BFGoodrich Aerospace

l
\_
i31FGooclrich
Aerospace
Aircraft Wheels and Brakes
P.O. Box 340
Troy, Ohio 45373
U.S.A.
TEL: 513-339-3811
FAX: 513-339-3813
CAGE: 97153
COMPONENT MAINTENANCE MANUAL
WITH
ILLUSTRATED PARTS LIST
CESSNA
CITATION I, II
MODELS 500, 501 WITH POWER HYDRAULIC SYSTEMS
AND MODELS 550 AND 551
MAIN LANDING GEAR BRAKE ASSEMBLY
PART NUMBERS
2-1528-1
2-1528-2
2-1528-3
2-1528-4
2-1528-5
2-1528-6
C © IIFGooclrloh 19 94
Ael0llpace
Page T-1
82
32-46-42 Apr 30/94
BF GOODRICH AEROSPACE
MAIN BRAKE ASSEMBLY, P/N 2-1528
REVISION HIGHLIGHTS
Revision No. 4
Dated: Apr 30/94
NOTICE:
This manual is being reissued to replace the previous manual of
the same number, Dated Aug Apr 26/91.
Revisions to this manual include:
1. Addition of brake assemblies, P/N 2-1528-4, 2-1528-5, and
2-1528-6
2. Addition of shuttle valve overhaul
3. Revised WARNINGS
4. Revised Magnetic Particle Inspection standard from MIL-STD-1946
to ASTM E1444-91
Page RH-1
32-46-42 Apr 30/94
(
MAIN BRAKE ASSEMBLY, PIN 2-1528
RECORD OF REVISION
Keep this record in front of the manual. On receipt of revision,

insert revised pages in the manual, and write the revision number,
date inserted and initial.
REV. REV. DATE REV. REV. DATE

NO. DATE INSERTED BY NO. DATE INSERTED BY
Issued Nov 30/88
1 Feb 15/89
2 Mar 24/89
3 Apr 26/91
4 Apr 30/94
32-46-42 Page RR-1

Apr 30/94
RECORD OF TEMPORARY REVISION
Keep this record in front of the manual. On receipt of temporary
I
revision, insert yellow revision pages into manual opposite pages
being revised. Write the temporary revision number, date
inserted, and initial. Do not remove yellow sheets until a
permanent revision including this information is issued.
TEMPORARY
REVISION PAGE DATE BY DATE BY
NUMBER NUMBER ISSUED REMOVED
32-1 701, 801 Jan 29/90 Apr 26/91

32-2 401 Feb 26/90 Apr 26/91
32-46-42 Page TR-1

Apr 30/94
SERVICE BULLETIN RECORD
Keep this record in the front of the manual. When Service
Bulletins or Service Letters are included into a new revision of
the manual, they are shown on this page. Service Letters usually
only contain general data, but are included here for a record and
because they can contain added procedures and modification data.
SERVICE SERVICE DATE OF

BULLETIN LETTER NUMBER INCORP. DESCRIPTION
NUMBER NUMBER REVISION INTO
MANUAL
2-1528-32-1 Apr 26/91 SHUTTLE VALVE
(BFG 517) INSPECTION AND
REPLACEMENT
1477 1 Apr 26/91 CONVERSION TO THE
2-1530-1 BRAKE ASSEMBLY
NO EFFECT TO THIS MANUAL
1500 Apr 26/91 PISTON SLEEVE BACK-UP
RINGS
1504 1 Apr 26/91 PRESSURE AND TORQUE
PLATE ASSEMBLY WEAR
PLATE EVALUATION
1507 Apr 26/91 ALTERNATE PROCEDURE FOR
ASSEMBLING THE PRESSURE
PLATE TO THE PISTON
HOUSING AND SETTING
ADJUSTER
1508 Apr 26/91 CARRIER AND LINING
ASSEMBLY DRIVE SLOT
WEAR EVALUATION
1521 1 Apr 26/91 CONVERTING THE 2-1528-1
TO THE 2-1528-2 BRAKE
ASSEMBLY
1524 1 Apr 26/91 BLEEDING PROCEDURE TO
AVOID BRAKING
SENSITIVITY
1571 Apr 26/91 BRAKE CHATTER
1581 Apr 30/94 BLEEDER BLOCK
CONVERSION KIT (489-33)
Page SB-1
32-46-42 Apr 30/94
l
C -
LIST OF EFFECTIVE PAGES
SUBJECT llif DATE SUBJECT PAGE DATE
Title Page T-1 Apr 30/94 Cleaning 401 Apr 30/94
2 BLANK 402 Apr 30/94
Revision RR-1 Apr 30/94 Check 501 Apr 30/94
Highlights 2 BLANK 502 Apr 30/94
503 Apr 30/94
Revision RR-1 Apr 30/94 504 Apr 30/94
Record 2 BLANK 505 Apr 30/94
506 Apr 30/94
Temporary TR-1 Apr 30/94 507 Apr 30/94
Revision 2 BLANK 508 Apr 30/94
Record 509 Apr 30/94
510 Apr 30/94
Service SB-1 Apr 30/94 511 Apr 30/94
Bulletin 2 BLANK 512 Apr 30/94
Record
Repair 601 Apr 30/94
List of LEP-1 Apr 30/94 602 Apr 30/94
Effective 2 Apr 30/94 603 Apr 30/94
Pages 604 Apr 30/94
605 Apr 30/94
List of LSM-1 Apr 30/94 606 Apr 30/94
Special 2 Apr 30/94 607 Apr 30/94
Materials 3 Apr 30/94 608 Apr 30/94
4 BLANK 609 Apr 30/94
610 Apr 30/94
Table of T/C-1 Apr 30/94 611 Apr 30/94
Contents 2 Apr 30/94 612 Apr 30/94
Introduc- INTR0-1 Apr 30/94 Assembly 701 Apr 30/94
tion 2 Apr 30/94 702 Apr 30/94
703 Apr 30/94
Description and 1 Apr 30/94 704 Apr 30/94
Operation 2 Apr 30/94 705 Apr 30/94
3 Apr 30/94 706 Apr 30/94
4 Apr 30/94 707 Apr 30/94
708 Apr 30/94
Testing and 101 Apr 30/94 709 Apr 30/94
Fault 102 Apr 30/94 710 Apr 30/94
Isolation 103 Apr 30/94 711 Apr 30/94
104 Apr 30/94 712 Apr 30/94
713 Apr 30/94
Disassembly 301 Apr 30/94 714 Apr 30/94
302 Apr 30/94 715 Apr 30/94
303 Apr 30/94 716 Apr 30/94
304 Apr 30/94 717 Apr 30/94
305 Apr 30/94 718 Apr 30/94
306 Apr 30/94 719 Apr 30/94
BLANK
C
Page LEP-1
32-46-42 Apr 30/94
LIST OF EFFECTIVE PAGES
SUBJECT PAGE .2!ll
Fits and 801 Apr 30/94
Clearances 802 BLANK
Special Tools, 901 Apr 30/94
Fixtures and 902 Apr 26/91
Equipment 903 Apr 26/91
904 Apr 26/91
905 Apr 26/91
906 Apr 26/91
Illustrated 1001 Apr 30/94
Parts List 1002 Apr 30/94
1003 Apr 30/94
1004 Apr 30/94
1005 Apr 30/94
1006 Apr 30/94
1007 Apr 30/94
1008 Apr 30/94
1009 Apr 30/94
1010 BLANK
32-46-42 PageLEP-2
Apr 30/94
~. LIST OF SPECIAL MATERIALS
~= Equivalent replacements may be used for materials listed
below, but not for bearing grease and antiseize compound.
WHERE
USED
PRODUCT VENDOR'S VENDOR'S T C C R A
NOMENCLATURE TRADE NAME ADDRESS E L H E s
s E E p s
T A C A Y,
N K I
R
Cleaning Product Commercially X
DRY CLEANING Available
SOLVENT
P-D-680 Type II
TOLUOL Available
BUTYL ALCOHOL Available
Paint Remover Allied-Kelite 2701 Lake Street X
CHEMICAL REMOVER Division of Melrose Park,
A-127-B Witco Illinois 60160-
Chemical Corp. 3041
U.S.A.
Abrasive Blasting Abrasive Products 712 East Ohio St. X
WALNUT HULLS P.O. Box 217
Fortville, Indiana
or 46040
U.S.A.
PLASTIC MEDIA
Examination Approved Vendor X X
Product
PENETRANT FLUID
MIL-STD-6866
Metal Repair Smooth-On Inc. 1000 Valley Road X
Product Gillette,
METALSET A-4 New Jersey 07933
U.S.A.
or
Metal Repair Devcon Corp. 61 Endicott Street X
Product Danvers,
DEVCON F Massachusetts
01923
U.S.A.
Page LSM-1
32-46-42 Apr 30/94
LIST OF SPECIAL MATERIALS
WHERE
USED
PRODUCT VENDOR'S VENDOR'S T C C R A
s E E p s
T A C A Y,
N K I
R
Anti-Corrosion Approved Vendor X
Product
SURFACE
TREATMENT
MIL-C-5541
Paint Product Ashland Chemical 1-800-228-0965 X
THINNER Company U.S.A.
MIL-T-81772 D-385
Cleaning Product Commercially X X
NAPHTHA Available
TT-N-95 or TT-N-97
METHYL-ETHYL- Available
KETONE CM.E.K.)
Paint Product U.S. Paint 831 s. 21st Street X
ALUMIGRIP Corporation St. Louis,
URETHANE PAINT Missouri 63103-
SYSTEM) 3092
U.S.A.
REDUCER THINNER X
CT0003)
EPOXY POLYAMIDE X
PRIMER CMIL-P-
23377)
TYPE I, CLASS 1
Alternate Primer Deft Inc. 17451 Von Karman X
Avenue,
WATER-REDUCIBLE Irvine,
EPOXY POLYAMIDE California 92714
PRIMER U.S.A.
MIL-P-85582 1-800-544-DEFT
Anti-Corrosion Commercially X X
ZINC CHROMATE Available
PRIMER
TT-P-1757
Page LSM-2
32-46-42 Apr 30/94
LIST OF SPECIAL MATERIALS
WHERE
USED
PRODUCT VENDOR'S VENDOR'S T C C RA
s E E p s
T A C A Y,
N K I
R
Sealant X
LOCTITE SEALENT Loctite 705 North
(NO. 262) Corporation Mountain Road
Newington,
Connecticut
06111-1411
Page LSM-3
32-46-42 Apr 30/94
-)
TABLE OF CONTENTS
SECTION PAGE
DESCRIPTION AND OPERATION
DESCRIPTION . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . 3
TESTING AND FAULT ISOLATION
PREPARATION FOR FUNCTIONAL TEST. . . . . . • . 101
FUNCTIONAL TEST . . . . . . . . . . . 102
SHUTTLE VALVE ASSEMBLY TEST . . . . . 102
. . . .
ADJUST THE ROD AND INSERT ASSEMBLIES . • 103
FAULT ISOLATION CHART . . . . . . . . . . . 104
DISASSEMBLY
PISTON HOUSING REMOVAL . . . . • . . . . . • 301
PRESSURE PLATE AND WEAR PLATE ASSEMBLY REMOVAL . . 302
PISTON HOUSING DISASSEMBLY . . . . . 303
ADJUSTER ASSEMBLIES . . . . . . 304
HEAT SINK REMOVAL . . 305
SHUTTLE VALVE DISASSEMBLY . . . . . 305
CLEANING
CLEAN METAL PARTS . . . . . . 401
CLEAN NON-METAL PARTS . . . . . 401
REMOVE PAINT FROM PISTON HOUSING . . . . . . 402
ABRASIVE BLASTING . . . . 402
CHEMICAL PAINT REMOVER . . . . . . 402
CHECK
EXAMINE WEAR PLATE . . . . . . 501
EXAMINE CARRIER AND LINING ASSEMBLY .
. . 503
EXAMINE DISK . . . . . . 505
EXAMINE TORQUE PLATE . . . . . 506
EXAMINE PRESSURE PLATE .
EXAMINE ADJUSTER ASSEMBLY COMPONENTS .
. . .
. .
. .
. 507
508
EXAMINE SHUTTLE VALVE . . . . . . 510
EXAMINE PISTON HOUSING ASSEMBLY . . . . 510
MISCELLANEOUS EXAMINATIONS . . . . 511
REPAIR
PRESSURE PLATE ASSEMBLY REPAIR . . . . . . . . 601
TORQUE PLATE ASSEMBLY REPAIR . . • . • . . . 603
CARRIER AND LINING ASSEMBLY REPAIR
. . . . .
.
. .• .• . 604
DISK REPAIR . . . . . . . . 605
SHUTTLE VALVE REPAIR . . . . . . . . . 605
PISTON HOUSING ASSEMBLY REPAIR . . . . . . . . • . 606
REPLACE LEE PLUGS . . . . . . . . • . . . . 607
SURFACE TREATMENT . . . . . 608
PACKING REPLACEMENT ;, . . 608
PAINT PISTON HOUSING . . . 608
Page TC-1
32-46-42 Apr 30/94
TABLE OF CONTENTS
t'
SECTION !ill
ASSEMBLY
ASSEMBLE ADJUSTERS • • • • • . 701
ASSEMBLE SHUTTLE VALVE •••• . 703
PISTON HOUSING ASSEMBLY • • • • . 704
INSTALL PRESSURE PLATE AND WEAR PLATE ASSEMBLY • • •
ALTERNATE PROCEDURE FOR INSTALLATION OF PRESSURE PLATE
. 706
AND WEAR PLATE ASSEMBLY • . 707
SET ADJUSTERS ••• . 707
INSTALL WEAR INDICATOR PARTS • . 708
HEAT SINK ASSEMBLY AND PISTON HOUSING ASSEMBLY • • . 708
SHUTTLE VALVE INSTALLATION WITHOUT ADAPTER • • • • . 709
SHUTTLE VALVE INSTALLATION WITH ADAPTER •• . 710
ADAPTER AND BLEEDER ASSEMBLY INSTALLATION . 711
BLEEDING PROCEDURE TO AVOID SENSITIVITY OF BRAKES •
ADJUST THE ROD AND INSERT ASSEMBLIES WITH NEW HEAT SINK
. 711
COMPONENTS • • • • • • • •
ADJUST ROD AND INSERT ASSEMBLIES WITH USED HEAT SINK
. 716
COMPONENTS . 717
STORAGE INSTRUCTIONS • . 719
FITS AND CLEARANCES . 801
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT
PEEN AND ANVIL RIVETING TOOL . 902
FURNACE FLATTENING FIXTURE . 903
PRESSURE PLATE INSTALLATION TOOL . . 904
PURPOSE
EXPLANATION AND USAGE OF SECTION
. 1001
1001
EXPLODED VIEW . 1005
PARTS LIST . 1006
32-46-42 Page TC-2

