not flat are permitted if the passage
ball plug is within the limits specified in paragraphs D.(1) and (2).
E. Treat all bare metal with chemical film solution, Specification SAE AMS 2473 or
MIL--C--5541, as specified in the Surface Treatment and Paint paragraph.
F. Identify the brake housing subassembly as follows:
(1) Metal stamp “R1--1” in 0.09 inch (2,3 mm) characters adjacent to the brake housing
subassembly number.
(2) Metal stamp “R” in 0.09 inch (2,3 mm) characters adjacent to the passage ball plug
hole.
(3) Treat and repaint any stamped area as specified in the Surface Treatment and Paint
paragraph.
ARKAS S.A.
REPAIR
Repair No. 1
CO: 5668
Page 603
32--43--14 Sep 27/04
THIS PAGE
KEPT
BLANK
ARKAS S.A.
REPAIR
Repair No. 1
CO: 5668
32--43--14 Page 604

Sep 27/04
REPAIR NO. 2 -- BLEEDER VALVE HOLE REPAIR

A. The procedure given is used to repair damaged threads in the bleeder valve holes on the
brake housing subassembly (530 or 530A).
B. This repair gives instructions to make modifications to the bleeder valve holes so that a
threaded bushing (620) and a preformed packing (630) can be installed.
NOTE: This repair permits the Hydraulic Bleeder Valves 9534661 and MS27611 (400
and 400A) to be used again.
2. R2--1 -- Repair of the Damaged Bleeder Valve Holes
A. If the threads in the bleeder valve hole do not have bad damage, repair the threads as
follows:
(1) Repair the threads with a 9/16--18UNF--3B tap that is lubricated as told in Specification
MIL--S--8879.
(2) Install a new hydraulic bleeder valve (400A) and preformed packing (410 or 410A) as
told in the ASSEMBLY AND STORAGE section.
(3) If the torque necessary to correctly install the hydraulic bleeder valve (400) can be
applied to the hydraulic bleeder valve without failure and if there are no leaks around
the threads of the hydraulic bleeder valve, the brake housing subassembly (530 or
530A) can be used again.
B. If the threads in the hydraulic bleeder valve hole have bad damage and cannot be repaired
by the procedure in step A., repair the damaged hydraulic bleeder valve hole as follows:
(1) Make the modifications to the dimensions of the hydraulic bleeder valve hole as shown
in Repair Figure 601.
(2) Remove all burrs and sharp edges from the hydraulic bleeder valve hole. Make sure
that all burrs and sharp edges are removed on the surfaces that will touch the
preformed packing (630).
(3) Clean the surfaces that were changed as told in the CLEANING section.
(4) Apply the chemical film solution, Specification SAE AMS 2473 or equivalent, to all re-
paired surfaces as told in the Surface Treatment and Paint paragraph in the REPAIR
section.
(5) Identify the brake housing subassembly as follows:
(a) Metal stamp “R2--1” in 0.09 inch (2,3 mm) characters adjacent to the brake
housing subassembly number. Remove all burrs and lifted metal.
(b) Metal stamp “R” in 0.12 inch (3,0 mm) characters adjacent to the hydraulic
bleeder valve hole. Remove all burrs and lifted metal.
ARKAS S.A.
(c) Apply chemical film solution, Specification SAE AMS 2473 or equivalent, and
paint to all areas that were metal stamped as told in the Surface Treatment and
Paint paragraph (Refer to the REPAIR section).
REPAIR
Repair No. 2
CO: 5668
Page 601
32--43--14 Sep 27/04
*
A
MACHINING DETAIL
MACHINE SCREW (380)
HYDRAULIC
BLEEDER VALVE (400 OR 400A)
SPECIAL BLEEDER
ADAPTER (420)
FLAT WASHER (390) THREADED BUSHING
(620) TORQUE TO 35
PREFORMED PACKING (410) LB--FT (47,4 N--M)
PREFORMED PACKING (430)
PREFORMED PACKING (630)
SECTION A--A
INSTALLATION DETAIL
ARKAS S.A.
Bleeder Valve Hole Repair

Figure 601 (Sheet 1 of 2) REPAIR
Repair No. 2
CO: 5668
32--43--14 Page 602

Sep 27/04
1 0.025 +0.015 --0.000 RADIUS

(0,64 +0,38 --0,00)
4
32 C
T
B
32
2
3
120 °
REF
5 A
45 °
D C
REF
0.020 (0,51)
RADIUS
MAXIMUM
MACHINING DETAIL
SEQUENCE OF
DIAMETER/SIZE DEPTH NOTES
OPERATIONS
0.000--0.005 (0,00--0,13)
REPAIR THE 1.344 MINIMUM 0.000--0.010
1 A CORNER RADIUS AND
SPOTFACE (34,14) (0,00--0,25) BELOW THE SURFACE
INCREASE THE 0.020 (0,51) MAXIMUM

0.896+0.005--0.000 0.107+0.015--0.000 CORNER RADIUS AND
2 DIAMETER OF THE B
COUNTERBORE (22,76+0,13--0,00) (2,72+0,38--0,00)
90° POINT ANGLE
INCREASE THE
0.812+0.004--0.001 0.734+0.030--0.000 FLAT BOTTOM
3 HOLE C
DIAMETER (20,62+0,10--0,02) (18,64+0,76--0,00) TAP DRILL
COUNTERSINK 1.000+0.015--0.000
4 -- ---- ----
120° + 5° (25,40+0,38--0,00)
TAP FULL
0.627+0.030--0.000 BOTTOMING
5 THREADS (SEE 0.8750--14 UNJF--3B D
ARKAS S.A.
MIL--S--8879) (15,92+0,76--0,00) TAP
COUNTERBORE, COUNTERSINK AND THREAD DIAMETERS MUST BE CONCENTRIC TO LESS THAN

0.005 (0,13) TIR
Bleeder Valve Hole Repair

Figure 601 (Sheet 2 of 2) REPAIR
Repair No. 2
CO: 5668
Page 603
32--43--14 Sep 27/04
(6) Install the threaded bushing (620) and a preformed packing (630) as follows:
(a) Lubricate the repair preformed packing 630) with hydraulic assembly fluid
MCS352.
(b) Install the repair preformed packing (630) on the threaded bushing (620). To
prevent damage to the preformed packing (630), use a thimble or a short,
thin--walled tube to install the preformed packing over the bushing threads.
(c) Install the threaded bushing (620), with the repair preformed packing (630)
attached, into the hydraulic bleeder valve hole that was repaired. Tighten the
bushing to a torque value of 35 pound--feet (47,4 N--m).
(7) Install the Bleeder Valve (400 or 400A) as specified in the ASSEMBLY AND STOR-
AGE section.
ARKAS S.A.
REPAIR
Repair No. 2
CO: 5668
32--43--14 Page 604

Sep 27/04
REPAIR NO. 3 -- SELF--LOCKING INSERT REPAIR (BTMS)
A. This procedure is used to repair stripped or damaged self--locking inserts on Brake Housing
Subassembly 5012982--1.
B. This repair gives instructions to remove self--locking inserts M45932/1--9L and to install Self
Locking Insert SRW192L.
2. R3--1 — Repair of Damaged Self--Locking Inserts
A. Remove damaged self--locking insert M45932/1--9L. Use Removal Tool SR 19R and Drive
Wrench SR19W--A.
(1) If the threads in parent material are good and the counterbore is not damaged, install
a new self--locking insert M45932/1--9L.
(2) Install an appropriately sized screw in the insert. If the self--locking insert turns under
the normal screw installation torque, remove it and proceed as specified below.
B. Remachine the self--locking insert hole to the dimensions shown in Figure 601, Machining
Detail.
C. Treat newly machined surfaces with chemical film solution, Specification MIL--C--5541, as
specified in the Surface Treatment and Paint paragraph in the REPAIR section.
D. Install Self--Locking Insert SRW192L as follows:
(1) Coat the outer threads of the self--locking insert with polyamide primer, Specification
MIL--P--23377 immediately before installing the insert.
(2) Install Self--Locking Insert SRW192L 0.010 to 0.020 inch (0,25 to 0,51 mm) below the
surface of the parent material using Drive Wrench SR19W--A and Swage Tool
SRW19S--A .
NOTE: Self--locking inserts and tools are available from:
ROSAN Fasteners Corp.

102--24 Jamaica Avenue
Richmond Hill
NY 11418
Ph.: (800) 969--2188
Fax: (718) 847--6321
E. Identify the brake housing subassembly as follows:
(1) Metal stamp “R” in 0.09 inch (2,3 mm) characters adjacent to the repair area and re-
move any displaced metal to maintain a flat surface.
(2) Metal stamp “R3--1” adjacent to the brake housing subassembly number in 0.09 inch
ARKAS S.A.
(2,3 mm) characters. Remove displaced metal to maintain a flat surface.

(3) Retreat and repaint any stamped metal as specified in the Surface Treatment and
Paint paragraph in the REPAIR section.
REPAIR
Repair No. 3
CO: 5668
Page 601
32--43--14 Sep 27/04
C
D
B
A
1, 2, 3
7 90° 5 4&6
REF
INSERT REMOVAL DETAIL MACHINING DETAIL
SEQUENTIAL
DIAMETER/SIZE DEPTH REMARKS
OPERATION
DRILL THRU 0.296+0.004--0.001 0.107+0.000--0.010 DO NOT DRILL INTO

1 A
LOCKRING (7,52+0,10--0,03) (2,72+0,00--0,25) PARENT MATERIAL
DRIVE SQUARE SCREW

EXTRACT EXTRACTOR INTO INSERT AND
2 NOT APPLICABLE -- NOT APPLICABLE
INSERT
ROTATE FOR REMOVAL
IF REQUIRED, COLLAPSE
LOCKRING WITH PUNCH &
3 CLEAN--UP NOT APPLICABLE -- NOT APPLICABLE
REMOVE. REMOVE ALL CHIPS AND
SLIVERS.
ENLARGE
EXISTING 0.343+0.004--0.001 0.082+0.010--0.000 TAP MARKS PERMITTED IN
4 B
(8,71+0,10--0,03) (2,08+0,25--0,00) COUNTERBORE AREA
COUNTERBORE
ENLARGE 0.302+0.004--0.001 0.519+0.020--0.000 FLAT BOTTOM

5 C
EXISTING HOLE (7,67+0,10--0,03) (13,18+0,51--0,00) TAP DRILL
COUNTERSINK 0.343+0.000--0.010
6 -- NOT APPLICABLE NOT APPLICABLE
90° (8,71+0,00--0,25)
TAP FULL
THREADS PER 0.415+0.020--0.000
7 0.3438--24NS--3B D BOTTOMING TAP
(10,54+0,51--0,00)
MIL--S--8879
COUNTERBORE AND THREAD DIAMETERS MUST BE CONCENTRIC WITHIN 0.006 (0,15) TIR
ARKAS S.A.
Repair of Self--Locking Insert

Figure 601
REPAIR
Repair No. 3
CO: 5668
32--43--14 Page 602

Sep 27/04
REPAIR NO. 4 -- PASSAGE EXPANDER PLUG REPAIR
A. The procedure given is used to repair damaged or leaking expander plug (610 or 610A) in
brake housing subassembly (530A).
NOTE: This repair is not applicable to the plugs (590).
B. This repair gives instructions to remove the damaged or leaking expander plug, machine
the expander plug hole and install pin plug (615).
C. Disassemble as specified in DISASSEMBLY.
2. R4--1 -- Repair of Damaged Expander Plug Holes
A. Remove the existing expander plug (610 or 610A) 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
(530A).
(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 Figure 602 and Figure 601.
(2) Clean the machined surfaces as told in the CLEANING section.

♦ CHEMICAL FILM SOLUTION CONTAINS CHROMIC ACID, IT IS CAUS-
TIC AND POISONOUS.
ARKAS S.A.
(3) Apply chemical film solution, Specification SAE AMS 2473 or MIL--C--5541, to all re-
paired surfaces as told in “Surface Treatment and Paint” in the REPAIR section.
REPAIR
Repair No. 4
CO: 5668
Page 601
32--43--14 Sep 27/04
C. Install Pin Plug 2500010A (615) 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 LU-

BRICANT.
♦ 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.
Repair Dimensions for Plug Installation
Figure 602
Part Number Ream Diameter, Class 2 Ream Depth Material Remaining

(Short Pin)
(A) (B) (C)
Minimum Maximum Minimum Minimum
0.2500 inch 0.2515 0.212 inch 0.125 inch
2500010A
(6,350 mm) (6,388 mm) (5,39 mm) (3,18 mm)
B C
0.0003 (0,008)
45° 0.013
A
(0,33)
16--63 MINIMUM
√
0.003 (0,08)
MAXIMUM
ARKAS S.A.
Machining Detail
Figure 601 REPAIR
Repair No. 4
CO: 5668
32--43--14 Page 602

Sep 27/04
D. Identify the brake housing subassembly (530A) as follows:
(1) Metal stamp “R4--1” in 0.09 inch (2,3 mm) characters adjacent to the brake housing
subassembly number.
(2) Metal stamp “R” in 0.12 inch (3,0 mm) characters adjacent to the repaired plug hole.

♦ CHEMICAL FILM SOLUTION CONTAINS CHROMIC ACID, IT IS CAUS-
TIC AND POISONOUS.
(3) Apply chemical film solution, Specification SAE AMS 2473 or MIL--C--5541, and paint
to all metal--stamped surfaces as told in “Surface Treatment and Paint” in the REPAIR
section.
ARKAS S.A.
REPAIR
Repair No. 4
CO: 5668
Page 603
32--43--14 Sep 27/04
THIS PAGE
KEPT
BLANK
ARKAS S.A.
REPAIR
Repair No. 4
CO: 5668
32--43--14 Page 604

Sep 27/04
ASSEMBLY AND STORAGE
1. Assembly Materials

Capacity: 1000 lb (454 kg) minimum 724 Robbins Road
Ph: 616--842--7110
Fax: 616--842--0859
Antiseize Compound (Molylube) Convoy Oil Corporation
Specification MIL--PRF--83483 1412 North Front Street
Philadelphia, PA 19122
Ph: 215--739--5281
Cylinder Sleeve Wrench 2--6068 See the SPECIAL TOOLS, FIXTURES AND
Spring Compression Tool 2--10890 EQUIPMENT section
(alternate Mobil Aviation Grease SHC100)
Hydraulic Assembly Fluid Aviation Fluids Service Company
MCS352 St. Louis, MO 63130
Lockwire MS20995C32 Commercially available
Pressure Sensitive Acrylic Adhesive Tape Commercially available
MIL--P--19834, Type 1 (3M Company 567MP or 468MP)
Retaining Ring Installation/Removal Tool, See the SPECIAL TOOLS, FIXTURES AND
No. P--102L EQUIPMENT section
(General use)
Spring Compression Tool 2--10890 See the SPECIAL TOOLS, FIXTURES AND
EQUIPMENT section
Rust Veto 4214 E.F. Houghton & Company
MIL--C--16173D, Grade 3 Madison and Van Buren Avenue
Valley Forge, PA 19482 ARKAS S.A.
CO: 5668
32--43--14 Page 701

Sep 27/04
A. Assemble the brake assembly as told in the procedures and instructions given.
CAUTION: ♦ ASSEMBLE THE BRAKE ASSEMBLY ON A CLEAN, FLAT SURFACE.
♦ DO NOT NICK, SCRATCH OR DAMAGE THE PAINT OR THE SURFACE FIN-

ISH OF THE BRAKE ASSEMBLY.
♦ MAKE SURE THE CORRECT PARTS ARE USED FOR EACH BRAKE ASSEM-
BLY.
B. Install all new preformed packings, backup rings and wiper rings at assembly. If wiper ring
(350) is removed from the cylinder sleeve, it must be replaced with an new wiper ring.
CAUTION: ♦ DO NOT USE POWER WRENCHES TO INSTALL PARTS THAT HAVE

THREADS INTO MATERIAL THAT IS NOT FERROUS AND HAS THREADS.
♦ DO NOT USE POWER WRENCHES TO INSTALL PARTS THAT ARE NOT FER-
ROUS AND HAVE THREADS.
♦ THE USE OF POWER WRENCHES TO INSTALL FERROUS BOLTS, NUTS OR