Apr 30/94
INTRODUCTION
This manual gives the function of parts and the maintenance data
that is required for full shop repair.
Each section of this manual has a title and its own range of
special page numbers.
Refer to the TABLE OF CONTENTS for the page location of sections
and subsections.
The start of the REPAIR section includes the Dimensioning
Tolerances used.
How to use the ILLUSTRATED PARTS LIST is given in the Introduction
to that section.
All weights and measurements in the manual are in U.S. English
units followed by the S.I. (metric units> in parentheses. English
units are shown with a period for the decimal point and metric
units are shown with a comma for the decimal point. Large numbers
with five or more digits to the left of the decimal point have a
space (instead of a comma) between the "thousands" and "hundreds''
digits to prevent confusion with metric decimal points.
The manual will be revised as necessary to add current information.
Verification:
Testing: Disassembly: Assembly:
Jul 1/88 Jul 1/88
Federal and MIL Specifications referenced in this publication may
be ordered from:
NAVAL PUBLICATIONS AND FORMS CENTER
5801 TABOR AVENUE
PHILADELPHIA, PA 19120
U.S.A.
ASTM publications referenced in this manual can be ordered from:
AMERICAN SOCIETY FOR TESTING AND MATERIALS
1916 RACE STREET
PHILADELPHIA, PA 19103-1187
U.S.A.
I Page INTR0-1
Apr 30/94
INTRODUCTION
NOTICE!!
This manual gives maintenance procedures that will keep the brake
assembly in an airworthy condition. These procedures are recommended,
but are not required. The overhaul facility is responsible for
careful analysis of procedures that are different than BFGoodrich
procedures, to make sure that the brake assembly stays in an airworthy
condition.
NOTICE!!
Carefully read and obey CAUTION and WARNING statements in this
manual. Refer to the descriptions of these statements that
follow:
• equipment.
A "CAUTION" statement is given to prevent damage to
• A "WARNING" statement is given to prevent personal injury.
WARNING: THE USE OF REPLACEMENT PARTS THAT ARE NOT AUTHORIZED BY

BFGOODRICH WILL AUTOMATICALLY VOID ALL WARRANTIES EXTENDED
BY BF GOODRICH UNLESS THE OPERATOR CAN SUBSTANTIATE IN
WRITING THAT SUCH PARTS HAVE BEEN AUTHORIZED FOR
INSTALLATION UNDER FAA REGULATIONS AND MEET ALL AIRFRAME
MANUFACTURER'S REQUIREMENTS FOR ORIGINAL EQUIPMENT APPROVAL.
NOTWITHSTANDING ANY FAA APPROVALS OR DEMONSTRATED COMPLIANCE
WITH AIRFRAME MANUFACTURER'S ORIGINAL EQUIPMENT
REQUIREMENTS, BF GOODRICH DOES NOT WARRANT OR ASSUME THE
RISK OF THE USE OF REPLACEMENT PARTS NOT AUTHORIZED FOR USE
BY BF GOODRICH. OPERATORS WHO USE REPLACEMENT PARTS NOT
AUTHORIZED BY BF GOODRICH DO SO AT THEIR OWN RISK AND TAKE
FULL RESPONSIBILITY FOR ALL PROPERTY DAMAGE, PERSONAL INJURY
OR DEATH CAUSED BY SUCH REPLACEMENTS PARTS. USE ONLY BF
GOODRICH APPROVED REPLACEMENT PARTS GIVEN IN THE ILLUSTRATED
PARTS LIST OF THIS MANUAL.
WARNING: IGNORING OF TORQUE LIMITS AND OTHER SPECIFIC VALUES GIVEN BY
THIS MANUAL, CAN CAUSE PROPERTY DAMAGE, PERSONAL INJURY, OR
DEATH.
Page INTR0-2
32-46-42 Apr 30/94
1. DESCRIPTION
NOTE: Refer to IPL Figure 1 and Figure 1 for identification of
components.
A. The 2-1528 Series brake is a piston actuated, three rotor
unit which operates from the aircraft hydraulic system.
Only Phosphate Ester hydraulic fluid is to be used.
The 2-1528-1 brake assembly is the initial brake design
with a wear pin setting of 0.61 inch (15,49 mm>.
The 2-1528-2 brake assembly introduces a stronger adjuster
spring which is available in Kit No. 380-90. Wear pin
setting is 0.61 inch (15,49 mm>.
The 2-1528-3 brake assembly has a reduced wear pin setting
of a.so inch (12,7 mm> which was required for Civil
Aviation Administration <CAA) approval.
The 2-1528-4 brake assembly introduces a bleeder block kit
CPIN 489-33> which converts the single bleeder brake
assembly to a dual bleeder brake assembly with a·wear pin
setting of 0.61 inch (15,49 mm>.
The 2-1528-5 brake assembly introduces a bleeder block kit
CPIN, 489-33) which converts the single bleeder brake
assembly to a dual bleeder brake assembly with a wear pin
setting of 0.50 inch C12,7 mm>. This brake is CAA approved.
The 2-1528-6 brake assembly introduces changes in the
stator disk and carrier and lining assemblies to improve
the fatigue life. The wear pin setting is 0.590 inch
(14,99 mm) with FAA and CAA approval.
B. The brake has five major components: A piston housing
assembly C315) Cwith related hydraulic components>, a
pressure plate and wear plate assembly (125), two stator
disks (155), a torque plate and wear plate assembly (160),
and three rotating carrier and lining assemblies (150).
C. The piston housing assembly (315), contains five
replaceable piston sleeves (245), five pistons (250), four
adjuster assemblies (190), a shuttle valve assembly <60),
and a bleeder screw assembly (280) with adapter (90) and
attaching hardware. The shuttle valve assembly and bleeder
screw assembly with adapter can be installed in either of
the two ports to permit right hand or left hand mounting of
the brake.
I 32-46-42 Page 1
Apr 30194
D. Each piston housing bore is a hydraulic enclosure that l
contains the following: Piston sleeve (245), piston (250),
backup packing (255), preformed packing (260), backup
packing retainer (265), and preformed packing (270). The
bore sealing surfaces are protected from external damage
from dust and grit by a scraper ring (275) installed in the
hexagon end of the piston sleeve.
E. Two lining wear indicators are installed in the piston
housing assembly (315). Each indicator consists of a stud
assembly (120) attached to the pressure and wear plate
assembly (125). A rod and insert assembly (115) is
attached to the stud assembly. With the brake pressurized,
I the indicator rod protrudes from the piston housing

assembly to give a visual means of determining lining wear.
When the rod end is flush with the surface of the piston
housing <refer to Figure 301), the brake heat sink is worn
and the brake should be removed from the aircraft within
the next five landings for overhaul.
F. Four adjuster assemblies (190) are attached to the piston
housing assembly (315) with retaining ring (185). Each
adjuster assembly contains a nut (195), ball (200>, tube
<205), pin (210), retaining ring (215), tube retainer
<220), helical spring (225), and adjuster housing <230).
G. The heat sink has all the components that have friction
surfaces which, when clamped together, cause the stop.
These components include the pressure plate and wear plate
assembly (125), three carrier and lining assemblies (150),
two disks (155>, and a torque plate and wear plate assembly
(160).
H. The pressure plate and wear plate assembly (125> consists
of a steel pressure plate (145) and 11 wear plates (135).
The wear plates are fastened to the pressure plate with
rivets (130). When the brake is assembled, four adjuster
pins (120) engage slots in the pressure plate.
I. Three carrier and lining assemblies (150) are the turning
parts of the heat sink. Each carrier and lining assembly
has a steel carrier with lining material sintered to each
side.
J. The torque plate and wear plate assembly (160) has a steel
torque plate (180) and 11 wear plates (175). The wear
plates are attached to the backleg of the torque plate with
rivets (170).
K. A spacer (310) ensures proper alignment of the brake to the
wheel assembly.
Page 2
32-46-42 Apr 30/94
( DESCRIPTION AND OPERATION
L. A hydraulic shuttle valve assembly (60> is attached to the
piston housing assembly (315> with two bolts (53) and
washers (55). The shuttle valve assembly provides emergency
operation of the brake assembly if the main source
hydraulic pressure fails. A packing retainer (65) and
preformed packing C70) seals the unit against leakage.
An overhaul kit, P/N 380-110 is available to overhaul the
shuttle valve assembly (60).
2. OPERATION
The following events occur when the brake is actuated.
A. Hydraulic fluid, under pressure, forces the pistons (250)
against the pressure and wear plate assembly (125).
B. As the pistons and pressure plate and wear plate assembly
(125> continue to advance, the three carrier and lining
assemblies (150> and two stator disks (155) are clamped
between the pressure plate assembly (125) and torque plate
assembly (160). The friction between rotating and
non-rotating parts of the heat sink result in brake action.
NOTE: The preceding paragraphs explain only the effect of
brake application on the heat stack. The remainder
of this explanation deals with the simultaneous
effect of braking on the adjusters.
C. During brake operation, pressurized hydraulic fluid forces
the pistons forward, moving the pressure plate forward and
pulling the adjuster pin (210), ball (200), and tube (205)
forward, thus compressing the adjuster spring. The tube
retainer (220) will bottom out on the adjuster housing,
restraining the spring from further movement. Any further
motion of the pressure plate due to lining wear will draw
the pin and ball deeper into the tube.
D. When the brake hydraulic pressure is decreased, the
adjuster springs will pull the pressure plate back a
distance equal to the travel of the adjuster tube retainer
from the bottoming out position to the original position,
giving a constant running clearance after each brake
release. The distance that the ball is drawn into the tube
compensates for lining wear.
Page 3
32-46-42 Apr 30/94
SHUTTLE VALVE ASSY. (60)
BOLT (50> BLEEDER SCREW ASSY (280)

ADAPTER ROD & INSERT
ASSY (115)
STUD ASSY (120)
(85)
CARRIER & LINING

ASSY (150)
PRESSURE PLATE &
WEAR PLATE ASSY (125)
TORQUE (160)
PLATE
ASSY
ADJUSTER - -
ASSY.(190) PISTON (315)
HOUSING "'-..
!
SPACER (310)
ASSY ~
RETAINING WASHER
RING (185)
BOLT
PREFORMED PACKING (260)
.
PACKING BACK UP (255)
PISTON (250)
DISK-STATOR (155)
SLEEVE (245) ULATOR (235)
PREFORMED PACKING (270) SPACER (240)
PACKING RETAINER (265)
Figure 1. Description of Main Brake Assembly
Page 4
32-46-42 Apr 30/94
l!Q.ll: See IPL Figure 1 for identification of components.
EQUIPMENT AND MATERIALS
NOTE: Equivalent replacements can be used for listed items.
a. 850 psig <58,6 bars> Pressure Source
b. Phosphate Ester Hydraulic Fluid
I 1. PREPARATION FOR FUNCTIONAL TEST
WARNING: BRAKE MUST BE PROPERLY BOLTED TOGETHER. DO NOT
OVER-PRESSURIZE BEYOND MAXIMUM LIMITS. NON-COMPLIANCE
MAY RESULT IN BRAKE DAMAGE AND/OR PERSONAL INJURY.
WARNING: PHOSPHATE ESTER HYDRAULIC FLUID IS DANGEROUS TO THE EYES,
SKIN AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS
REQUIRED. PREVENT REPEATED CONTACT WITH THIS FLUID OR
CONTACT FOR A LONG TIME. GOOD GENERAL AIR FLOW IS
USUALLY SUFFICIENT.
CAUTION: HYDRAULIC FLUID THAT SPILLS ON THE BRAKE PARTS MUST BE
CLEANED OFF AS INSTRUCTED IN CLEANING SECTION.
A. Put the brake assembly on a table with the torque plate
side down.
B. Connect pressure source to the larger diameter union
fitting (40) on the shuttle valve assembly (60).
c. Remove the screw <285> and washer (290). Connect a bleeder
hose to the bleeder valve (295).
D. Loosen the bleeder valve (295) and bleed the brake assembly
with low pressure until the hydraulic fluid runs clear of
air bubbles.
NOTE: Brake assemblies that do not have adapter (73)
installed Csingle bleeding system>, refer to
ASSEMBLY, section, paragraph 11 for alternate
bleeding procedures. Brake assemblies with the
adapter (73) installed (dual bleeding system) use
standard bleeding procedures.
NOTE: To ensure proper bleeding, the brake should be put
in an installed position.
2. FUNCTIONAL TEST
WARNING: PUT A PROTECTIVE SHIELD AROUND THE BRAKE ASSEMBLY WHEN
I A.
HYDRAULIC PRESSURE IS HIGHER THAN 100 PSIG (6,9 BARS)
Put a protective shield around the brake assembly.
Page 101
32-46-42 Apr 30/94
e. Pressurize the brake to 750 - 800 psig (51,7 - 55,2 bars)
l
and hold for five minutes. After five minutes, decrease
the pressure to zero psig <zero bars>. Remove the
protective shield and examine the brake assembly. Reject
the brake assembly if leakage is found.
c. Put a protective shield around the brake assembly.
D. Pressurize the brake assembly to 750 - 800 psig (51,7 -
55,2 bars> and decrease to zero psig (zero bars> for 25
cycles. Remove the protective shield and examine the brake
assembly. Reject the brake assembly if leakage is found.
E. Pressurize the brake assembly to 2 - 7 psig C0,14 - 0,5
bars) and hold for five minutes. After five minutes,
decrease the pressure to zero psig (zero bars>. Examine
the brake assembly. Reject the brake assembly if leakage
is found.
F. Pressurize the brake to 2 - 7 psig (0,14 - 0,5 bars) and
hold. Check brake assemblies with a new heat sink, for
minimum clearance of 0.040 inch (1,02 mm) between the
pressure plate assembly (125) and carrier and lining
assembly (150). A minimum clearance of 0.020 (0,51 mm) is
I
permitted in the area of the pressure plate (labeled "TOP")
and between the two adjacent pistons. Check clearance on
brake assemblies with one or more used heat sink components
by turning the rotors by hand. Reject the brake assembly
if the rotors can not be turned, or if minimum clearance is
not met.
G. Decrease the pressure to zero psig <zero bars).
3• SHUTTLE VALVE TEST
I A.
Pressurize the brake assembly to 100 - 150 psig (6,9 - 10,3
bars). Decrease the pressure to 2 - 7 psig C0,14 - 0,5
bars> and hold for 1 minute. Hydraulic fluid leakage is
permitted when applying pressure; however, once the 2 - 7
psig C0,14 - 0,5 bars> is obtained, no leakage is permitted
from the union fitting (25) port.
B. Pressurize brake to 750 - 800 psig (51,7 - 55,2 bars> and
hold for 1 minute. No hydraulic fluid leakage is permitted
from the union fitting (25) port.
c. Decrease the pressure to zero psig <zero bars>.
Page 102
32-46-42 Apr 30/94
I WARNING: PUT A PROTECTIVE SHIELD AROUND THE BRAKE ASSEMBLY WHEN

D. Remove hydraulic source from union fitting (40) and connect
to union fitting (25) port on the shuttle valve. Keep the
union fitting (40) port on the shuttle valve open.
E. Pressurize the brake to 100 - 150 psig C6,9 - 10,3 bars>.
Decrease the pressure to 2 - 7 psig C0,14 - 0,5 bars> and
hold for 1 minute. Hydraulic fluid leakage is permitted
when applying pressure; however, once the 2 - 7 psig C0,14
- 0,5 bars> is obtained, no leakage is permitted from the
union fitting (40) port.
F. Pressurize the brake to 750 - 800 psig (51,7 - 55,2 bars>
and hold for 1 minute. No leakage is permitted from the
union fitting (40) port.
G. Decrease the pressure to zero psig <zero bars>.
NOTE: Shuttle valves without serial numbers and shuttle valves
with serial numbers under 2000 (without an "R" following
the serial number> should be replaced as referenced in
Service Bulletin No. 2-1528-32-1.
I NOTE: Malfunctioning shuttle valves (60) can be overhauled or

returned to BFGoodrich for repair.
NOTE: Brakes that fail the test should be examined for defects in
accordance with FAULT ISOLATION CHART and re-tested after
defects have been corrected.
4. Adjust the rod and insert assembly (115) according to the
ASSEMBLY section.
Page 103
32-46-42 Apr 30/94
FAULT ISOLATION
FAULT PROBABLE CAUSE CORRECTION

Hydraulic fluid Worn preformed packings Replace preformed
leaking from (260) and packing backup packings and packing
piston area. (255). backup.
Damaged piston (250) bore. Replace piston.
Hydraulic fluid Worn preformed packing Replace preformed
leaking from (270) and packing retainer packing and packing
piston sleeve (265). retainer.
area.
Damaged piston sleeve Replace piston sleeve.
(245) bore.
Fluid Leaking Lee plugs (320) damaged or Replace Lee plugs.
from Lee plugs. improperly installed.
Fluid leaking Loose or damaged bleeder Tighten or replace
from bleeder assembly (280). bleeder assembly
assembly, plugs,
bleeder fittings Loose or damaged reducer Tighten or replace
or reducer fitting (300) or preformed reducer fitting and
fitting. packing (305). preformed packings
Insufficient Heat stack warped beyond Repair or replace
clearance. tolerance. components out of
tolerance.
Weak adjuster springs Check springs load.
(225). Replace if necessary.
Refer to CHECK section.
Incorrect assembly of Disassemble adjuster
adjusters assemblies (190) assemblies and replace
adjuster tubes.
Non-releasing Malfunctioning shuttle Overhaul shuttle valve.
I brake. Brake
inoperative when
emergency or
hydraulic system
valve (60)
Worn preformed packing

Refer to the REPAIR
section
Replace preformed
is applied. (70) and packing retainer packing and packing
(65). retainer.
Shuttle valve
(60) leaking.
Page 104
32-46-42 Apr 30/94
( DISASSEMBLY
NOTE: Refer to IPL Figure 1 for identification of components.
NOTE: Refer to TESTING AND FAULT ISOLATION section to make an
estimate of the condition of a component or the cause of its
malfunction.
a. Standard shop tools
b. Arbor press.
c. 3/8 inch C9 mm> O.D. plug
NOTE: Make sure to remove the axle spacer (310) from the axle
after the brake assembly is removed.
1. PISTON HOUSING REMOVAL
NOTE: Measure and record the rod and insert assembly setting on
brakes that are disassembled for reasons other than wear
(refer to Figure 301).
NOTE: Brake assemblies removed from the aircraft for reasons
other than wear should not have heat sink components
disturbed unless necessary. Brake should be returned to
service with the rod and insert assembly undisturbed.
When heat sink components must be disturbed, index and
handle carefully to assure reinstallation of carrier and
lining assemblies (rotors> and stator disks in the same
relative position as before disturbance. This is necessary
to maintain proper surface contact of mating parts.
WARNING: PHOSPHATE ESTER HYDRAULIC FLUID IS DANGEROUS TO THE
EYES, SKIN AND RESPIRATORY TRACT. SKIN AND EYE
PROTECTION IS REQUIRED. PREVENT REPEATED CONTACT
WITH THIS FLUID OR CONTACT FOR A LONG TIME. GOOD
GENERAL AIR FLOW IS USUALLY SUFFICIENT.
A. Lay the brake on a clean work surface with the piston
housing facing up.
B. Remove the bolts (10) and washers (15). Remove the piston
housing assembly (315) with the pressure plate and wear
plate assembly (125) from the torque plate and wear plate
assembly (160).
c. Cut the lockwire (5) and remove bolts (50 or 53) and
washers (55). Remove the shuttle valve assembly (60),
spacers (72>, adapter (73> and gasket (75).
Page 301
Apr 30/94
DISASSEMBLY (
D. Remove the bleeder screw <48) from the adapter (73).
E. Hold the piston housing assembly (315) in a vertical
I position and drain the fluid from the shuttle valve port
into a container. Remove the screw (285), and washer (290)
and loosen the bleeder valve (295) to speed drainage.
ROD & INSERT ASSY. --FLUSH
(PRESSURIZED)
(120) STUD ASSY.
BRAKE
PRESSURIZED
MEASURE
(125) PRESSURE AND
(315) PISTON WEAR PLATE
HOUSING
NEW BRAKE FULLY WORN BRAKE
PROCEDURE:
With the parking brake applied or with the brake pressurized,
measure from the front of the piston housing assembly (315) to the
end of the rod (115). Measurement should be taken on the shortest
rod for recording purpose in 1/32 inch <0,79 mm> increments.
Determine whether brake is full or partially worn as follows:
Fully worn brake <see example above): With the parking brake
applied or with the brake pressurized, end of rod is flush with
the front of the piston housing assembly (315). The brake must be
removed for overhaul within the next five landing.
Figure 301. Brake Wear Measurement
2. PRESSURE PLATE AND WEAR PLATE ASSEMBLY REMOVAL
A. Remove rod and insert assembly (115).
B. Remove stud assembly (120).
CAUTION: DAMAGE TO THE ADJUSTER PIN CAN OCCUR IF TOO MUCH FORCE IS
USED TO REMOVE THE PRESSURE PLATE AND WEAR PLATE ASSEMBLY
FROM THE PISTON HOUSING ASSEMBLY.
c. Turn the piston housing assembly (315) with the pressure
plate and wear plate assembly (125) facing up. Push down
on the pressure plate to push the pistons into the piston
housing. Push down on the pressure and wear plate assembly
and turn clockwise to disengage the adjuster pins (210)
from the pressure plate and wear plate assembly. Lift and
remove the pressure plate and wear plate from the piston
housing.
Page 302
32-46-42 Apr 30/94
DISASSEMBLY
D. Do not remove the helical coil inserts (140) unless damaged
(refer to the REPAIR section>.
NOTE: Refer to the REPAIR section to replace the wear
plates (135) that are attached to the pressure
plate assembly (125).
3. PISTON HOUSING DISASSEMBLY
A. Remove the bleeder screw assembly (280), reducer fitting
(300) and preformed packing (305) from the bleeder adapter
(90).
B. Cut lockwire CS) and remove the bolts (80) and washers (85)
from the bleeder adapter (90).
C. Remove the bleeder adapter (90) and gasket (95) from the
piston housing assembly (315).
D. Remove the packing retainer (105) and preformed packing
(110) from the bleeder adapter (90).
E. Remove the insulators (235) and spacers (240) from the
pistons (250).
F. Cut the lockwire and remove sleeves (245) from the piston
housing assembly (315).
G. PISTON AND PISTON SLEEVE DISASSEMBLY
(1) Remove the pistons (250) from the sleeves <245).
C2) Remove the scraper ring (275) from the I.D. of each
sleeve (245).
C3) Remove the preformed packing (270) and packing
retainer (265) from the O.D. of each sleeve (245).
(4) Remove the preformed packing (260) and packing backup
(255) from the O.D. of piston (250).
H. Remove the retaining rings (185) from the piston housing
assembly (315) and remove the adjuster assemblies (190).
I. Do not remove the lee plugs (320) or helical coil inserts
(325, 330) unless damaged (refer to the REPAIR section).
Page 303
32-46-42 Apr 30/94
DISASSEMBLY (
4. ADJUSTER DISASSEMBLY
WARNING: WEAR EYE PROTECTION. THE ADJUSTER ASSEMBLY CONTAINS
SPRING-LOADED COMPONENTS. DISASSEMBLY WITHOUT PROPER
EQUIPMENT OR PARTS WITH THE FOLLOWING, CAN CAUSE SERIOUS
INJURY TO PERSONNEL.
A. Remove the nut (195), ball (200), pin <210> and adjuster
tube (205).
B. Insert a 3/8 inch (9 mm) O.D. plug in a drill or arbor
press. Put the adjuster on the base plate, with adjuster
housing facing upward <refer to Figure 303).
c. Lower the press and depress the tube retainer (220) to
permit retainer ring (215) removal. Lock the press and
remove the retainer ring.
D. Unlock the press and slowly relax the force on the tube
retainer (220) until all tension has been removed from the
spring (225).
E. Remove the tube retainer (220) and spring (225) from the
adjuster housing (230).
NUT (195) RING RETAINER

(215)
ADJUSTER TUBE\ HELICAL SPRING

(205) (225)
\ \
@~O l C@• ~/~ 1,1ffl111,jJ-.....~
BALL (200) ADJUSTER HOUSING

(230) I
ADJUSTER PIN (210)
TUBE RETAINER (220)
Figure 302. Exploded View of Adjuster Assembly
Page 304
32-46-42 Apr 30/94
DISASSEMBLY
t
ARBOR PRESS RETAINER RING (215)
3/8 (9 mm) O.D. PLUG

OR EQUIVALENT SIZE SOCKET
HELICAL
SPRING
(225) ADJUSTER HOUSING (230)
Figure 303. Adjuster Disassembly Procedure

5. HEAT SINK REMOVAL
A. Remove the carrier and lining assemblies (150) and stator
disks (155) from the torque plate and wear plate assembly
(160).
B. Do not remove the helical coil insert (165) unless damaged
<refer to the REPAIR section).
NOTE: Refer to the REPAIR section to replace the wear plates
(175) on the torque plate assembly (160).
6. SHUTTLE VALVE DISASSEMBLY
CAUTION: DO NOT DISASSEMBLE THE SHUTTLE VALVE UNLESS IT IS TO BE
OVERHAULED AND THE PARTS KIT, PIN 380-110, IS AVAILABLE.
THE SHUTTLE VALVE BODY (350) AND END CAP (355) ARE NOT
AVAILABLE IN THE PARTS KIT.
A. Remove the shipping caps (20, 35) if present.
B. Remove the union fittings (25, 40) and preformed packings
(30, 45).
c. Remove the preformed packings (70), packing retainers (65),
from the shuttle valve assembly (60) and the adapter (73>.
Page 305
32-46-42 Apr 30/94
DISASSEMBLY
D. Cut the lockwire from the end cap (355). Discard the
lockwire and lead seal.
WARNING: WEAR EYE PROTECTION. THE SHUTTLE VALVE CONTAINS
SPRING-LOADED PARTS. DISASSEMBLY WITHOUT FOLLOWING THE
PROPER INSTRUCTIONS CAN CAUSE SERIOUS EYE INJURY TO
PERSONNEL.
CAUTION: SHUTTLE VALVE CONTAINS SMALL PARTS THAT ARE EASILY LOST.
E. Carefully remove the end cap (355) which contains the
poppet assembly (360), balls (375), and spring (380).
F. Carefully remove the poppet assembly (360), balls (375),
and spring (380). Discard these parts.
G. Remove the preformed packings (365, 370). Discard these
parts.
PREFORMED
PACKING (370)
I
SHUTTLE VALVE
BODY (350)
BALL (375)
Figure 304. Shuttle Valve Disassembly
Page 306
32-46-42 Apr 30/94
CLEANING
a. Dry Cleaning Solvent e. Paint Stripper A-127-B
P-D-680 Type II f. Abrasive Blasting Equipment
b. Butyl Alcohol g. Walnut Hulls
c. Brushes h. Plastic Media and Blasting
d. Compressed Air Equipment
WARNING: EYE INJURY FROM FLYING PARTICLES IS POSSIBLE WHEN USING
COMPRESSED AIR FOR CLEANING. MAKE SURE PRESSURE IS NOT OVER
30 PSI (2 BARS). EYE PROTECTION IS REQUIRED.
WARNING: DRY CLEANING SOLVENT P-D-680 TYPE II IS DANGEROUS TO EYES,
SKINS AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION
REQUIRED. PREVENT REPEATED CONTACT WITH THE SOLVENT OR
CONTACT FOR A LONG TIME. GOOD GENERAL AIR FLOW IS USUALLY
SUFFICIENT.
WARNING: BUTYL ALCOHOL IS FLAMMABLE AND IS DANGEROUS TO EYES, SKIN
AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION REQUIRED.
PREVENT REPEATED CONTACT WITH BUTYL ALCOHOL OR CONTACT FOR A
LONG TIME. GOOD GENERAL AIR FLOW IS USUALLY SUFFICIENT.
WARNING: SOLVENTS WILL DAMAGE THE SHUTTLE VALVE 0-RINGS. KEEP
SOLVENTS AWAY FROM SHUTTLE VALVE 0-RINGS.
1. CLEANING METAL PARTS:
CAUTION: THE ANODIZE LAYER WILL BE DAMAGED IF SAND IS USED IN THE
ABRASIVE BLAST PROCEDURE OR IF A WIRE BRUSH IS USED TO
CLEAN THE PARTS.
Clean all metal parts with dry cleaning solvent CP-D-680 Type
II> or equivalent. Use a soft bristle brush to remove stubborn
grease or dirt. Blow dry with clean, dry compressed air.
2. CLEANING NON-METAL PARTS:
CAUTION: SOLVENT SUCH AS (NAPHTHA, THINNER, P-D-680, ETC.) CAN
DAMAGE RUBBER SEALS AND PACKINGS. USE ONLY SPECIFIED
CLEANING MATERIALS.
WARNING: PHOSPHATE ESTER HYDRAULIC FLUID IS DANGEROUS TO THE EYES,
SKIN AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS
REQUIRED. PREVENT REPEATED CONTACT WITH THIS FLUID OR
USUALLY SUFFICIENT.
Clean all rubber packings and backups with a soft, clean cloth
damped with hydraulic fluid or a mild soap and water solution.
32-46-42 Page 401