SCREWS FROM FERROUS MATERIALS WILL DECREASE THE LIFE OF THE
BOLTS, NUTS OR SCREWS.
C. When power wrenches are used to assemble bolts and nuts, the tightness of the fastener
must not be more than 50 percent of the full torque value. Use manual torque wrenches to
tighten the fasteners to the full torque value.
(1) Automatic wrenching systems which give an initial load or torque accuracy of +4 per-
cent or better may be used to tighten bolts and nuts to the full torque value.
D. Use Lubtork antiseize compound, Specification MIL--PRF--83483, as the fastener lubricant

to give a consistent preload on each subsequent fastener tightening. The brake assembly
and the fasteners must be thoroughly cleaned and degreased before lubrication.
3. Assembly Procedures (Refer to Figure 1 and IPL Figure 1)
CAUTION: ♦ MAKE SURE THE CORRECT PARTS ARE USED FOR EACH BRAKE
ASSEMBLY.
A. Assemble brake assembly as follows:
NOTE: Install all new preformed packings and packing retainers when the brake is as-
sembled again.
ARKAS S.A.
CO: 5668
Page 702
32--43--14 Sep 27/04
B. Assemble the brake housing subassembly as follows:
(1) Put brake housing subassembly (530 or 530A) on a clean, flat surface with cylinder
sleeve cavities down.
(2) Install Skydrol data plate (640) and instruction data plate (650) if removed at
disassembly as follows:
(a) Apply the tape to the instruction data plate (640 or 650) as follows:
WARNING: ♦ DO NOT USE ISOPROPYL ALCOHOL NEAR SPARKS OR

FLAMES.
♦ KEEP ALCOHOL AWAY FROM EYES OR SKIN.
♦ DO NOT DRINK ISOPROPYL ALCOHOL.
♦ ISOPROPYL ALCOHOL IS POISONOUS AND FLAMMABLE.
♦ REFER TO THE MATERIAL SAFETY DATA SHEET (OR
EQUIVALENT) BEFORE ISOPROPYL ALCOHOL IS USED.
1 Make sure the instruction data plate (640 or 650) is clean and dry. Use a
cloth moist with isopropyl alcohol, Specification TT--I--735.
2 Apply the tape to the instruction data plate (640 or 650). Push on the tape
with a finger or a rubber roller.
(b) Apply the instruction data plate (640 or 650) to the brake housing subassembly
(530 or 530A) as follows:
1 Make sure the areas where the data plates must be installed are clean and
dry. Use a clean cloth moist with isopropyl alcohol, Specification TT--I--735.
2 Remove the paper cover from the tape. Be careful not to touch the adhe-
sive.
3 Apply the instruction data plate (640 or 650) to the correct location. (Refer
to Figure 1). Push the instruction data plate tightly against the brake hous-
ing with a finger or rubber roller. Make sure that the edges of the identifica-
tion plate are not lifted up.
(3) Do not move the instruction data plate (640 or 650) for a minimum of 72 hours.
CAUTION: ♦ DO NOT OVER--TIGHTEN THE HYDRAULIC FITTINGS

.
♦ DO NOT USE IMPACT OR POWER WRENCHES TO INSTALL THE HY-
DRAULIC FITTINGS.
ARKAS S.A.
♦ TOO MUCH TORQUE ON THE HYDRAULIC FITTING CAN BREAK THE

HYDRAULIC FITTING SEAT.
CO: 5668
32--43--14 Page 703

Sep 27/04
(4) Lubricate the preformed packing (480) and the fitting reducer (470) with hydraulic as-
sembly fluid, MCS--352.
(a) Install the preformed packing (480) on the fitting reducer (470) and thread the
fitting into the housing (540 or 540A).
(b) Tighten the fitting reducer (470) to a torque value of 30 pound--feet (41 N--m).
(c) Install the protective cap (460A).
(5) Lubricate the preformed packing (450) and solid plug (440) with hydraulic assembly
fluid, MCS--352.
(a) Install the preformed packing (450) on the plug (440) and thread the plug into the
housing (540 or 540A).
(b) Tighten the solid plug (440) to a torque value of 30 pound--feet (41 N--m).
(6) Lubricate the preformed packing (430 or 430B) and the bleeder valve adapters (420)
with hydraulic assembly fluid, MCS--352.
(a) Install the preformed packing (430 or 430B) on each bleeder valve adapter (420).
(b) Install the adapters in housing (540 or 540A) and tighten to a torque value of 70
pound--inches (7,9 N--m).
(7) Lubricate preformed packings (410 or 410B) and bleeder valves (400 or 400A) with
hydraulic assembly fluid, MCS--352.
(a) Install preformed packing (410 or 410B) on bleeder valves and thread the bleed-
er valve into bleeder valve adapter (420).
(b) Tighten the bleeder valves to a torque value of 70 pound--inches (7,9 N--m).
(8) Install the bleeder washer (390) on the bleeder screw (380) and install the bleeder
screws into the bleeder valves (400 or 400A).
(9) Turn the brake housing over so that the cylinder sleeve cavities are up.
(10) Lubricate the packing retainers (340), preformed packing (330 or 330B), and wiper
ring (350) with hydraulic assembly fluid, MCS--352 and install as follows:
(a) Install both packing retainers (340) in the groove of the cylinder sleeve (290).
(b) Install the preformed packing (330 or 330B) in each groove between the packing
ARKAS S.A.
retainers (340) of the cylinder sleeve (290) in accordance with Figure 701.
(c) Install the wiper ring (350) in the inside groove of cylinder sleeve.
CO: 5668
Page 704
32--43--14 Sep 27/04
FILING INSTRUCTIONS: Insert facing page 704 (32--43--14).

DESCRIPTION: In paragraph 3.B.(6)(b) corrected the torque to 15 pound--feet (20,3 N--m).
(6) Lubricate the preformed packing (430 or 430B) and the bleeder valve adapters (420)
with hydraulic assembly fluid, MCS--352.
(a) Install the preformed packing (430 or 430B) on each bleeder valve adapter (420).
(b) Install the adapters in housing (540 or 540A) and tighten to a torque value of
15 pound--feet (20,3 N--m).
(7) Lubricate preformed packings (410 or 410B) and bleeder valves (400 or 400A) with
hydraulic assembly fluid, MCS--352.
ARKAS S.A.
CO: 5668
32--43--14 Page 2 of 6
Apr 11/05
(11) Lubricate the packing retainers (370), preformed packings (360 or 360B), and the pis-
ton subassembly (320) with hydraulic assembly fluid, MCS--352 and install as follows:
(a) Install the packing retainers (370) in the groove of the piston (320).
(b) Install a preformed packing (360 or 360B) in each groove between the packing
retainer (370) and the lip of the piston as shown in Figure 701.
(12) Lubricate the piston and the inside diameter of the cylinder sleeve with hydraulic as-
sembly fluid, MCS--352 and then wet with hydraulic fluid.
(13) Install a lubricated piston subassembly (300), insulator end first, into the large end of
a cylinder sleeve with packing and retainers in place in each cylinder sleeve. (Refer
to Figure 701).
NOTE: Rotate the pistons slightly as they are installed to prevent displacement of
backup retainer, wiper ring, and preformed packing.
PACKING RETAINER (370)

CYLINDER SLEEVE (290)
PREFORMED PACKING
(360 or 360B)
PISTON (320) PISTON INSULATOR (310)
PREFORMED PACKING WIPER RING (350)

(330 or 330B)
PACKING RETAINER (340)
Preformed Packing and Packing Retainer Installation

Figure 701
ARKAS S.A.
CO: 5668
32--43--14 Page 705

Sep 27/04
CAUTION: ♦ REMOVE ALL OF THE EXTRA LUBRICANT FROM LIP OF THE CYLIN-
DER SLEEVE AFTER THE PISTON IS INSTALLED.
(14) After inserting the piston into the cylinder sleeve, push the piston back and forth in the
sleeve several times. Then push the piston through to an extended position and wipe
off all excess lubricant on the lip of the cylinder sleeve.
NOTE: Excess lubricant may give false indication of seal leakage during test.
(15) Lubricate the brake housing bores and the outside diameter of the cylinder sleeve/pis-
ton with hydraulic assembly fluid, MCS--352 and then wet with hydraulic fluid.
(16) Install the lubricated cylinder sleeve with the piston in the cavities of the brake housing.
Use the Cylinder Sleeve Wrench 2--6068 to tighten the cylinder sleeve (290) to a
torque value of 55 pound--feet (75 N--m).
NOTE: Lockwiring of cylinder sleeves is not required. Cylinder sleeves are pro-
vided with holes for lockwiring if desired, using MS20995C32 lockwire.
C. Assemble each of the return spring holder subassembly (230A) as follows:
(1) Put the return spring (260) on the sleeve of the spring holder (250).
(2) Put the return spring housing (270A) over the spring (260).
CAUTION: ♦ IF A PREVIOUSLY INSTALLED RETAINING RING 7200--66STZD (240)

SHOWED SIGNS OF STRESS, REPLACE THE PART AT EACH OVER-
HAUL.
(3) Put the spring holder (250) on the base of the arbor press, place the retaining ring (240)
on top of the return spring housing (270A), and put the Spring Compression Tool
2--10890 on top of the return spring housing (270A) flange with the open slot forward
for access to the retaining ring (240) opening.
(4) Depress the return spring housing (270A) with the arbor press and install the retaining
ring (240) into groove in return spring housing (270A) with Installation Tool No.
P--102L. Release the arbor press slowly to ensure the retaining ring has seated fully
in the groove.
NOTE: Do NOT force the retaining ring (240) to open further than needed. This will
lead to a retaining ring failure. ARKAS S.A.
CO: 5668
Page 706
32--43--14 Sep 27/04
D. Assemble each of the five swage tube subassemblies (150) as follows:
(1) The swage tube subassembly (150), as received, consists of one adjuster swage
(160) and one coated self--adjusting swage tube (170A).
(2) The adjuster swage (160) can be installed into the self--adjusting swage tube (170A)
using a small arbor press, vise, or any similar compression device. The correct proce-
dure for such installation is as follows:
(a) Place the adjuster swage (160) in the end of the self--adjusting swage tube
(170A) and put in an arbor press or vise as shown in Figure 702.
(b) Press the adjuster swage (160) into the self--adjusting swage tube (170A) until
the top of the swage is flush with the top of the self--adjusting swage tube or until
the press engages the top of the self--adjusting swage tube (Refer to Figure 702).
NOTE: In this operation, make sure the press and self--adjusting swage tube
(170A) are perpendicular to each other before the installation begins.
Several adjuster swages can be installed simultaneously as long as
perpendicularity is maintained.
ARBOR PRESS ADJUSTER

SWAGE
SWAGE
SELF--
ADJUSTING
TUBE
ADAPTER
SWAGE TUBE
SETTING BLOCK SUBASSEMBLY
Assembly of Swage Tube Subassembly

Figure 702
ARKAS S.A.
CO: 5668
32--43--14 Page 707

Sep 27/04
E. Assemble the brake housing and pressure plate unit as follows:
(1) Put the brake housing subassembly (530 or 530A) on a clean work bench with the pis-
ton insulators facing up.
(2) Install the spring holder subassembly (230A) in each of the brake housing holes and
put the retaining ring over the collar and seat it fully in the groove.
(3) Put the pressure plate subassembly (190) on a work bench with the wear pads facing
down.
(4) Install five return pins (180) with the pin head in the slots of pressure plate subassem-
bly.
NOTE: There are four slots originating from the outside diameter and one symmet-
rical slot originating from the inside diameter of the pressure plate subas-
sembly.
(5) Position the brake housing subassembly (540 or 540A) on the pressure plate so that
the return pins are centered in the return spring housing holes.
NOTE: The return pin on the inside diameter of the pressure plate must be located
adjacent to torque takeout bushing.
(6) Install a swage tube subassembly (150) over each of the return pins (180) with the
swage adjuster (160) at the threaded end of the pin.
CAUTION: ♦ USE FN12--02 NUTS ONLY. SUBSTITUTE NUTS CAN INTERFERE

WITH THE INSIDE DIAMETER OF THE TUBE AND KEEP THE AD-
JUSTER FROM FUNCTIONING.
(7) Make sure, the self--adjusting mechanism is seated correctly, and secure the swage
tube subassembly in place with the self--locking nuts (140).
(8) Tighten self--locking nuts to a torque value of 25 pound--inches (2,8 N--m).
F. Build up disk stack unit as shown in Figure 703 and 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 the disk stack, use the Illustrated Parts List and IPL Figure 1
to determine part numbers of disks to be used in each position.
(1) Place the backplate and torque tube subassembly (100) on a flat work surface with
the wear pads facing up.
ARKAS S.A.
(2) First, install a rotating disk (50 or 50A), then a stationary disk subassembly (60 or 60A)
keyed to the torque tube, and then another rotating disk (50 or 50A).
CO: 5668
Page 708
32--43--14 Sep 27/04

DESCRIPTION: Added new paragraph F(3).
(3) Since operators have reported that at brake overhaul R1 is worn much more than R2,
at 50 percent brake life reverse the rotating disks (50 or 50A) as follows :
NOTE: This optional installation is permitted only if the disks have worn evenly
across the wear surface, are not warped, if the clearance is even all around
the pressure plate, and all disks move smoothly during testing.
(a) Reinstall rotating disk R1 next to the backplate and torque tube subassembly, with
side 1 (Refer to Figure 703, Sheet 2 of 2) toward the backplate.
(b) Install stationary disk subassembly (60 or 60A), then install former R2 with
side 4 toward the pressure plate (Refer to Figure 703, Sheet 2 of 2.
NOTE: No mixing of disks from other brake stacks is permitted.
NOTE: After reassembly examine the Self--Locking Nuts (140) for tightness
and retorque if required.
G. Put the torque tube spacer (40) on the torque tube subassembly (100) with the two
countersunk heat sensor holes facing away from the torque tube and align the heat sensor
holes in the torque tube spacer with the heat sensor holes in the torque tube subassembly.
ARKAS S.A.
CO: 5668
32--43--14 Page 3 of 6
Apr 11/05
G. Put the torque tube spacer (40) on the torque tube subassembly (100) with the two counter-
sunk heat sensor holes facing away from the torque tube and align the heat sensor holes
in the torque tube spacer with the heat sensor holes in the torque tube subassembly.
H. Put the brake housing and pressure plate unit on top of rotating disk (50 or 50A) and engage
the torque tube keys. Be sure to align heat sensor holes in the brake housing with holes in
torque tube flange and torque tube spacer.
I. Install brake fasteners as follows:
(1) Lubricate the bolt threads and bearing surfaces of tie bolts (30), recessed washers
(20), and self--locking nuts (10) with antiseize compound, Specification
MIL--PRF--83483.
NOTE: Use antiseize compound as received. Do not dilute. It is suggested that op-
erators use antiseize compound, Specification MIL--PRF--83483 instead of
other equivalent compounds.
CAUTION: ♦ INSTALL THE BOLTS WITH THE BOLT HEADS ON THE TORQUE
TUBE SIDE OF BRAKE.
♦ DO NOT FORCE THE BRAKE BOLTS DURING INSTALLATION.
(2) Install the tie bolts (30) from the torque tube side, through the torque tube spacer and
the brake housing. Secure hand tight with recessed washers (20) and self--locking
nuts (10).
ARKAS S.A.
CO: 5668
32--43--14 Page 709

Sep 27/04
PRESSURE PLATE SUBASSEMBLY

(190)
ROTATING DISK (50 or 50A)
STATIONARY DISK SUBASSEMBLY

(60 or 60A)
BACKPLATE AND
TORQUE TUBE
(20) (100)
SELF--LOCKING NUT TIE BOLT (30)

(10)
TORQUE TUBE SPACER

(40)
BRAKE HOUSING
SUBASSEMBLY
(530 or 530A)
ARKAS S.A.
Disk Stack Installation

Figure 703
CO: 5668
Page 710
32--43--14 Sep 27/04

DESCRIPTION: Added Sheet 1 of 2 designation to Figure 703.
PRESSURE PLATE SUBASSEMBLY

(190)
ROTATING DISK (50 or 50A)
STATIONARY DISK SUBASSEMBLY

(60 or 60A)
BACKPLATE AND
TORQUE TUBE
(20) (100)
SELF--LOCKING NUT TIE BOLT (30)

(10)
TORQUE TUBE SPACER

(40)
BRAKE HOUSING
ARKAS S.A.
SUBASSEMBLY
(530 or 530A)

CO: 5668
32--43--14 Page 4 of 6
Apr 11/05
FILING INSTRUCTIONS: Insert following page 4 of 6 of this Temporary Revision (32--43--14).