Apr 30/94
CLEANING
3. REMOVE PAINT FROM PISTON HOUSING Cif required) by one of the
two procedures that follow.
A. If required, remove paint from the piston housing assembly
using the abrasive blasting procedure in paragraph 3.B.
NOTE: It is necessary to remove the paint for fluorescent
penetrant inspection. It is not necessary to remove the
paint for eddy current inspection.
CAUTION: THE ANODIZE LAYER WILL BE DAMAGED IF SAND IS USED IN THE
ABRASIVE BLAST PROCEDURE OR IF A WIRE BRUSH IS USED TO
CLEAN THE PARTS.
B. ABRASIVE BLASTING
Blast the parts CMIL-STD-1504) with plastic media
CMIL-P-85891) (maximum media hardness of 3.5 MOH) or with
walnut hulls CMIL-G-5634), Types II or III (grain soft
abrasive walnut hulls, Grade 20/30). This method will not
remove the surface treatment, but will require sealing of
all openings.
WARNING: CHEMICAL CONVERSION COATING CMIL-C-5541), IS
DANGEROUS TO EYES, SKIN AND THE RESPIRATORY
TRACT. SKIN AND EYE PROTECTION REQUIRED.
PREVENT REPEATED CONTACT OR CONTACT FOR A LONG
TIME. USE IN A WELL VENTILATED AREA.
Apply chemical conversion coating MIL-C-81706 to meet
requirements of MIL-C-5541 to areas where damage to the
anodize layer by improper use of plastic media is suspected.
C. CHEMICAL PAINT REMOVER
WARNING: CHEMICAL PAINT REMOVER A-127-B IS FLAMMABLE AND IS
DANGEROUS TO EYES, SKIN AND RESPIRATORY TRACT. SKIN AND
EYE PROTECTION REQUIRED. PREVENT REPEATED CONTACT WITH
THE PAINT REMOVER OR CONTACT FOR A LONG TIME. GOOD
GENERAL AIR FLOW IS USUALLY SUFFICIENT.
If the piston housing will be fully put into the paint
remover chemical, seal the holes that have helical coil
inserts (325, 330).
Use chemical paint remover A-127-B (full strength if
desired) and a stiff fiber bristle brush to help remove
stubborn paint.
Thoroughly rinse chemical paint remover off parts with
clean, cold water. Dry parts with low-pressure compressed
air.
32-46-42 Page 402

Apr 30/94
CHECK
Equipment and Materials:
a. Penetrant Inspection CMIL-STD-6866)
b. Magnetic Particle Inspection CASTM E1444-91)
c. Torque Wrench
d. Spring Tester (Figure 508)
e. Micrometer
f. Surface Plate
g. Hardness Tester (Rockwell or Brinell)
NOTE: The brake heat sink parts are designed to last for the full
interval between overhauls. Examination of specific parts
are not required except at overhaul. However, if a brake
assembly requires removal before an overhaul, the heat sink
parts should be reused unless the manual requires that they
be discarded. Assemble the brake assembly with used parts as
referenced in the ASSEMBLY section.
1. EXAMINE WEAR PLATES
A. Examine for wear limits (refer to Figure 501). Discard
wear plates (135, 175) if they do not meet limits. Replace
wear plates in sets. Do not use a mixture of new and used
wear plates on a surface unless new wear plates are ground
to the average thickness of the used wear plates. Knife
edge curling and uneven wear between the wear plates is
usual.
B. Examine the rivets (130, 170) for looseness. These rivet
attached to the pressure plate (125) and torque plate
(180). Replace loose rivets.
c. Inspect wear plates (135, 175) for a high ridge of material
at the inner diameter which can cause brake chatter. Remove
this ridge <refer to the REPAIR section, paragraph 2. A).
Page 501
32-46-42 Apr 30/94
CHECK
I USUAL HEAT CHECKING 0.070

(1,28)
NIN. 1r
VIEW A
USUAL UNEVEN
WEAR
INITIAL WEAR PLATE

MATERIAL THAT WARPS
UP AND WEARS OFF
t< -~
._.
(<ZZC?a
_ / VIEW A-A
KNIFE EDGE CURLING
VIEW B
NOTE: 1. Brush or sand blast to remove embedded lining material from
wear plate surface.
Figure 501. Wear Plate Examination
Page 502
32-46-42 Apr 30/94
( CHECK
2• EXAMINE CARRIER AND LINING ASSEMBLIES
WARNING: PENETRANT FLUIDS, ARE DANGEROUS TO EYES, SKINS AND
RESPIRATORY TRACT. SKIN AND EYE PROTECTION REQUIRED.
PREVENT REPEATED CONTACT WITH THE FLUIDS OR CONTACT FOR A
A. Examine for cracks, warping, and pitting (refer to Figure
502>. Magnetic particle or penetrant inspect for cracks.
B. Cracks at slots are permitted in the lining material only
<refer to Figure 502>. Discard if cracks indications are
found in the carrier.
c. Pitting is permitted if the area of pitting is not more
than 25% on each side.
D. Crumbling of lining material is permitted in the I.D.,
O.D., and slot areas <as shown> if loss from edges is not
more than 0.250 inch (6,41 mm> wide (in from the edges>.
E. Discard carrier and lining assemblies if it does not meet
the limits in Figure 502.
PITTING -.I ~0.275

I I <6,99>
MIN.
4.126
(104,8) CRACKS ARE
MIN PERMITTED
ct_ TO
(TYP)
FLAT IN THE LINING
MATERIAL ONLY f
4.785
J_ (121,54)
MIN.
DIA.
_l
CRUMBLING
0.010
(0,25)
MIN. ON
EACH SIDE
Figure 502. Carrier and Lining Assembly Examination
Page 503
32-46-42 Apr 30/94
CHECK (
F. Carrier and lining assemblies can be cold-flattened to
within 0.020 inch C0,51 mm). Magnetic particle or
penetrant inspect for cracks after flattening. Discard
carrier and lining assemblies if cracks are found.
"A II
j
II
t
BII
~" C"
TABLE 1.
ITEM NO. PART NUMBER DIMENSION A II II

DIMENSION B II II
(150) 244-641-1 0.255 inch (6,48 MM) 0.195 INCH (4,95 MM)
TABLE 2.
DIMENSION C 11 11 INSPECTION SCHEDULE

0.755 - 0.850 INCH (19,18 - 21,59 MM) NEXT TIRE CHANGE
0.850 - 0.875 INCH (21,59 - 22,22 MM) 100 LANDINGS
0.875 - 0.899 INCH (22,22 - 22,83 MM) 75 LANDINGS
0.900 INCH & ABOVE (22,86 MM & ABOVE) DISCARD ROTOR
Figure 503. Carrier And Lining Assemblies Drive Slots
G. Examine carrier and lining assemblies, P/N 244-641-1, for
I drive slots damage <refer to Figure 503). Does not apply
to the carrier and lining assemblies, PIN 244-641-4.
C1) Measure the width of all the drive slots to determine
the slot with the greatest wear. Discard carrier and
lining assemblies that have a drive slot width that
is 0.900 inch (22,86 mm> or greater.
(2) Material that has been laterally displaced from the
rotor surface <refer to Figure 503, Area "A does 11 )
not have to be removed unless greater than 0.255 inch

(6,48 mm).
Displaced carrier material (Area "A") can be removed
with a hand file. Remove material from both sides of
the carrier <refer to dimension B in Figure 503).
11 11
(
No adjustment of the rod and insert assemblies is
I
necessary.
Page 504
32-46-42 Apr 30/94
l CHECK
(3) Recommended Inspection Schedule
Refer to TABLE 2. and dimension "C" in Figure 503.
3. EXAMINE STATOR DISKS
A. Examine stator disks (155) for wear and cracks. Magnetic
particle or penetrant inspect for cracks. Discard a stator
disk if a crack is found, or if it does not meet the limits
in Figure 504.
B. A stator disk can be furnace-flattened if flatness is not
equal to or less than 0.015 inch C0,38 mm>. Use the
furnace flattening fixture in Figure 902 and procedures in
Figure 602. Magnetic particle or penetrant inspect for
cracks after flattening. Discard a disk if a crack is
found.
4.596
(116,74)
MIN. DIA.
'----'!------.......--0.325
(8,26)
MINIMUM
REUSABLE
~ 1--
I 0.235
(5,97)
MIN.
Figure 504. Disk Examination
I 32-46-42 Page 505

Apr 30/94
CHECK
4. EXAMINE TORQUE PLATE
A. Visually examine for gouges or grooves. Defects can be
removed to a maximum depth of 0.030 inch (0,76 mm> by local
blending except where shown. Deeper gouges or grooves are
not permitted.
B. Visually examine the slots on the torque tube O.D. for
roughness. Slots must be smooth to permit the disk to move
easily. Remove burrs, radius sharp edges, and polish
rubbing surfaces.
c. At each wear plate change, magnetic particle or penetrant
inspect for cracks. Surface cracks can be removed <refer to
the REPAIR section).
D. Examine the backleg for warpage <refer to Figure 505). If
backleg is straightened, magnetic particle or penetrant
inspect for cracks. Discard if a crack is found which can
not be removed by local blending.
E. Check the torque plate for minimum hardness of 297 BHN
(Rockwell C 32)Crefer to Figure 505). Discard a torque
plate if it does not meet minimum hardness.
NOTE: Hardness check is only required on brakes that have
overheated. Overheating has occurred when the
thermal relief plugs in the wheel assembly have
released.
F. Examine helical coil inserts (165) for damage. Discard if
damaged.
7r 0.020
(0,51)
I' MAX.
I ,I
DAMAGED AREAS :
I
CHECK FOR MINIMUM I
297 BHN HARDNESS I
I
I
CROCKWELL C 32)
ON A FLAT SURFACE
BETWEEN MOUNTING
BOLT HOLE
C
Figure 505. Torque Plate Examination and Repair
I 32-46-42 Page 506

Apr 30/94
l CHECK
5. EXAMINE PRESSURE PLATE
A. Visually examine for cracks. At each wear plate change,
magnetic particle or penetrant inspect for cracks. Discard
a pressure plate if a crack is found, or if it does not
meet limits in Figure 506.
B. Examine for flatness at each wear plate change. Flatten a
pressure plate if it is warped more than 0.015 inch C0,38
mm>. Furnace flatten a pressure plate using the fixture in
Figure 902 and procedures in Figure 602. Magnetic particle
and penetrant inspect for cracks after flattening. Discard
a pressure plate if a crack is found.
c. Check pressure plate for minimum hardness of 332 BHN
(Rockwell C 36) (refer to Figure 506). Discard a pressure
plate if it does not meet minimum hardness.
released.
D. Examine helical coil inserts (140) for damage. Discard if
damaged.
"TOP" STAMf>ED
FOR ASSEMBLY
FUNCTION
, , C116
' , Ml • I
· · DI
-
I
Figure 506. Pressure Plate Examination and Repair
Page 507
32-46-42 Apr 30/94
CHECK
6. EXAMINE ADJUSTER ASSEMBLY COMPONENTS
A. Visually examine all adjuster parts for wear and damage.
Discard badly worn or damaged parts.
B. Examine adjuster housing (230) <refer to Figure 507>.
Discard if not it does not meet limits.
4
0.758
(19,25)
MAX
DIA.
_t.,_______ ..._...J'-:.:=.=-:::2..=-~=-:::~::::z:::;::;:::..4
Figure 507. Adjuster Housing Examination

C. Discard adjuster tubes (205) at each lining change or every
time a heat sink part is replaced.
D. Check nuts (195) for locking capability by turning a nut on
I a dry adjuster pin (210) as far as possible by hand. If

the end of the pin is flush with, or extends beyond the top
of the nut, discard the nut.
E. Check adjuster spring <225) for damage and load at
installed height <refer to Figure 508). Discard springs
that are damaged or do not meet minimum load.
I 32-46-42 Page 508

Apr 30/94
CHECK
DIAL INDICATOR MOUNTED

ON LOAD RAM WITH PICKUP
AGAINST SPRING BALANCE
PLATFORM
LOAD APPLIED
THIS DIRECTION
LOAD RAM
PRESSURE FOOT
SPRING
BALANCE
PLATFORM
WARNING: A SPRING THAT IS NOT PUT IN THE CORRECT POSITION CAN BE

EJECTED FROM THE TEST EQUIPMINT. SET UP A PROTECTIVE
SHIELD AROUND THE TEST EQUIPMENT.
PROCEDURE: Position the dial indicator to read zero at the spring
height dimension shown in table below. Position spring
on balance platform under pressure foot of ram. Apply
Load to compress spring until dial indicator shows zero.
The Load required to compress spring must be above Limit
for spring Load given in table below.
BRAKE PART SPRING PART SPRING HEIGHT SPRING LOAD LIMIT

NUMBER NUMBER INCH (MM) POUNDS (Kg) MIN.
2-1528-1 40-654 1.450 (36,83) 21 (9,4)
2-1528-2 40-672 1.450 (36,83) 43 (19,5)
2-1528-3
2-1528-4
2-1528-5
I 2-1528-6
Figure 508. Spring Load Check
I 32-46-42 Page 509

Apr 30/94
CHECK
7. Examine insulator (235) for chips and signs of disintegration.
Examine insulator for 0.425 (10,8 mm> minimum thickness.
Discard insulator if below minimum thickness and/or shows signs
of disintegration.
8. EXAMINE SHUTTLE VALVE
A. Visually examine the shuttle valve body (350) and end cap
(355) for corrosion, cracks, gouges, stripped or crossed
threads, and other damage. Examine all sealing surfaces and
packing grooves. Discard a damaged part.
B. Examine the end cap (355) (refer to Figure (509). Discard
the end cap if it does not meet the limits in Figure 509.
Q.470
(11,94)
MAX. DIA.
Figure 509. Examination of Shuttle Valve End Cap