DESCRIPTION: Added Figure 703, Sheet 2 of 2.
R1 R2
SIDE
1 2 3 4
AT 50 PERCENT BRAKE LIFE FLIP

ROTATING DISKS R1 AND R2
AS SHOWN BELOW R2 R1
SIDE
4 3 2 1
ARKAS S.A.

CO: 5668
32--43--14 Page 5 of 6
Apr 11/05
CAUTION: ♦ REPLACE THE BOLT IF THE BOLT IS TIGHTENED TO MORE THAN

110 PERCENT OF THE RECOMMENDED TORQUE VALUE. TOO
MUCH TORQUE WILL CAUSE DAMAGE TO THE BOLT.
♦ DISASSEMBLE ALL FASTENERS THAT WERE TIGHTENED WITH A

POWER WRENCH TO MORE THAN 50 PERCENT BUT LESS THAN
110 PERCENT OF THE RECOMMENDED TORQUE VALUE.
♦ LUBRICATE ALL FASTENERS WITH ANTISEIZE COMPOUND, SPE-

CIFICATION MIL--PRF--83483, BEFORE THEY ARE ASSEMBLED
AGAIN.
(3) Draw the self--locking nuts (10) up evenly in a criss--cross pattern to a final Lubtork
value of 25 pound--feet (34 N--m).
(a) When power wrenches, other than automatic wrenching systems are used to as-
semble bolts and nuts, fastener tightness shall not exceed 50 percent of final
torque value. Do a tightening to final torque value with 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 reduce the service life of bolts and nuts.
J. If necessary, cover the heat sensor probe holes with the cover plate subassembly (490),
secure with the machine bolt (520).
K. Test brake assembly as told in the TESTING AND FAULT ISOLATION section.
4. Storage Instructions
A. Brake Assembly
CAUTION: ♦ SEAL ALL FITTINGS WITH CAPS IF THE BRAKE ASSEMBLY IS TO BE

STORED.
♦ USE A SUITABLE CAP OR EQUIVALENT TO GIVE PROTECTION TO

THE QUICK--DISCONNECT FITTINGS WHEN NECESSARY.
(1) Keep the brake assembly in a water--resistant material and a sealed corrugated card-
board container or equivalent.
(2) Store the brake assembly in a clean, dry storeroom. The storeroom temperature range
must be between 50° and 70° F (10° and 21° C). If this temperature range cannot be
ARKAS S.A.
kept, temperatures as high as 125° F (+52° C) and as low as --20° F (--29° C) are per-
mitted for short times. The full time above 100° F (38° C) must not be more than three
months.
CO: 5668
32--43--14 Page 711

Sep 27/04
B. Subassemblies
(1) Backplate and torque tube, pressure plates, and stationary disks that are to be stored
for an indefinite period should be treated as follows:
(a) Vapor degrease subassemblies to remove all oil and residue.
WARNING: ♦ DO NOT USE RUST VETO 4214 NEAR SPARKS OR FLAMES.

♦ KEEP RUST VETO 4214 AWAY FROM EYES OR SKIN.
♦ DO NOT DRINK RUST VETO 4214.
♦ RUST VETO 4214 IS POISONOUS AND FLAMMABLE.
♦ REFER TO THE MATERIAL SAFETY DATA SHEET (OR EQUIVA-
LENT) BEFORE RUST VETO 4214 IS USED.
(b) Dip subassembly in rust inhibitor (Rust Veto 4214 or equivalent). Drip dry for five
minutes or fast--dry with clean compressed air.
(c) Wrap subassembly in moisture--barrier material and package in a cardboard

container.
(d) Before the subassembly is put back in service, degrease in a vapor degreaser.
ARKAS S.A.
CO: 5668
Page 712
32--43--14 Sep 27/04

DESCRIPTION: For item 420, corrected the torque to 15 pound--feet (20,3 N--m)
FITS AND CLEARANCES
Item No. Nomenclature Torque Value Necessary

(See IPL Figure 1) Wrench Size
290 Cylinder Sleeve 55 pound--feet Special Tool

(75 N--m) 2--6068
400 or 400A Bleeder Valve 70 pound--inches 9/16 inch socket
(7,9 N--m)
420 Bleeder Valve Adapter 15 pound--feet 13/16 inch socket
(20,3 N--m)
440 Solid Plug 30 pound--feet 1 inch socket
(41 N--m)
*Lubtork: At each installation, lubricate bolt threads and bearing surfaces of bolts, washers and nuts
with antiseize compound, Specification MIL--T--84383. Use full strength. Do not dilute.
Torque Values
Figure 801
ARKAS S.A.
CO: 5668
32--43--14 Page 6 of 6
Apr 11/05
FITS AND CLEARANCES
Item No. Nomenclature Torque Value Necessary

(See IPL Figure 1) Wrench Size
10 Self--Locking Nut 25 pound--feet 1/2 inch twelve

(34 N--m) (Lubtork*) point socket
30 Tie Bolt Lubtork* 7/16 inch twelve
point socket
140 Self--Locking Nut 25 pound--inches 1/4 inch socket
(2,8 N--m)
290 Cylinder Sleeve 55 pound--feet Special Tool
(75 N--m) 2--6068
400 or 400A Bleeder Valve 70 pound--inches 9/16 inch socket
(7,9 N--m)
420 Bleeder Valve Adapter 70 pound--inches 13/16 inch socket
(7,9 N--m)
440 Solid Plug 30 pound--feet 1 inch socket
(41 N--m)
470 Fitting Reducer 30 pound--feet 1 inch socket
(41 N--m)
520 Machine Bolt -- 3/8 inch socket
*Lubtork: At each installation, lubricate bolt threads and bearing surfaces of bolts, washers and nuts
with antiseize compound, Specification MIL--T--84383. Use full strength. Do not dilute.
Torque Values
Figure 801
Item No. Compressed

(See IPL Figure 1) Nomenclature Length Load
260 Helical Compression 0.699 inches 92 to 112 pounds
Spring (17,75 mm) (41,7 to 50,8 kgs)
0.586 inches 132 to 152 pounds
(14,88 mm) (59,9 to 68,9 kgs)
ARKAS S.A.
Spring Values
Figure 802
CO: 5668
32--43--14 Page 801

Sep 27/04
Item No.
(Refer to IPL Figure 1) Nomenclature Replacement Dimension
50 or 50A Rotating Disk
Minimum Thickness 0.252 inch (6,40 mm)
Maximum out--of--flatness (dishing) 0.020 inch (0,51 mm)
Minimum inside diameter 9.05 inches (229,9 mm)

(See Figure 502)
Minimum outside diameter 14.13 inches (358,9 mm)

(See Figure 502)
Maximum keyslot width 0.945 inch (24,0 mm)

60 or 60A Stationary Disk Subassembly
Minimum Thickness 0.368 inch (9,35 mm)

80, 120, and 210 Wear Pads
Minimum width on centerline between 1.60 inches (40,6 mm)

rivet holes
(See Figure 503)
100 Backplate/Torque Tube Subassembly
Minimum wear pad thickness 0.075 inch (1,91 mm)

(See Figure 504)

backplate section
Minimum torque tube key width at any 0.225 inch (5,70 mm)
point along length of key
(See Figure 505)
Wear Tolerance (Replacement Dimension)

ARKAS S.A.
CO: 5668
32--43--14 Page 802

Sep 27/04
Item No.
190 Pressure Plate Subassembly
Minimum thickness 0.375 inch (9,53 mm)
Maximum out--of--flatness 0.015 inch (0,38 mm)

150 Adjuster Swage
Minimum thickness across corners 0.420 inch (10,69 mm)

250 Spring Holder
Minimum flange diameter 1.13 inches (28,70 mm)

270A Return Spring Housing
Maximum inside diameter 1.067 inches (27,10 mm)
Return pin hole maximum diameter 0.689 inch (17,50 mm)
Maximum bow on pressure plate end 0.030 inch (0,76 mm)

300 Piston Subassembly
Minimum height 1.398 inch (35,51 mm)

290 Cylinder Sleeve
(See Figure 506)
Maximum inside diameter 1.306 inches (33,17 mm)
Minimum gland seal area diameter 1.497 inches (38,02 mm)
Minimum thin end diameter 1.409 inches (35,79 mm)

ARKAS S.A.
CO: 5668
32--43--14 Page 803

Sep 27/04
Item No.
530 or 530A Housing Subassembly
Maximum housing subassembly 1.680 inches (42,67 mm)

cylinder cavity diameter
Maximum housing torque takeout 1.187 inches (30,15 mm)

bushing diameter
Maximum brake housing bushing 2.946 inches (74,83 mm)

diameter

Item No.
(Refer to IPL Figure 1) Nomenclature Torque Value
10 Self--Locking Nut 7 pound--inches

(Brake Bolt) (0,80 N--m)
140 Self--Locking Nut 2 pound--inches
(Return Pins) (0,23 N--m)
NOTE: Degrease nut and corresponding threaded part. If less torque than specified is re-
quired to turn the nut on its threaded part past the self--locking feature, install a new
nut.
Self--Locking Nut Minimum Locking Values

Figure 804
Nomenclature Minimum Clearance
Brake Assembly 0.020 inch (with 30 psi pressure applied)

(with new disks) 0,51 mm (with 2,1 bar pressure applied)
Operating Clearance
Figure 805
ARKAS S.A.
CO: 5668
32--43--14 Page 804

Sep 27/04
Item No.
(Refer to IPL Figure 1) Nomenclature Maximum Thickness
60 or 60A Stationary Disk Subassembly 0.426 inch

(10,82 mm)
190 Pressure Plate Subassembly 0.408 inch
(10,36 mm)
NOTE: All subassemblies must be flat within 0.010 inch (0,25 mm).
Acceptable Limits for Newly Repadded Subassemblies

Figure 806
Item No. Minimum Thickness

(Refer to IPL Figure 1) Nomenclature (after grinding)
90 or 90A Stationary Disk Base Plate 0.216 inch

(5,49 mm)
220 Pressure Plate 0.290 inch
(7,37 mm)
Base Plate and Pressure Plate Grinding Limits

Figure 807
ARKAS S.A.
CO: 5668
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Sep 27/04
THIS PAGE
KEPT
BLANK
ARKAS S.A.
CO: 5668
32--43--14 Page 806

Sep 27/04
SPECIAL TOOLS, FIXTURES AND EQUIPMENT

Figure No. Tool/Fixture No. Description Application
Figure 901 ---- Straightening Fixture Used to straighten disks and
plates
Figure 902 1--25309 Flathead Anvil Used with compression riveter to
install flathead, semitubular
GYR8A rivets.
Figure 902 1--25310 Roundhead Driver Used with compression riveter to
install roundhead, semitubular
GY18B rivets.
Figure 902 1--25311 Swaging Peen Used with compression riveter to
form shop head on semitubular
GYR8A or GY18B rivets.
Figure 903 2--10066 Flathead Anvil Used with Taumel and Bracker riv-
eter to install flathead, semitubu-
lar GYR8A rivets
Figure 903 1--26126 Swaging Peen Used with Bracket (RN311) riveter
to form shop head on semitubular
GYR8A or GY18B rivets.
Figure 903 2--10067 Roundhead Anvil Used with Bracker or Taumel riv-
eter to install roundhead, semitub-
ular GY18B rivets.
Figure 904 1--25807 Swaging Peen Used with Taumel riveter to form
shop head of GYR8A and GY18B
rivets.
Figure 904 2--10080 Tool Holder Used with Taumel riveter head
T--21 to hold swaging peen.
Figure 904 2--5994 Taumel Riveter Head Used in conjunction with tool hold-
er (2--10080) to hold swaging
peen.
---- PRAM 31 Plastic Reclaimable Equipment for dry paint stripping.
Abrasive Machine
(PRAM)* (V86413)
Figure 905 ---- Brake Wear Measure- Used to measure the quantity of
ment Tools brake wear.
Figure 906 2--10890 Spring Compression Used as a standoff for the spring
Tool return mechanism for installing
and removing the retaining ring
ARKAS S.A.
Figure 907 2--6068 Cylinder Sleeve Used to engage the wrenching

Wrench feature on the cylinder sleeve
CO: 5668
Page 901
32--43--14 Sep 27/04

Figure 908 2--10240--1 Staking Tool Used to install oversized passage
ball plug in the brake housing.
-- SR 19R Insert Removal Tool Used to remove the self--locking
insert M45932/1--9L for the sen-
sor cover hole.
-- SR19W--A Drive Wrench Used to remove the self--locking
insert M45932/1--9L for the sen-
sor cover hole.
-- SRW19S--A Swage Tool Used to insert the oversize self--
locking insert SRW192L.
-- P--102L Retaining Ring Used for installation and removal
Removal/Installation of retaining ring (240).
Tool
Can be purchased
from:
Industrial Retaining
Ring Co.
57 Cordier Street
Irving, NJ
07111--4035
Ph.: 201--926--5000
Fax: 201--926--469
-- CUT Expander Plug Used to drive the expander plug
A2500203A Installation Tool into the cavity in the housing
ARKAS S.A.
CO: 5668
32--43--14 Page 902

Sep 27/04

HKW010108 Nosepiece Used for installation of expander
HK010308 Jaw Case plugs, item (610)
HK014208 Jaws
HK01508 Jaw Pusher
For information about special tools call your nearest ABSC representative or call:
Aircraft Braking Systems Corporation
Department 709, Technical Support Engineering
1204 Massillon Road
Akron, Ohio 44306--4186
Ph: 330--796--6972
Fax: 330--796--9873
NOTE: Aircraft Braking Systems’ special tools may be purchased by contacting:
Sales Manager
National Machine Company
4880 Hudson Drive
Stow, Ohio 44224
Ph: 330--688--6494
Fax: 330--688--6952
Commercial and Government Entities (CAGE) Code 6L817
*See IPL Commercial and Government Entities (CAGE) Codes for manufacturer’s names and
addresses.
The following types of riveters are used in the manufacture and repair of brakes:
Compression Riveter U.S. Industrial Tool & Supply Company

Model 150 (or equivalent) 15101 Cleat Street
Plymouth, MI 48170
Ph.: (800) 397--6193
Fax: (734) 455--3256
Bracker Radial Bracker Corporation
Model RN211 or RN311 105 Broadway Avenue
Carnegie, PA 15106--0441
Ph.: (412) 276--4400
Spin Riveter Taumel Noiseless Riveters, Incorporated
Model BK1000 or TC320 Rt. 22 Robin Hill Corporate Pk
P.O. Box 239
Patterson, NY 12563
Ph.: (914) 878--3100
ARKAS S.A.
CO: 5668
Page 903
32--43--14 Sep 27/04
2 x 2 ( 50,8 x 50,8 ) ANGLE IRON WELDED TO DIE
POINT OF ATTACHMENT TO HAND ARBOR PRESS
2.0 ( 50,8 )
A A
1.50 ( 38,1 )
0.0312 ( 0,794 ) x 45°
10.00 ( 254,0 ) SECTION A -- A

UPPER REGISTER PLATE
0.125 ( 3,175 )
B B
0.1875 ( 4,76 )
0.75 ( 19,05 )
SECTION B -- B
LOWER REGISTER PLATE
8.00 ( 203,2 )
14.31 ( 363,4 )
15.00 ( 381,0 ) NOTE:

1. LOCAL MANUFACTURE
ARKAS S.A.
Fabrication Details for Register Plates

Figure 901
CO: 5668
32--43--14 Page 904

Sep 27/04
FLATHEAD ANVIL 1 -- 25309
ROUNDHEAD DRIVER 1 -- 25310
SWAGING PEEN 1 -- 25311 ARKAS S.A.
Special Tools for Use with Compression Riveter

Figure 902
CO: 5668
Page 905
32--43--14 Sep 27/04
ROUNDHEAD ANVIL 2 -- 10067
FLATHEAD ANVIL 2 -- 10066
SWAGING PEEN 1 -- 26126
NOTE:
1. SWAGING PEEN AND ANVILS SHOWN ARE FOR USE WITH BRACKER RIVETER
PART NUMBER RN 211 OR RN 311.
ARKAS S.A.
Special Tools for Use with Bracker Riveter