9. EXAMINE PISTON HOUSING ASSEMBLY
LONG TIME. GOOD GENERAL AIR FLOW IS USUALLY SUFFICIENT
A. Visually examine the entire piston housing for cracks.
Refer to Figure 603 for piston housing repair limits.
Penetrant inspect the piston housing after repairs. Discard
the piston housing if a deeper crack is found.
NOTE: It is required to remove the paint from the piston
housing before penetrant inspection <refer to the
CLEANING section).
B. Examine the piston housing threaded ports for thread damage.
Page 510
32-46-42 Apr 30/94
CHECK
c. Examine piston housing for minimum hardness of 120 BHN
(Rockwell 8 68) (refer to Figure 509). Locally remove the
paint before checking the hardness. Discard the piston
housing if hardness is below 120 BHN <Rockwell B 68>.
released.
I CHECK FOR MINIMUM

120 BHN CROCKWELL B 68)
HARDNESS IN AREA BETWEEN
MOUNTING BOLT HOLES
~:::---+-:=:::f:.
Figure 509. Piston Housing Examination

D. Examine the Lee Plugs, and helical inserts in the piston
housing assembly for signs of damage. Replace if necessary
(refer to the REPAIR section).
E. Visually examine the piston bore holes for defects which
would affect the sealing capability. Discard piston
housing if defects are found.
10. MISCELLANEOUS EXAMINATIONS
A. Magnetic particle or penetrant inspect each mounting bolt
C10) for cracks. Discard bolts if cracks are found.
I
B. Replace preformed packings (30, 45, 70, 110, 260, 270,
305). Examine packing retainers (105, 255, 265) at each
overhaul.
Page 511
32-46-42 Apr 30/94
CHECK
c. Visually examine rod and insert assembly (115) and stud
assembly (120) for thread damage, distortion or other
damage that will affect proper operation. Discard damaged
parts.
I D. Examine washers (15, 55, 85, 290) for cracks. Discard all
washers that are cracked.
E. Visually inspect the I.D. surface of piston sleeve <245).
Discard piston sleeve if it does not meet the limits in
Figure 510.
t
1. 744
(44,30)
MAX. 32 RMS
MAX
DIA.
*
Figure 510. Piston Sleeve
Page 512
32-46-42 Apr 30/94
REPAIR
NOTE: The repairs approved and given in this section will extend
the life of the parts, but will not put the parts back to a
new condition.
Replace parts that are cracked, worn, distorted, or damaged
too much to be repaired.
NOTE: Refer to Page 901 for SPECIAL TOOLS AND FIXTURES.
NOTE: See IPL Figure 1 for identification of components.
DIMENSIONAL TOLERANCES
.XXX = ± 0.010 inch C0,25 mm>
.xx = ± 0.030 inch C0,76 mm>
Angular Dimensions=± 1/2°
Fractional Dimensions = ± 1/32 inch C0,8 mm>
a. Grinding/Burring Equip.
b. Surface Treatment per MIL-C-5541
c. Peen and Anvil Riveting Tools per Figure 901
d. Paint Equipment
e. Drill Press
f. Standard Shop Tools
g. Furnace Flattening Fixture per Figure 902
h. Penetrant Inspection per MIL-STD-6866
i. Magnetic Particle Inspection CASTM E1444-91)
1. PRESSURE PLATE ASSEMBLY REPAIR
NOTE: See CLEANING section for paint removal instructions.
A. Remove the ridge of material at the inner diameter with a
pencil grinder or disk grinder. Remove material until the
surface is even, or a little lower than the rest of the
wear surface (refer to Figure 601).
B. Furnace-flatten warped pressure plate (145) to 0.015 inch
C0,38 mm> or less (refer to Figure 602). Magnetic particle
or penetrant inspect for cracks after flattening. Examine
as referenced in the CHECK section, paragraph 5.
C. Replace worn or damaged wear plates (135). Replace wear
plates in sets. Do not use a mixture of new.and used wear
plates.
Page 601
32-46-42 Apr 30/94
REPAIR
l
--RIDGE OF NATERIAL
AT LOWER EDIE OF
WEAR PLATE
00
LOWER EDGE FLUSH
OR SLIGHTLY LOWER
- -THAN THE REST OF
WEAR SURFACE
SECTION A• SECTION A • A
AFTER GRINDING
Figure 601. Wear Plate Ridge Material Removal
(1) Drill out rivets (130) on wear plate side with an 1/8
inch (3 mm> diameter drill bit. Use a mallet and a
1/8 inch (3 mm> pin punch to remove remaining rivet
body.
(2) Clean and paint pressure plate (145).
WARNING: THINNER (MIL-T-81772) IS FLAMMABLE AND DANGEROUS
TO THE SKIN, EYES, AND RESPIRATORY TRACT. SKIN
AND EYE PROTECTION IS REQUIRED. PREVENT
REPEATED CONTACT WITH THE THINNER OR CONTACT FOR
A LONG TIME. GOOD GENERAL AIR FLOW IS USUALLY
SUFFICIENT.
Ca> Wipe all surfaces to be painted with a no-lint
cloth soaked in thinner CMIL-T-81772).
Page 602
32-46-42 Apr 30/94
REPAIR
Cb> Mask the wear pin threaded holes and apply one
layer of high temperature C1200°F C649°c>> paint
CTT-P-28), aluminum color to a dry film thickness
of 0.0005 - 0.0015 inch C0,013 - 0,038 mm).
C3> Put new wear plate (135) on pressure plate and align
with rivet holes. Insert the new rivet (130) from
the wear plate side.
C4> Make a rivet head on shank end of rivets using peen
and anvil· tools Crefer to Figure 901 >.
F. Do not remove helical insert (140) unless damaged.
C1> Use a needle nose plier to remove damaged helical
coil insert (140). Install new helical coil insert
with an appropriate standard helical coil
installation tool.
C2> Install a new helical coil insert (165> 3/4 - 1 1/2
turns below the top surface.
2. TORQUE PLATE ASSEMBLY REPAIR
NOTE: See CLEANING section for paint removal instructions.
A. Remove the ridge of material at the inner diameter with a
pencil grinder or disk grinder. Remove material until the
surface is even, or slightly lower than the rest of the
wear surface (refer to Figure 601).
B. Cold straighten a warped backleg if warpage exceeds 0.020
inch C0.51 mm> as shown in Figure 505. Magnetic particle
or penetrant inspect for cracks after straightening.
Examine as referenced in the CHECK section, paragraph 4.
I C. Replace worn or damaged wear plates (175) on torque plate
assembly. Do not use a mixture of new and used wear
plates. Replace wear plates in sets as follows:
(1) Drill off rivet (170) heads on wear plate side with
an 1/8 inch C3 mm> diameter drill bit. Use a mallet
and 1/8 inch C3 mm> pin punch to punch out rivets.
C2) Clean and paint the torque plate (180) with the wear
I plates off.
NOTE: Make sure all repairs have been completed
before painting the torque plate.
I 32-46-42 Page 603

Apr 30/94
REPAIR
SUFFICIENT.
Ca> Clean all surfaces to be painted by wiping with a
no-Lint cloth soaked in thinner CMIL-T-81772).
Cb) Mask threaded tie bolt holes and apply one Layer of
high temperature 1200°F C649°C> paint CTT-P-28),
aluminum color to a dry film thickness of 0.0005 -
0.0015 inch C0,013 - 0,038 mm>.
C3) Align rivet holes in new wear plates (175) with rivet
holes in the torque plate and insert new rivets (170)
from wear plate side.
C4> Upset the shank end of rivets using peen and anvil
tools. (Figure 901).
WARNING: PENETRANT FLUIDS, ARE DANGEROUS TO EYES, SKINS
AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION
REQUIRED. PREVENT REPEATED CONTACT WITH THE
FLUIDS OR CONTACT FOR A LONG TIME. GOOD GENERAL
AIR FLOW IS USUALLY SUFFICIENT.
D. Remove gouges or surface cracks by local blending to 0.030
inch C0,76 mm) maximum depth. Magnetic particle or
penetrant inspect all reworked areas for cracks. If cracks
are still found after maximum rework, discard torque plate.
E. Smooth any roughness in slots to 0.030 inch <0,76 mm>
maximum depth. Remove all burrs, radius sharp edges, and
polish rubbing surfaces with 320 grit Cor fine) abrasive
cloth.
F. Do not remove helical insert (165) unless damaged.
(1) Use a needle nose plier to remove a damaged helical
coil insert (140). Install a new helical coil insert
with an appropriate standard helical coil
installation tool.
C2) Install a new helical coil insert (165) 3/4 - 1 1/2
turns below the top surface.
3. CARRIER AND LINING ASSEMBLY REPAIR
Cold-flatten warped carrier and lining assemblies (150) to
0.020 inch C0,51 mm> or Less. Magnetic particle or penetrant
inspect for cracks after flattening (refer to CHECK section,
paragraph 2>.
Page 604
32-46-42 Apr 30/94
REPAIR
C
-FIXTURE
Figure 902
SPACER BRAKE PART
FIXTURE
CLAMP PARTS IN FIXTURE AND PLACE IN FURNACE
PROCEDURE:
1. Put pressure plateCs> or diskCs> in fixture. Tighten nut until
parts are held completely flat.
2. Put fixture in furnace for 4 1/2 hours at a temperature of
1150°F C621°C).
3. Remove from furnace and air cool to room temperature.
4. Inspect parts after furnace flattening for cracks per the CHECK
section.
Figure 602. Furnace Flattening
4. STATOR DISK REPAIR
Furnace-flatten warped stator disks (155) to 0.015 inch C0,40
mm> or less (refer to Figure 602). Magnetic particle or
penetrant inspect for cracks after flattening (refer to CHECK
section, paragraph 3).
5. SHUTTLE VALVE REPAIR
Repair nicks, gouges and scratches and corrosion on the outside
surface of the shuttle valve body (350) with fine abrasive
cloth (400 grit>.
Page 605
I 32-46-42 Apr 30/94
REPAIR
l
.....,.,.___ B
Repair nicks, gouges, grooves and scratches by hand filing or

sanding. Blend reworked areas to remove sharp edges. Do not
exceed limits as shown in chart below. If dimensions are
exceeded, replace piston housing.
AREA SERVICE REPAIR

TOLERANCE
A 0.020 C0,51 mm) BLEND 0.250 (6,35 mm> (SQ. IN. MAX.)
B 0.005 C0,13 mm> BLEND
C 0.000 C0,00 mm> NONE
Figure 603. Piston Housing Inspection and Repair
6. PISTON HOUSING ASSEMBLY REPAIR
A. Repair nicks, gouges and scratches and corrosion for the
piston housing (335) with fine abrasive cloth (400 grit).
(refer to Figure 603).
B. Do not remove helical coil inserts (325, 330> unless
damaged.
C1) Use a needle nose plier to remove a damaged helical
coil inserts. Install a new helical coil insert with
an appropriate standard helical coil installation
tool.
C2) Install a new helical coil inserts (325, 330) 3/4 - 1
1/2 turns below the top surface.
I 32-46-42 Page 606

Apr 30/94
REPAIR
l
- SPECIAL
SOLT
PIN
LEE PLUG
Figure 604. Piston Housing - Removal of Lee Plugs

C. LEE PLUG REPLACEMENT
Lee plugs (245) can be removed by any method that does not
damage reamed hole, or 45° angle seat. A long bolt and
striker bushing is recommended, as shown in Figure 604.
(1) Drill and tap a hole in the pin. Extract the pin.
C2) Tap the plug, then extract the plug.
C3) Measure diameter of Lee plug receiving hole. If hole
measures 0.2187 - 0.2212 inch (5,555 - 5,618 mm>,
install standard size PLGA2180010 Lee plug as
instructed in following paragraph (6).
If hole is larger than specified size, oversize Lee
plug is required. Refer to the following steps
WARNING: SURFACE TREATMENT (MIL-C-5541) ARE DANGEROUS TO
EYES, SKINS AND RESPIRATORY TRACT. SKIN AND EYE
PROTECTION REQUIRED. PREVENT REPEATED CONTACT
WITH THE TREATMENT OR CONTACT FOR A LONG TIME.
GOOD GENERAL AIR FLOW IS USUALLY SUFFICIENT.
(4) First Rework:
Ream hole to 0.2287 - 0.2312 inch (5,809 - 5.87 mm>
diameter and to a 63RMS Cor better> surface finish.
Apply surface treatment CMIL-C-5541> to reamed holes.
Install oversize PLGA2280010 Lee plug per paragraph
(6).
(5) Second Rework:

Drill and ream holes to 0.2500 - 0.2525 inch (6,350 -
6,414 mm> diameter and to a 63RMS <or better> surface
finish. Apply surface treatment CMIL-C-5541) to
reamed holes. Install oversize PLGA2500010 Lee plug
per paragraph (6).
Page 607
32-46-42 Apr 30/94
REPAIR
CAUTION: REAMED HOLES AND REPLACEMENT PLUGS MUST BE CLEAN
AND DRY.
(6) Press standard or oversize Lee plug <refer to
paragraphs C4> and C5> for part numbers> into reamed
hole until firmly seated on shoulder of reamed hole.
NOTE: Pins are factory prewaxed; additional
lubrication is not required.
Ca) Start pin, small end first, into tapered hole in
plug. Avoid tilting pin.
Cb) Firmly support piston housing and tap pin in
with hammer and pin punch until exposed end of
pin is flush with exposed end of plug,± 0.005
inch C0,13 mm). To minimize mushrooming (make
thicker than normal> of the pin, drive it in
with a few heavy hits instead of many light
hits.
D. SURFACE TREATMENT
SUFFICIENT.
(1) Clean surface with thinner.
WARNING: SURFACE TREATMENT CMIL-C-5541) ARE DANGEROUS TO
EYES, SKINS AND RESPIRATORY TRACT. SKIN AND EYE
PROTECTION REQUIRED. PREVENT REPEATED CONTACT
WITH THE TREATMENT OR CONTACT FOR A LONG TIME.
GOOD GENERAL AIR FLOW IS USUALLY SUFFICIENT.
(2) Apply surface treatment CMIL-C-5541) with brush,
sponge, pad, or spray to reworked areas. Do not touch
treated surface until completely dry.
7. PAINT PISTON HOUSING