Figure 903
CO: 5668
32--43--14 Page 906

Sep 27/04
SWAGING PEEN 1 -- 25807
TOOL HOLDER 2 -- 10080
2 -- 5994
TAUMEL
RIVETER HEAD T -- 21
ARKAS S.A.
Special Tools for Use with Taumel Riveter

Figure 904
CO: 5668
Page 907
32--43--14 Sep 27/04
1.1 (27,9)
0.30 (7,62)
2.5 (63,5)
0.10 (2,54)
1.0 (25,4) 0.0625 (1,59)
Brake Wear Measurement Tool

Figure 905
ARKAS S.A.
Spring Compression Tool 2--10890

Figure 906
CO: 5668
32--43--14 Page 908

Sep 27/04
Cylinder Sleeve Wrench Tool 2--6068

Figure 907
ARKAS S.A.
Staking Tool 2--10240--1

Figure 908
CO: 5668
Page 909
32--43--14 Sep 27/04
THIS PAGE
KEPT
BLANK
ARKAS S.A.
CO: 5668
32--43--14 Page 910

Sep 27/04
ILLUSTRATED PARTS LIST
1. Introduction
A. General
(1) The Illustrated Parts List (IPL) section illustrates and lists the procurable parts of the
assembly(ies) in this publication.
B. Parts List
(1) The figure is an exploded view of assembly(ies) included in the parts list.
(2) Components in the parts list are given in the order of disassembly. The attaching parts
are given immediately after the part which they attach. Alternate, optional or repair
parts are given after the primary part.
(3) The Figure and Item column contains the figure and item number for each part. The
item numbers in the parts list agree with the item numbers in the figure.
(4) The Part Number column gives the part number that is formatted to be compliant with
the ATA Specification 2000. When the part has a number that in its original format
is not compliant with Specification 2000, it will be included in the Nomenclature col-
umn in parentheses. Use the part number in its original format in the Nomenclature
column to confirm the correct part is ordered.
(5) The Airline Stock Number column is for the operator to write airline part numbers.
(6) The Nomenclature column gives the noun name of each part in upper case letters. De-
tails, dimensions and specifications that help identify the part are given after the noun
name. The names of the parts are indented to show the relation of the parts to their
subassemblies and the top assembly. Additional data in parentheses can identify op-
tional, alternate, and repair parts and can give other data to help identify and order the
part including the original part number when it is not compliant with Specification 2000.
Commercial and Government Entities (CAGE) codes identify the suppliers of vendor
parts. The letter “V” is put before the five--digit CAGE code.
(7) The Effect Code column shows the parts to be used on each top assembly. Each top
assembly is given a letter such as A, B, C, D, etc. This letter will be in the Effect Code
column of each part used in that top assembly. A part number identified by an effectiv-
ity code ( a single upper case alpha designation) denotes that the coded part must be
used with other parts identified with the same alpha designation. A coded part can be
used with all other non--coded parts (Effect Code column will be blank).
(8) The Units Per Assembly column gives the number of parts contained in each as-
sembly or subassembly. An RF in this column means that the item is listed for
REFERENCE ONLY. An AR in this column means that the item quantity is AS RE-
QUIRED and could vary if alternate build options are used.
ARKAS S.A.
CO: 5668
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Sep 27/04
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 NOMENCLATURE 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.
Optional This part is sold separately.
Use of this part in the assembly is not required.
D. Commercial and Government Entities (CAGE) Codes
Code No. Name and Address
0VMN9 Sherex Industries

1400 Commerce Parkway
Lancaster, NY 14086
Ph.: 716--681--6250
Fax: 716--681--0270
09257 Busak and Shamban Inc.

Shamban Seals Division
2531 Bremer Drive
P.O. Box 176
Fort Wayne, IN 46803--3014
Ph.: 310--450--0020
Fax.: 219--749--0066
56878 SPS Technologies, Incorporated

Aerospace and Industrial Products Division
310 Highland Avenue
ARKAS S.A.
Jenkintown, PA 19046
Ph.: 215--572--3017
Fax: 215--572--3193
CO: 5668
32--43--14
Page 1002
Sep 27/04
Code No. Name and Address
79136 Waldes Truarc, Incorporated

Division of Seeger Incorporated
500 Memorial Drive
P.O. Box 6723
Somerset, NJ 08875--6723
Ph.: 800--228--4460
Fax: 732--469--2532
83324 Rosan/Aerospace Fastener Division

Fairchild Fastener Group
3000 W. Lomita Blvd.
Torrance CA 90505--5103
Ph.: 310--784--0700
Fax: 310--784--6606
86413 Pauli and Griffin Company, Incorporated

907 Cotting Lane
Vacaville, CA 95688--9338
Ph.: 707--429--2434
Fax: 707--429--2424
92555 The Lee Company

Technical Center
2 Pettipaug Road
P.O.Box 424
Westbrook, CT 06498--0424
Ph.: 860--399--6281
Fax: 860--399--7058
97464 Industrial Retaining Ring Company

57 Cordier Street
Irvington, NJ 07111--4035
Ph.: 973--926--5000
Fax: 973--926--4699
99017 Protective Closures Co., Inc.

Caplugs Division
2150 Elmwood Ave.
Buffalo, NY 14207--1910
Ph.: 716--876--9855
Fax: 716--874--1680
ARKAS S.A.
CO: 5668
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Sep 27/04
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KEPT
BLANK
ARKAS S.A.
CO: 5668
32--43--14
Page 1004
Sep 27/04
30
50A
60A B
100 A
460A
50A 470
E
480
530A D
180
340
290
190 C 40 650
350 370
360 or
330 or 360B
330B 640
300 20
280 10
450
440
490 G
150 F
140
ARKAS S.A.
230A H 520
Brake Assembly 5012609

IPL Figure 1 (Sheet 1 of 2)
CO: 5668
32--43--14 Page 1005

Sep 27/04
120 80
70
110
130 90A
A B
570
580
210
220
560
540A
200 C 550 D
400 or 170A
380
400A 160
420
F 240
390 250
410 or 270A
510
ARKAS S.A.
430 or 410B 260

430B
E 500 G H
Brake Assembly 5012609
IPL Figure 1 (Sheet 2 of 2)
CO: 5668
32--43--14
Page 1006
Sep 27/04
2. Parts List
FIGURE PART NUMBER AIRLINE NOMENCLATURE EFFECT UNITS

ITEM STOCK CODE PER
NUMBER 1 2 3 4 5 6 7 ASSY
1 --1 5012609 BRAKE ASSEMBLY RF

10 42FLW624 . NUT, Self--Locking (V56878) 5 R
(42FLW--624)
20 MS14155--6 . WASHER, Recessed 5
30 MS21250--06020 . BOLT, Tie (Twelve Point, 5
External Wrenching)
40 5011315 . SPACER, Torque Tube 1
--50 5012603** . DISK, Rotating 2 R
50A 5013431 . DISK, Rotating 2
--60 5012608** . DISK SUBASSEMBLY, 1 R
Stationary
60A 5013656 . DISK SUBASSEMBLY, 1
Stationary
70 GYR8A20 . . RIVET, Tubular 32 R
(GYR8A--20)
80 5006954 . . PAD, Wear 32
--90 5012601** . . DISK, Stationary 1 R
90A 5013654 . . DISK, Stationary 1
100 5006971 . TUBE SUBASSEMBLY, 1
Backplate and Torque
110 GY18B11 . . RIVET, Tubular 32 R
(GY18B--11)
120 5006954 . . PAD, Wear 16
130 5006972 . . TUBE, Backplate and 1
Torque
-- Item not illustrated.

* Item not furnished -- order separately.
ARKAS S.A.
** Item no longer available, use until stock is depleted.