NOTE: Reapply paint at each brake overhaul.
NOTE: Refer to CLEANING section for paint removal.
Page 608
32-46-42 Apr 30/94
REPAIR
WARNING: A FIRE OR EXPLOSION HAZARD IS POSSIBLE WHEN WATER COMES
IN CONTACT WITH ALUMINUM POWER (PRODUCING HYDROGEN GAS).
THIS SITUATION CAN OCCUR WHEN WATER-BORNE PAINT WASTE IS
DISPOSED OF IN THE SAME WASTE CONTAINER AS IS
SOLVENT-BORNE PAINTS CONTAINING ALUMINUM PIGMENTS (SUCH
AS METALLIC TOP LAYER PAINT). TO ELIMINATE ANY
POSSIBILITY OF THIS HAZARD, IT IS RECOMMENDED THAT WASTE
PRODUCTS FROM THE WATER REDUCIBLE PRIMER BE KEPT SEPARATE
FROM OTHER PAINT WASTE PRODUCTS.
WARNING: SURFACE TREATMENT (MIL-C-5541) IS DANGEROUS TO EYES,
SKINS AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION
REQUIRED. PREVENT REPEATED CONTACT WITH THE TREATMENT OR
USUALLY SUFFICIENT.
A. For Touch-up surface repairs, use #320 abrasive cloth and
finish with #400 abrasive cloth to give surface a fine
smooth finish. Apply apply chemical conversion coating
CMIL-C-81706) to meet requirements of CMIL-C-5541) to all
exposed aluminum and permit it to dry.
WARNING: THINNER (MIL-T-81772) IS FLAMMABLE AND DANGEROUS TO THE
SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE
PROTECTION IS REQUIRED. PREVENT REPEATED CONTACT WITH
THE THINNER OR CONTACT FOR A LONG TIME. GOOD GENERAL AIR
FLOW IS USUALLY SUFFICIENT.
B. Clean all surfaces to be painted with a no-lint cloth
soaked in thinner CMIL-T-81772).
c. Mask all areas where epoxy primer is not wanted <refer in
Figure 606>.
WARNING: EPOXY POLYAMIDE PRIMER (MIL-P-23377) AND EPOXY PRIMER ARE
FLAMMABLE AND DANGEROUS TO THE SKIN, EYES, AND
RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED.
PREVENT REPEATED CONTACT WITH THE PRIMER OR CONTACT FOR A
D. Apply one layer of epoxy polyamide primer CMIL-P-23377) or
epoxy primer CMIL-85582). Air dry for one hour minimum
<refer to Figure 605).
E. Mask all ares where urethane paint is not wanted <refer to
Figure 606).
WARNING: ALUMIGRIP PAINT IS FLAMMABLE AND DANGEROUS TO THE SKIN,
EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS
REQUIRED. PREVENT REPEATED CONTACT WITH THE PAINT OR
USUALLY SUFFICIENT.
F. Apply two layers of Alumigrip Urethane Paint. Permit 15
minutes drying time between layers.
Page 609
32-46-42 Apr 30/94
REPAIR
NOMENCLATURE MATERIAL MIXING DRY LAYER DRYING TIME MIXTURE
IDENTIFICATION REQUIRED THICKNESS BETWEEN POT LIFE
LAYERS
--- --- --- ---
I ***Thinner, MIL-T-81772
D-385
*Thinner,
Reducer
T0003 --- --- --- ---
**Epoxy MIL-P-85582 See 0.0006 inch 30 Minutes 6 Hours
Polyamide Type I, NOTE 5 <0,015 11m) Min. Max. at
I Primer
(Water
Reducible)
Class 1 One Layer 6 Hrs.
Max.
Temp.
71-75°F
(22-24°c:
*Epoxy MIL-P-23377 See 0.0005 1 Hrs. Min.

Polyamide Type I, NOTE 1 inch 2 Days 4 Hours
Primer Class 1 <0,013 mm> Max.
(Thinner One Layer
Reducible>
*Topcoat Aluminum See 36 Hrs.
Alumigrip Color NOTE 2 0.0015 inch Max. 6 Hours
Urethane Catalogue <0,038 mm>
Paint No. 61053 Two Layers See NOTE 3
See NOTE 4
Topcoat AWL-CAT #2,
Alumigrip Catalogue
Catalyst No. 63010
* Paint Vendor:u.s. Paint

831 s. 21st Street
St. Louis, MO 63103-3092
U.S.A.
** Primer, 44-GN-7: Deft Inc.
<Water Reducible) 17451 Von Karman Avenue,
Irvine, CA 92714 U.S.A.
(Telephone: 1-800-544-3338)
*** Thinner, D-385: Ashland Chemical Co.
(Telephone: 1-800-228-0965)
NOTE: 1. Mix one part by volume of Component Number 1 to one part by
volume of Component Number 2. Allow catalyzed material to
stand 30 minutes before appli~ation. Reduce to spraying
viscosity, 17-19 Zahn #2 cup, with thinner MIL-T-81772.
Figure 605. Alumigrip Urethane Paint System (Sheet 1 of 2)
I 32-46-42 Page 610

Apr 30/94
REPAIR
NOTES:2.Mix one part by volume Alumigrip Urethane topcoat to one
part by volume Alumigrip catalyst. Reduce to spraying
viscosity 18-22 Zahn #2 cup, with Urethane Reducer
Catalogue Number T0003.
3. After topcoated part<s> has set 30 minutes, bake for two
hours at 150 F. C65°C).
Alternate Method: Air dry at room temperature for two
weeks.
4. If parts set in excess of 36 hours, wipe down area to be
painted with tac rag soaked in M.E.K., T0003 or Naphtha.
5. Mixing Ratio - 3:1 System
COMPONENT A COMPONENT B WATER
Three Volumes One Volume Eight Volumes (Approx.)
A. 1. Component A is a pigmented compound.
2. Component Bis a clear compound.
B. Add one volume of Component B to three volumes of
Component A, and mix thoroughly.
c. To the mixture specified in Paragraph B, add eight
volumes of tap water. Add the water in one-third
increments and mix thoroughly between additions of
water.
D. When all the water has been added and thoroughly
mixed, adjust to desired application viscosity with
water.
NOTE: Typically 200-225% total water reduction is
required to obtain an application viscosity of 20
seconds and varies from batch to batch. For spray
viscosity application, the reduced viscosity should
be 20 seconds in a #2 Zahn cup.
EXAMPLE: Mix 0.75 U.S. gallon (2.8 liters) of Component A
and 0.25 U.S. gallon C0.9 liters) of Component
B, to make a total of one gallon of catalyzed
material.
To this add all 0.75 U.S. gallon (2.8 liters) of
water, mix thoroughly.
To this add all 0.75 U.S. gallon (2.8 liters> of
To this add all a.so u.s. gallon <1.9 liters> of
Figure 605. Alumigrip Urethane Paint System (Sheet 2 of 2)
I 32-46-42 Page 611

Apr 30/94
REPAIR
----&-,
i
I
SECTION A-A
& NO PRIMER OR URETHANE PAINT

~ PRIMER ONLY
& PRIMER AND URETHANE PAINT
~ PRIMER ONLY. MASK TO 0.697 - 0.797 (17,70 - 20,24 MM) DIA.
Figure 606. Paint Masking
Page 612
32-46-42 Apr 30/94
ASSEMBLY
NOTE: Refer to IPL Figure 1 for identifica tion of component s.
NOTE: Refer to Page 901 for special tools.
Equipment and Materials:
NOTE: Equivalent replacemen ts can be used for listed items, but
not for antiseize compound.
a. Arbor Press
b. Standard Shop Tools
c. Antiseize Compound CMIL-T-5544>
d. Rust Veto Spray
e. Phosphate Ester Hydraulic Fluid
1. ASSEMBLE ADJUSTERS
WARNING: ADJUSTER ASSEMBLIES CONTAIN SPRING-LOADED PARTS.
DISASSEMBLY WITHOUT PROPER EQUIPMENT OR COMPLIANCE WITH
THE FOLLOWING INSTRUCTIONS, CAN RESULT IN SERIOUS INJURY
TO PERSONNEL. EYE PROTECTION IS REQUIRED.
CAUTION: LOSS OF BRAKE CLEARANCE WILL RESULT IF ADJUSTER TUBES
(205) ARE NOT REPLACED AT EACH HEAT SINK CHANGE OR
REPLACEMENT OF ANY HEAT SINK PART.
CAUTION: MAKE SURE THAT TUBE RETAINER (220) HAS A"(" BEFORE THE
WORD "WARNING", AND A")" AFTER THE WORD "WARNING", OR A
THICKNESS OF 0.125 INCH (3,18 MM).
A. Install the spring <225), tube retainer (220) with the
(WARNING> side up inside the adjuster housing (230).
B. Put the adjuster housing (230> face up on press (refer to
Figure 701).
C. Insert 3/8 inch (9 mm> O.D. plug in the press, and slide
retainer ring (215> up the arbor shaft.
D. Press tube retainer (220> inside adjuster housing (230)
until retaining ring (215) can be installed in the I.D. of
the adjuster housing (230).
E. Lock the press and install the retaining ring (215).
I CAUTION: MAKE SURE RETAINING RING IS SEATED BEFORE RELEASING PRESS.

F.
G.
Release press and slowly relax the spring force on the tube
retainer <220).
Remove adjuster housing (230) from press.
H. Install the adjuster pin (210) through the bottom of the
adjuster housing (230).
I 32-46-42 Page 701

Apr 30/94
ASSEMBLY
NUT (195) RING RETAINER

(215)
ADJUSTER TUBE\ HELICAL SPRING

(205) (225)
\ i\ \ ~
or~ )\!J(q)- ~/~ WI.Ii----~
BALL (200) ADJUSTER HOUSING
(230)
ADJUSTER PIN (210)
TUBE RETAINER (220)
ARBOR PRESS RETAINER RING (215)
3/8 (9 mm) O.D. PLUG

OR EQUIVALENT SIZE SOCKET
TUBE RETAINER (220)

SPRING
(225)
ADJUSTER HOUSING (230)
Figure 701. Adjuster Reassembly
Page 702
32-46-42 Apr 30/94
ASSEMBLY
I. Install adjuster tube (205>, ball (200), and nut (flared
end toward ball) (195) through retaining ring (215) side of
adjuster housing and on to adjuster pin (210).
C1> If pressure plate fixture (Figure 903) is to be used
(paragraph 4 of this section> to install the pressure
plate, apply locktite to the adjuster pin threads and
dry torque each nut (195) to 10 - 20 lbf inch (1,1 -
2,3 Nm).
(2) If the alternate procedure for assembling the
pressure plate is used (paragraph 5 of this section>,
thread each adjuster pin nut (195> only 1 to 1 1/2
turns onto the adjuster pin.
2. ASSEMBLE SHUTTLE VALVE
A. Replace all preformed packings (365, 370) at each overhaul.
Lubricate preformed packings (365, 370) and threads of
parts with phosphate ester hydraulic fluid.
B. Install the preformed packings (365, 370) onto the O.D. of
the end cap (355)
c. Install the spring (380) and balls (375) into the poppet
(360> <refer to Figure 702).
D. Put the poppet assembly (360) and assembled parts in the
end cap (355). Push the poppet into the end cap until the
balls (375) engage the shoulder, and the spring (280) holds
the poppet assembly in position.
E. Install the end cap (355) with assembled part into the
valve body (350). Dry torque the end cap to 25 - 40 Lbf
foot (33,90 - 67,80 Nm>.
PREFORMED
PACKING (370)
I PREFORMED
PACKING (365)
BALL (375)
END CAP
........._ ___,,___ [ (355)
SHUTTLE VALVE _j POPPET ~
,._
BODY (350) o·
ASSEMBLY__............/
<360> / jo
SPRING
(380)
L
BALL (375)
Figure 702. Shuttle Valve Assembly
Page 703
32-46-42 Apr 30/94
ASSEMBLY
C
3. ASSEMBLE PISTON HOUSING
A. Replace all preformed packings and examine packing
I retainers at each overhaul. Lubricate preformed packings
and threads of hydraulic parts with phosphate ester
hydraulic fluid before installing.
B. Check to make sure all Lee plugs <320), and helical coils
(140, 165, 325, 330) are installed <refer to the REPAIR
section>.
c. Install a packing backup retainer <265) on each sleeve
I (245) <refer to Figure 703).

(1) Pull up on the packing backup retainer to stretch and
install over the hex end of sleeve (245).
NOTE: The packing backup retainer will return to size and
permit installation of sleeve in piston housing
after a 45 minute resting period.
NOTE: To speed reducing process, heat the sleeve and
packing backup retainer to 250°F C121°C)for no
longer than 15 minutes. Permit the sleeve and
packing backup retainer to slowly cool to room
temperature before installing preformed packing
(270) and scraper ring (275).
(2) Install preformed packings (270) on the O.D. of
sleeves (245).
(3) Install scraper rings (275) in I.D. of the sleeves
(245).
PULL UP TO STRETCH
PACKING RETAINER (265)
SLEEVE (245>---
PACKING BACKUP
RETAINER (265)
Figure 703. Sleeve Packing Retainer Installation
Page 704
32-46-42 Apr 30/94
ASSEMBLY
PACKING BACKUP
PREFORMED PACKING (270) RETAINER (265)
PISTON HOUSING
ASSEMBLY (315)
INSULATOR (235)
SPACER (240)
PISTON (250>----.:~LJ-~r-r.. ..-i,l,l'A"
PREFORMED SCRAPER RING (275)
PACKING (260)
SLEEVE (245)
PACKING BACKUP·
RETAINER (255)
Figure 704. Piston and Sleeve Assembly

D. Assemble packings backup C255) and preformed packings C260)
on O.D. of pistons (250) (refer to Figure 704).
E. Install pistons (250) in sleeves (245).
F. Install sleeves (245) into piston housing assembly (315).
Dry torque sleeves to 90 - 100 lbf in C10,1 - 11,3 Nm) and
lockwire.
G. Install spacers (240) and insulators (235) in pistons (250).
H. Install the adjuster assemblies (190) in the piston housing
assembly (315) and attach with retaining rings (185).
I 32-46-42 Page 705

Apr 30/94
ASSEMBLY
I 4. INSTALL PRESSURE PLATE AND WEAR PLATE ASSEMBLY
<refer to paragraph 5, this section, for alternate procedure>
A. Lay the pressure plate fixture (Pressure Plate Installation
Fixture Figure 903 Sheet 1 and 2> on a flat surface.
B. Put the piston housing assembly (315) on the pressure plate
fixture with center bolt of pressure plate fixture going
through axle hole, and the fixture pins aligning with the
I adjuster pins (210). (refer to Figure 705).
PISTON HOUSING
ASSEMBLY (315)
ADJUSTER PIN
(210)
a FIXTURE
(REFER TO FIGURE
PIN 8 903, SHEET 1 & 2)
Figure 705. Pressure Plate Installation

c. Attach the half moon fixture to the center bolt with two
washers and nut. Attach two washers and nut to the other
bolt.
D. Evenly tighten both nuts Cone turn at a time) to extend the
adjuster pins (210) to allow pressure plate and wear plate
assembly (125> installation.
E. Install the pressure plate and wear plate assembly (125>.
Align and engage the adjuster pins in the keyhole slots of
the pressure plate and wear plate assembly. Press down and
rotate the pressure and wear plate assembly (125)
counter-clockwise. Make sure components are securely
attached before removing the piston housing from the
I fixture.
Page 706
I 32-46-42 Apr 30/94
ASSEMBLY
5. ALTERNATE PROCEDURE FOR INSTALLING PRESSURE AND WEAR PLATE
ASSEMBLY
A. Assemble adjuster assemblies <refer to paragraph 1 of this
section>.
B. Lay the piston housing assembly (315) and assembled
components on a flat surface with piston insulators (235)
facing up.
c. Align the pressure plate and wear plate assembly (125) on
the piston housing assembly so the keyhole slots align with
the adjuster pins.
D. With both components in position, turn the piston housing
assembly and pressure plate and wear plate assembly over.
E. Rotate the piston housing counter-clockwise to engage the
adjuster pins in the keyhole slots of the pressure plate.
F. Set Adjusters
C1) Install the short end of a 1/16 inch (1,58 mm) allen
wrench in the keyhole slot of the pressure plate and
slide into the slotted head of adjuster pin <refer to
Figure 706). This will prevent the adjuster pin from
turning while the adjuster nut is being torqued.
C2) Apply locktite sealant CNo. 262) on the threads of
nut (195) and adjuster pin (210). Torque to 10 - 20
lbf in (1,1 - 2,3 Nm).
LOCKTITE SEALANT
(NO. 262)
PISTON H
ASSEMBLY
ADJUSTER PIN
(210)
1/16 INCH PRESSURE PLATE AND

ALLEN WRENCH WEAR PLATE ASSEMBLY (125)
Figure 706. Alternate Pressure Plate Assemble Procedure
I 32-46-42 Page 707

Apr 30/94
ASSEMBLY
6. INSTALL WEAR INDICATOR PARTS
A. Thoroughly clean stud assemblies (120) to remove oil,
grease and other contaminants.
B. Apply 2 or 3 drops of Loctite sealant (No. 262) on end of
stud <refer to Figure 707).
c. Insert stud assemblies (120) through piston housing (315)
and into pressure and wear plate assembly (125). Screw
stud assemblies (120) down until the lock-nut comes in
contact with the pressure and wear plate assembly (125).
Dry torque nut to 35 - 40 lbf inch (4,0 - 4,5 Nm).
D. Install rod and insert assemblies (115) onto stud
assemblies (120).
LOCTITE SEALANT
ROD AND INSERT
ASSEMBLY (115)
STUD ASSEMBLY
(120) 0.170 (4,32)
LOCK NUT 0.160 (4,06)
Figure 707. Stud Assembly and Rod and Insert Assembly

7. HEAT SINK AND PISTON HOUSING ASSEMBLY
A. Alternately install three carrier and lining assemblies
I (150) and the two stator disk (155) with a stator disk
between each carrier and lining assemblies. on the torque
plate and wear plate assembly (160).
NOTE: Carrier and lining assemblies (150) and stator
disks (155) are color coded white.
B. Assemble the piston housing assembly (315) with attached
pressure plate assembly to the torque plate. Make sure the
word "TOP'' (impression stamped on torque plate and pressure
plate) are in line.
I Page 708
Apr 30/94
ASSEMBLY
c. Before installing bolts (10), and washers (15), apply
antiseize compound CMIL-T-5544) to the threads and bearing
surfaces <refer to Figure 708).
I NOTE: Antiseize compound (MIL-T-5544) can separate over a

period of time. A new container should be fully
mixed when first opened and should be covered when
not in use to prevent contamination. Mix every 60
days to prevent separation.
PUT COUNTERSUNK
SIDE OF WASHER
AGAINST BOLT HEAD
APPLY ANTISEIZE COMPOUND

(MIL-T-5544) TO THESE SURFACES
Figure 708. Antiseize Compound Application
E. Put washers (15) on bolts <10) with countersunk side of
washer against the bolt head. Install bolts and washers
through the piston housing assembly (315) and into the
torque plate assembly (160). Torque bolts to 38 - 40 lbf
ft (51,5 - 54,2 Nm).
8. SHUTTLE VALVE INSTALLATION WITHOUT ADAPTER
<2-1528-1, 2-1528-2, and 2-1528-3 brake assemblies only)
A. Install a lubricated packing retainer (65) and preformed
packing C70) on the shuttle valve assembly (60).
B. Install the shuttle valve in the piston housing assembly
(315) and attach with bolts (50> and washers (55).
c. Dry torque the bolts (50> to 70 - 80 lbf inch (7,9 - 9,0
Nm>. Lockwire the two bolts together.
D. Install a lubricated preformed packing (30) on the union
fitting (25). Install the union fitting (25) in the
shuttle valve assembly (60) and dry torque to 50 - 75 lbf
inch (5,6 - 8,5 Nm).
E. Install a lubricated preformed packing C45) onto the union
fitting (40). Install union fitting (40) in the shuttle
valve assembly (60) and dry torque to 50 - 75 lbf inch C5,6
- 8,5 Nm).
I Page 709
Apr 30/94
ASSEMBLY
9. SHUTTLE VALVE INSTALLATION WITH ADAPTER
(2-1528-4, 2-1528-5, and 2-1528-6 brake assemblies only)
A. Install a lubricated packing retainer (65), preformed
packing (70> and gasket (75> on the adapter (73) <refer to
Figure 709).
B. Install a lubricate packing retainer (65) and preformed
packing (70> on the shuttle valve assembly (60).
C. Install spacers (72), bolts (53) and washers (55) to attach
the adapter (73) and shuttle valve assembly to the piston
housing assembly (315).
D. Dry torque bolts (53) to 70 - 80 lbf inch (7,9 - 9,0 Nm).
Lockwire the two bolts together.
E. Install the bleeder screw (48) into adapter (73> and dry
torque to 35 - 45 lbf inch (3,9 - 5,1 Nm).
F. Install a lubricated preformed packing (30) on union
inch (5,6 - 8,5 Nm).
G. Install a lubricated preformed packing (45) to the union
inch C5,6 - 8,5 Nm).
- PREFORMED PACKING (30)
SPACER <72 >

'
BLEEDER VALVE (48)....._
-I~ "
ADAPTER <73 >'-....., , \ - ;,~
' ............ PACKING RETAINER (65)
PREFORMED PACKING (70)
'--,~- - PACKING RETAINER (65)
. ~ PREFORMED PACKING (70)

PISTON HOUSING GASKET (75)
ASSEMBLY (315)
Figure 709. Shuttle Valve Installation
I 32-46-42 Page 710

Apr 30/94
ASSEMBLY
10. BLEEDER ASSEMBLY INSTALLATION WITH ADAPTER
A. Install a lubricated packing retainer (105), preformed
packing (110), and gasket (95) on the bleeder adapter (90).
B. Attach the bleeder adapter (90) on the piston housing
assembly (315) with washers C85) and bolts (80). Dry
torque bolts to 70 - 80 lbf inch (7,9 - 9,0 Nm). Lockwire
the bolts together.
c. Install a preformed packing (305) on the reducer fitting
(300). Install the reducer fitting in the bleeder adapter
(90). Dry torque the reducer fitting to 70 - 80 lbf inch
(7,9 - 9,0 Nm).
D. Install the bleeder valve (295) in the reducer fitting
(300). Dry torque the bleeder valve to 50 - 75 lbf inch
(5,6 - 8,5 Nm).
E. Install a washer (290) and screw (285) in the bleeder valve

(295). Dry torque screw to 35 - 45 lbf inch (3,9 - 5,1 Nm).
NOTE: When the reducer fitting (300) is installed with
the bleeder screw assembly (280), always check the
torque on the bleeder screw assembly after torquing
the reducer fitting.
11. ALTERNATE BLEEDING PROCEDURE TO AVOID SENSITIVITY BRAKE
NOTE: Brake assemblies that do not have adapter (73) installed
(single bleeding system), use this section. Brake
assemblies with the adapter (73) installed (dual bleeding
system) use standard bleeding procedures.
A. PROCEDURE #1
WARNING: HYDRAULIC FLUID ARE DANGEROUS TO SKINS, EYES, AND
B. This procedure bleeds the brake assembly in two directions
to remove trapped air. If an auxiliary hydraulic pressure
source is used, make sure that the brake is not connected
to the aircraft hydraulic system while back bleeding.
c. Case #1: Brake installed on aircraft.
(1) Disconnect the hydraulic and pneumatic line~ from the

shuttle valve fittings. Disconnect the ground strap
from the piston housing assembly.
(2) If the aircraft hydraulic system is used, watch the
reservoir level and refill as necessary.
Page 711
I 32-46-42 Apr 30/94
ASSEMBLY
(3) Remove bleeder screw assembly (280), reducer fitting
(300), and preformed packing (305) from the bleeder
adapter C90>.
C4) Remove the pneumatic union fitting (25) and preformed
packing C30) from the shuttle valve assembly (60).
CS) Install pneumatic union fitting (25) and preformed
packing C30) into the bleeder adapter (90). Torque
the union fitting to 70 - 80 lbf inch C7,9 - 9,0 Nm).
C6) Connect the hydraulic pressure source to the
pneumatic union fitting C25> that is installed on the
bleeder adapter (90) (refer to Figure 710).
NOTE: Hydraulic pressure source can be either an
auxiliary source, such as a hydraulic hand pump, or
the aircraft hydraulic system. Using the aircraft
hydraulic system, connect an adapter hosed to the
aircraft hydraulic line and connect the other end
to the pneumatic union fitting (25) that is
attached to the bleeder adapter (90) (refer to
Figure 711>.
HYDRAULIC
FITTING (40)
OUTLET 3" MIN.
AUXILIARY
HYDRAULIC
PRESSURE
SOURCE
SHUTTLE VALVE HOSE FITTING

ASSEMBLY (60) COMPATIBLE
WITH AN815-4J
PISTON HOUSING BLEEDER

ASSEMBLY (315) ADAPTER (90)
Figure 710. Back Bleeding Using Auxiliary Hydraulic Pressure Source
Page 712
32-46-42 Apr 30/94
ASSEMBLY
BLEEDER --AIRCRAFT HYDRAULIC LINE

HOSE
ADAPTER HOSE
APPROXIMATELY
12 INCHES (304.8mm)
IN LENGTH. ONE END
COMPATIBLE WITH AN815-4J
OUTLET
SHUTTLE VALVE BLEEDER ADAPTER (90)

ASSEMBLY (60)
Figure 711. Back Bleeding Using Aircraft Hydraulic Pressure Source

(7) Connect a bleeder hose to the hydraulic fitting (40)
on the shuttle valve assembly (60). Outlet of the
bleeder hose must be at least three inches (76,2 mm>
above of piston housing assembly (315). Apply
hydraulic pressure and bleed brakes. Continue to
bleed until hydraulic fluid runs clear of air
bubbles. Disconnect hydraulic pressure source. Keep
the bleeder hoses in place for approximately 30
seconds to permit the brake to backfill.
(8) Reinstall pneumatic union fitting (25), preformed
packing (30), reducer fitting (300), and bleeder
screw assembly (280) in initial positions.
(9) Connect the aircraft hydraulic line to hydraulic
fitting C40) that is attached to the shuttle valve
assembly (60>. Applying hydraulic pressure and bleed
brakes until hydraulic fluid runs clear of air
bubbles.
(10) Reconnect pneumatic line to pneumatic union fitting

(25> and reattach ground strap to piston housing
assembly.
I 32-46-42 Page 713

Apr 30/94
ASSEMBLY C
c. Case #2: New installations or brake removal from axle.
(1) Perform Case #1 steps (2) through (5). Plug hydraulic
lines to prevent hydraulic fluid from spilling.
NOTE: Some aircraft will require additional fittings to
adapt the hydraulic line to a number 4-AN fitting.
<2> Temporarily install right-hand brake assembly on left
axle and left-hand brake assembly on right axle.
Connect hydraulic line<s> to union fittingCs> (25> on
bleeder adapter<s> (90). Connect the bleeder hose to
the hydraulic fitting (40) on shuttle valve assembly
(60). Outlet of the bleeder hose must be at least
three inches (76,2 mm> above of piston housing
assembly (315). Apply hydraulic pressure and bleed
brakes. Continue to bleed the brakes until hydraulic
fluid runs clear of air bubbles. Disconnect
hydraulic pressure source. Keep the bleeder hoses in
place for approximately 30 seconds to permit the
brake to backfill.
(3) Reinstall the pneumatic union fitting (25), preformed
packing (30), reducer fitting (300), and bleeder
screw assembly (280) in their initial positions. Plug
all hydraulic lines.
C4> Remove brakes and install then again on initial axles
from which removed. Connect aircraft hydraulic lines
to hydraulic fitting on shuttle valve assembly (60).
Attach ground strap to piston housing assembly.
CS> Bleed brakes by applying pressure to the brakes and
allowing air to escape from open bleeder screw on
bleeder adapter (90). Bleed the brakes until
hydraulic fluid runs clear of air bubbles
(6) Check reservoir level and add fluid as necessary.
D. PROCEDURE #2: Using Bleeding Apparatus Shown In Figure 709.
(1) Check reservoir level and replenish as necessary.
Repeat this step periodically during bleeding
operation.
<2> Remove tie wraps and hose clamp from brake hose, if
necessary.
I 32-46-42 Page 714

Apr 30/94
ASSEMBLY
~----AIRCRAFT
HYDRAULIC
LINE
HYDRAULIC
FITTING (40)
SHUTTLE VALVE
ASSEMBLY (60)
PNEUMATIC
UNION FITTING
(25)
Figure 712. Using Bleeding Apparatus

C3> Disconnect the pneumatic line from the shuttle valve
fitting C25>.
C4> Disconnect the hydraulic line from the shuttle valve
hydraulic fitting C40) and quickly connect upstream
side of valve #1 to hydraulic line. Make sure valve
is closed before disconnecting hydraulic line from
the shuttle valve hydraulic fitting to prevent
hydraulic fluid from spilling.
C5) Connect ends of tubing to the tee and hydraulic union
on the shuttle valve assembly (60). Connect the
other section of tubing to valve #2. Close valve #2
and open valve #1.
NOTE: Use "POWER ON" bleeding, if aircraft has a powered
system. Apply pressure to the brakes and bleed
brake normally to remove trapped air from
installation.
C6> Bleed the brakes until hydraulic fluid runs clear of
air bubbles.
C7) Apply pressure to the brakes. Close valve #1 with
pressure applied.
C8> Open valve #2 and bleed until fluid runs clear of air.
I 32-46-42 Page 715