◊ Item not procurable, order item (300)
CO: 5668
32--43--14 Page 1007

Sep 27/04

ITEM STOCK CODE PER
140 FN12--02 . NUT, Self--Locking (V56878) 5

150 5012607 . TUBE SUBASSEMBLY, 5
Swage
160 5004743 . . SWAGE, Adjuster 1
--170 5012596 . . DELETED (Superseded -- R
by item 170A)
170A 5009642 . . TUBE, Self--Adjusting 1
Swage
180 5008245 . PIN, Straight Headed 5
(Return)
190 5009841 . PLATE SUBASSEMBLY, 1
Pressure
200 GY18B8 . . RIVET, Tubular 32 R
(GY18B--8)
210 5006954 . . PAD, Wear 16
220 5009840 . . PLATE, Pressure 1
--230 5012660 DELETED (Superseded by --
item 230A in Service Bulle-
tin ATR42--500--32--1)
230A 5013266 . HOLDER SUBASSEMBLY, 5
Spring
240 7200--66STZD . . RING, Retaining (V97464) 1 R
(7200--66--ST--ZD)
250 5012599 . . HOLDER, Spring 1
260 5012598 . . SPRING (Helical Com- 1 R
pression)

ARKAS S.A.
CO: 5668
32--43--14
Page 1008
Sep 27/04

ITEM STOCK CODE PER
--270 5012600 . . DELETED -- R

(Superseded by item
270A in Service Bulletin
ATR42--500--32--1)
270A 5013265 . . HOUSING, Return Spring 1 R
280 RS115L . RING, Retaining (V80756) 1 R
(RS--115--L)
290 5012986 . SLEEVE, Cylinder 5
300 5012984 . PISTON SUBASSEMBLY, 5
Brake
--310 5012985 ◊ . . INSULATOR, Piston 1 R
--320 5012594 ◊ . . PISTON, Brake 1 R
330 5007173 . PACKING, Preformed 5
--330A NAS1611--128 DELETED R
330B ABP002--128 . PACKING, Preformed 5 R
(Alternate for item 330)
340 MS28774--128 . RETAINER, Packing (Backup) 10
350 5012616 . RING, Piston Wiper 5
(alternate for item 360)
370 MS28774--215 . RETAINER, Packing (Back- 5
up)
380 MS35207--259 . SCREW, Machine (Bleeder) 2
390 511846--4 . WASHER, Bleeder (Flat) 2

ARKAS S.A.

CO: 5668
32--43--14 Page 1009

Sep 27/04

ITEM STOCK CODE PER
400 MS27611 . VALVE, Bleeder 2

400A 9534661 . VALVE, Bleeder (alternate 2
for item 400)
420 MS27612--7 . ADAPTER, Hydraulic Bleed- 2
er Valve
440 AN814--8L . PLUG, Solid 1
(Referred to as PLUG &
BLEEDER in AN814)
--460 1604--167 DELETED (Superseded by -- R
item 460A)
460A ASC4DN . CAP, Protective (V99017) 1 R
(ASC--4DN)
470 MS21916K8--4 . REDUCER, Fitting 1
490 5004627 . PLATE SUBASSEMBLY, 2
Cover
500 5004624 . . PLATE, Cover 1

ARKAS S.A.
CO: 5668
32--43--14
Page 1010
Sep 27/04

ITEM STOCK CODE PER
510 GYR8B7 . . RIVET, Tubular 1 R

(GYR8B--7)
(ATTACHING PARTS)
520 AN3C3A . BOLT, Machine 2
-- -- -- *** -- -- --
--530 5012982 . HOUSING SUBASSEMBLY, 1 R
Brake (Superseded by
item 530A)
530A 5012982--1 . HOUSING SUBASSEMBLY, 1
Brake
--540 5012983 . . HOUSING, Brake 1
(Superseded by item
540A, refer to
ATR42--500--32--1)
540A 5012983--1 . . HOUSING, Brake 1
550 5006955 . . BUSHING, Torque Takeout 1
560 5006956 . . BUSHING, Housing 1
570 5006957 . . BUSHING, Housing 1
580 M45932--1--9L . . INSERT, Self--Locking 2 R
(M45932/1--9L)
585 SRW192L . . INSERT, Self Locking 2 R
(Repair only)
--590 GYP00 . . PLUG, Passage Ball 6 R
(used in item 530)
--600 GYP1 . . PLUG, Passage Ball AR
(Repair only, oversize)

ARKAS S.A.
CO: 5668
32--43--14 Page 1011

Sep 27/04

ITEM STOCK CODE PER
--610 HK050CK11--111* . . PLUG, Expander 6 R

(VOVNM9)
(Replaced by
item 610A)
(used in item 530A)
--610A SK550--050 . . PLUG, Expander 6 R
(VOVNM9)
(used in item 530A)
--615 2500010A . . PLUG, Pin (V92555) R
(used on item 530A)
--620 5002018 . BUSHING, Bleeder Valve, AR R
Threaded (Repair only,
use with items 400 or
400A)
--630 MS28778--10 . PACKING, Preformed AR R
(Repair only, use with
item 620)
640 5007474 . PLATE, Data Skydrol 1
650 5007388 . PLATE, Instruction Data 1

ARKAS S.A.
CO: 5668
32--43--14
Page 1012
Sep 27/04

Illustred Part Brake assemblyAP-766

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TO: HOLDERS OF AP--766 (32--43--14) COMPONENT MAINTENANCE MANUAL WITH

REVISION NO. 2 DATED 27 SEPTEMBER 2004

Chapter/Section/Page No. Description of Change

Title Page Revised to current revision number and date.

Record of Revisions, Added Revision No. 2.

Record of Temporary Revisions, Added Temporary Revision Nos. 32--3 through 7.

Table of Contents, Revised to reflect current revision.

Chapter/Section/Page No. Description of Change

All pages as applies Changed MIL--G--81322 to MIL--PRF--81322,

page 6 Described improvement in terminal slots design.

page 101 Updated the Materials paragraph.

page 106 In paragraph 3.K.(2) changed preformed packing to 330B.

pages 107 and 108 In paragraph 4.A.(2)(b) revised pressure requirement.

page 301 Updated the Materials paragraph.

page 303 In paragraph 3.E.(3) inserted disassembly instructions if stressed

page 402 Revised conversion of 15 psi in caution note.

Chapter/Section/Page No. Description of Change

page 403 In paragraph 2.A. and 2.A.(3) revised conversion of 15 psi.

Page 404 Revised warning note to paragraph 3.

page 514 Added item 460A.

page 603 Corrected fluid specification.

page 605 In paragraph 4.A.(1) rounded off metric drill size.

page 606 In paragraph 4.D. rounded off metric conversion.

Chapter/Section/Page No. Description of Change

page 613 Added note to paragraph 6.C.

Page 616 In paragraph 6.E. added “...as given in paragraph 7.H.”

page 617 In paragraphs 6.I., 7.A.,7B. and 7C. changed references to

page 620 In paragraph 7.G. added reference to paragraph 7.H.

page 623 Changed to new chemical film specification.

page 625 Made minor editorial corrections.

page 626 In paragraph 9.C. added reference to Repair No. 4.

page 629 Updated chemical film solution specification.

page 632 Notes 1 was revised for application of topcoat only.

Chapter/Section/Page No. Description of Change

page 633 Paragraph 15.C.(3) updated chemical film solution

page 634 Paragraph 15.D.(2) updated chemical film solution specification.

page 635 In paragraph 15.E.(3)(c) corrected the paint thickness

page 601 to 603, Repair 1 Added not to paragraph 1.A.

page 701 In paragraph 1. corrected supplier addresses, etc.

page 702 In paragraph 2.D. updated the lubtork specification.

page 703 Changed protective cap to 460A.

pages 704 and 705 Changed to brake piston subassembly per

Chapter/Section/Page No. Description of Change

page 708 Updated antiseize compound specification.

page 710 Added caution note about over--torqued bolts.

page 1001 Added new introduction to Illustrated Parts List.

pages 1002 and 1003 Added paragraph C.

page 1008 Deleted item 170 per Temporary Revision 32--3.

page 1010 Deleted item 410A, Added item 410B

Deleted item 460 and added item 460A.

Chapter/Section/Page No. Description of Change

page 1011 Added full part number to item 510.

page 1012 Added item 610A.

COMPONENT MAINTENANCE MANUAL

ILLUSTRATED PARTS LIST

PART NO. 5012609

BASIC ISSUE AUG 27, 1996

© ABSC 2004 ALL RIGHTS RESERVED

CAGE CODE 0B9R9 (RELEASED: 9/27/04 )

TEMPORARY REVISION NO. 32--8

TO: HOLDERS OF AP-766 (32-43--14) COMPONENT MAINTENANCE MANUAL WITH

RECORD OF TEMPORARY REVISIONS