Apr 30/94
ASSEMBLY
C9) Repeat steps D. C7> & C8) until there is no sign of
air in the fluid from bleeder.
(10) Remove valves, tubing sections, and tee. Attach the
hydraulic line to the hydraulic fitting C40) on the
shuttle valve assembly (60). Attach pneumatic line
to the pneumatic union fitting (25> on the shuttle
valve assembly.
(11) Secure the lines with clamps and tie wraps.
(12) Check reservoir level and add fluid if necessary.
12. ADJUST ROD AND INSERT ASSEMBLIES WITH NEW HEAT SINK COMPONENTS
A. Perform functional test as referenced in TESTING AND FAULT

ISOLATION section.
B. Pressurize the brake assembly to 350 - 400 psig (24,13
27,57 bars) and hold.
c. Turn the rod and insert assembly (115) to the correct

length for the brake assemblies that follow (refer to
Figure 713).
2-1528-1 = 0.61 inch (15,49 mm>
2-1528-2 = 0.61 inch (15,49 mm>
2-1528-3 = 0.50 inch (12,7 mm)
2-1528-4 = 0.61 inch (15,49 mm)
2-1528-5 = a.so inch (12,7 mm)
2-1528-6 = 0.59 inch (14,99 mm)
D. Decrease the pressure to zero (0) psig co bars).
ROD & INSERT ----EVEN WITH

ASSEMBLY (115) PISTON HOUSING
ASSEMBLY (BRAKE PRESSURIZED)
BRAKE
PRESSURIZED
PARA. C.
PRESSURE PLATE AND WEAR
PISTON HOUSING PLATE ASSEMBLY (125)
ASSEMBLY (315)
NEW BRAKE FULLY WORN BRAKE
NOTE: Indicator rod positions are shown with the brake pressurized
to 350 - 400 psig (24,13 - 27,57 bars>.
Figure 713. New and Worn Indicator Rod Positions
Page 716
32-46-42 Apr 30/94
C ASSEMBLY
13. ADJUST ROD AND INSERT ASSEMBLIES WITH USED HEAT SINK COMPONENTS
Wear plates do not need to be removed from the torque plate
or pressure plate to determine the remaining lining wear.
A. Measure the thickness of each carrier and lining assembly
C150>, each stator disk <155>, and each pressure plate and
wear plate assembly (125) in three equally-spaced location.
Also measure the thickness of three wear plates <175>,
equally-spaced on the torque plate assembly (160). Measure
the wear plates between the rivets <170>. Add the three
measurements for each part and divide by three to calculate
the average thickness of each part.
B. For each part, find the adjustment of the rod and insert
assembly (115) that agrees with the average part thickness
<refer to Figure 714). Between measurements should use the
shortest rod and insert assembly setting for that brake
assembly
CARRIER AND STATOR WEAR PLATE PRESSURE LENGTH OF ROD AND INSERT ASSEMBLIES
LINING ASSY. DISK THICKNESS PLATE AND
(ROTOR) THICKNESS ON TORQUE WEAR PLATE 2-1528-1 2-1528-3 2-1528-6
THICKNESS PLATE THICKNESS 2-1528-2 2-1528-5
2-1528-4
0.445 (11,30) 0.285 (7,24) 0.087 (2,21) 0.265 (6,73) 0.600 (15,24) 0.490 (12,45) 0.580 (14,73)
0.437 (11,10) 0.283 (7,19) 0.086 (2,18) 0.264 (6,71) o. 570 C14,41> 0.470 (11,90 0.550 (13,97)
0.429 (10,89) 0.280 (7,11) 0.085 (2,16) 0.263 (6,68) 0.540 (13,72) 0.440 (11,11> 0.520 (13,21)
0.420 (10,67) 0.278 (7,06) --- --- --- --- o. 510 C12,95 > 0.420 (10,69) 0.490 (12,45)
0.412 (10,46) 0.275 (6,99) 0.084 (2,13) 0.262 (6,65) 0.410 (12,19) 0.390 (9,91) 0.470 (11,94)
0.404 (10,46) 0.273 (6,93) 0.083 (2,11) o. 261(6,63) 0.450 (11,43) 0.370 (9,40) 0.440 (11,18)
0.396 (10,06) 0.270 (6,86) 0.082 (2,08) 0.260 (6,60) 0.420 (10,69) 0.350 (1,89) 0.410 (10,41)
0.387 (9,83) 0.268 (6,81) 0.081 <2,06) 0.259 (6,58) 0.390 (9,91) 0.320 Cl,13) 0.380 (9,65)
0.379
0.371
(9,63)
(9,42)
0.265
0.263
(6,73)
(6,68)
--- ---
0.080 (2,03)
--- ---
0,258 (6,55)
0.360 (9,14) 0.300 (7,62) 0.350
0.320
(8,89)
(8,13)
0.330 (3,31> 0.270 (6,16)
0.363 (9,22) 0.261 (6,63) 0.079 (2,01) 0.257 (6,53) 0.310 (7,17> 0.250 (6,35) 0.300 (7,62)
0.354 (9,00) 0.258 (6,55) 0.078 (1,98) 0,256 (6,50) 0.280 <7,11) 0.230 CS,10 0.270 (6,86)
0.346
0.338
(8,79)
(8,59)
0.256
0.253
(6,50)
(6,43)
--- ---
0.077 (1,96)
--- ---
0.255 (6,48)
0.250
0.220
(6,35)
CS,59>
0.200
0.110
(5,01)
<4,57>
0.240
0.210
(6,10)
(5,33)
0.330 (8,38) 0.251 (6,38) 0.076 (1,93) 0.254 (6,45) 0.190 <4,13) o. 150 <3,11 > 0.180 (4,57>
0.321 (8,15) 0.248 (6,30) 0.075 (1,91) 0.253 (6,43) 0.160 U,06> 0.130 (3,30) 0.150 (3,81)
0.313 (7,95) 0.246 (6,25) 0.074 (1,88) 0.252 (6,40) 0,130 (3,30) 0.110 <2,79) 0.120 (3,05)
0.305
0.297
(7,75)
(7,54)
0.243
0.241
(6,17)
(6,12)
--- --- --- ---
0.073 (1,85) 0,251 (6,38)
0.100 (2,54) 0,010 <2,03) 0.100
0.070
(2,54)
(1,78)
0.070 (1,71) 0.060 (1,52)
0.288 (7,32) 0.238 (6,05) 0.072 (1,83) 0,250 (6,35) 0.040 (1,02) 0.030 (0,76) 0,040 (1,02)
0.280 (7,11) 0.236 (5,99) 0.071 (1,80) 0,249 (6,32) 0.010 (0,25) 0.010 <0,25) 0.010 (0,25)
Figure 714. Adjust The Rod And Insert Assemblies

With Used Heat Sink Parts
Page 717
32-46-42 Apr 30/94
ASSEMBLY
c. Adjust the rod and insert assembly (115) at the shortest
adjustment that is shown for all the parts in the heat sink
<refer to example Figure 715).
NOTE: The example values (Figure 715) are calculated to
the 2-1528-6 brake assembly.
D. If all the parts are thicker than the dimensions in Figure
714, adjust the rod and insert assembly (155> at the
longest setting for that brake assembly.
NOMENCLATURE AVERAGE LENGTH OF ROD

THICKNESS OF AND INSERT
USED PARTS ASSEMBLY FROM
INCH (mm> Figure 714.
Pressure Plate & Wear Plate Assembly 0.256 (6,50) 0.270 (6,86)
Stator Disk #1 0.253 (6,43) 0.210 (5,33)
Stator Disk #2 0.262 (6,65) 0.300 (7,62)
Carrier and Lining Assembly <Rotor> #1 0.375 (9,63) 0.320 (8,13)
Carrier and Lining Assembly (Rotor> #2 0.334 (6,53) 0.180 (4,57)
Carrier and Lining Assembly <Rotor> #3 0.404 (10,46) 0.440 (11,18)
Torque Plate Wear Plates 0.082 (2,08) 0.410 (10,41)
Shortest length of rod and insert assemblies 0 .180 (4,57)

Figure 715. Example To Determine Length of Rod and Insert Assembly
E. Pressurize brake assembly to 350 - 400 psig (24,13 - 27,57
bars). and hold.
F. Turn the rod and insert assemblies (115) to the correct
length. Measure from the top of the rod to the surface of
rod access hole in the piston housing assembly (315) (refer
to Figure 713).
G. Decrease the pressure to zero psig <zero bars>.
14. Perform functional test (refer to the TESTING AND FAULT
ISOLATION section).
15. Install spacer (310) on aircraft axle before installation of
the brake assembly.
Page 718
32-46-42 Apr 30/94
ASSEMBLY
l
16. STORAGE INSTRUCTIONS
A. Store rubber parts in a cool C150°F C66°C MAX.>, dark, dry,
I B.
no dust area. Also keep parts away from air flow,
radiation, ozone <made by electric arcs, fluorescent lamps,
and other electrical equipment>, and other contamination.
If brake is to enter long term storage, apply Rust Veto
Spray or equivalent to the disk.
NOTES: 1. This film does not have to be removed before
installing brake on aircraft. At first brake
application the film will burn off and exhibit a
little smoke.
C. Install shipping cap plugs <20, 35>.
Page 719
32-46-42 Apr 30/94
(
FITS AND CLEARANCES
NOTE: Refer to IPL Figure 1 for identifica tion of component s.
ITEM ITEM TORQUE ANTI SEIZE

NUMBER NOMENCLATURE VALUE COMPOUND
FROM IPL REQUIRED
FIGURE 1. CMIL-T-554 4)
10 BOLTS 38 - 40 lbf foot YES
(51,5 - 54,2 Nm)
25, 40 UNION FITTINGS 50 - 75 lbf inch NO
(5,6 - 8,5 Nm)
48 BLEEDER 35 - 45 lbf inch NO
I
(4,0 - 5,1 Nm)
50, 53 SHUTTLE VALVE BOLTS 70 - 80 lbf inch NO
(7,9 - 9,0 Nm)
80 ADAPTER BOLTS 70 - 80 lbf inch NO
(7,9 - 9,0 Nm)
120 STUD ASSEMBLY NUT 35 - 40 lbf inch NO
(4,0 - 4,5 Nm)
195 ADJUSTER PIN NUT 10 - 20 lbf inch NO
(1,1 - 2,2 Nm)
245 PISTON SLEEVE 90 - 100 lbf inch NO
(10,1 - 11,3 Nm)
285 BLEEDER SCREW 35 - 40 lbf inch NO
(4,0 - 4,5 Nm)
295 BLEEDER VALVES 50 - 75 lbf inch NO
(5,6 - 8,5 Nm)
300 REDUCER FITTING 70 - 80 lbf in NO
(7,9 - 9,0 Nm)
355 SHUTTLE VALVE 25 - 40 Lbf foot NO
END CAP (33,9 - 54,2 Nm)
Page 801 /802

32-46-42 Apr 30/94
C
(
The special tools, fixtures and equipment in this section will
facilitate the disassembly, repair, testing and reassembly of the
brake assembly.
FIGURE NO. NOMENCLATURE APPLICATION
Figure 508. Spring Tester Required to check
I
Figure 604.
Figure 901.
Long Bolt And Striker
Tool, Peen & Anvil
adjuster spring
load
Removal of lee plugs.
Required to rivet
wear plates to
pressure and torque
plate.
Figure 902. Furnace Flattening Required to flatten
Fixture pressure plate and
disk assembly.
Figure 903. Pressure And Wear To install the
Plate Assembly Fixture pressure and wear
plate assembly
32-46-42 Page 901

Apr 30/94
0.122
0.118 ___ BREAK EDGE
(3,10)
(4,10) DIA 0.010 C0,25) MAX
.,.
_,_
(0
C
-,
tD
0.035 R
~(6,47)
0.255
0.245
(6,.22)
R
'
0.260
(6,60)
t
DIA
,,
en
m
...> ,..
n
r
3
... n
zO
'° .... 3
.,,
0
...a 0.030
(0,89) 0
0
r
m ,, m
,a 0
> z.,.
(0,76) en ~m
m ...,.o
zcn
tD
tD
.,_ 0.056 (1,42)
0.052 (1,32)
::::,
a,
0.250
....,.>< > 0
en ::s 0
en> ::iu
m ......
::::,
.... 3 z n
~~ :u:i:::m
0.
(6,35) m -t :z:
,.. C0.380 LENGT C:
::::,
<
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DIA 9ot!a) /~\
~ l '.,. Fl~
VET IIACHIIIE R
:;iu
m
en
rm,-
-< z
' ,..
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z"'
~ ~
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I l_j_ >
- z ,,
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J r 'ion==i_j_
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< N ,-n
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u) tD
"'
-
,0
I\) "::::, 0.380

45°
LENGTH & DIAMETER 0.28~ 7 ...
C:
...a C:
"'Nr,..
~ ....
f0 (9,65) 4.00 TO FIT CUSTOMER c1,1u I 1-- "'111
3 00
O') 0
DIA (101,60) RIVET MACHINE 0.60 "'
z
....
0
(15,24)
~ r-
I\)
ANVIL SWAGING PEEN
,..
"O .,, MATERIAL: W1 OR W2 TOOL STEEL MATERIAL: W1 OR W2 TOOL STEEL
-, a,
f0
HARDEN TO RH 'C' 50-55 HARDEN TO RH 'C' 50-55
N tD
c,.
. . . '°
-00
...a N
(-·,
r-- 0.250 (6,35)
5.00
(127,0)
DIA.
10.50
(266,7)
DIA.
SPACER
13.00
330,2)
MIN. DIA.
0
2.0
(50,8)
MIN.
1.50 - 2.00 THICKNESS
(38,1 - 50,8)
BOLT
2.0
(50,8)
MIN.
THICKNESS
FIXTURE
(
Figure 902. Furnace Flattening Fixture
Page 903
32-46-42 Apr 26/91
4 X 1.000 (25,40)
....
'Tl
IC
1.535 (38,99) 1.535 (38,99)
C
-, ---=ii- 1.00 (25,4) -
n,
0
,0 0.500 (12,7) 1.441 0.56
."" 2 X 0.500 (12,7) (36,60) (14,22)
,,
en
,.., m
en
:,-
n,
I -c- I I I♦
...>
n 3
> n
....
n,
"....
I I
-+- r
-I
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a,
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"V ID
0 0
:::a
2 X 3.292 > z 'Tl
....
0
(83,62)
r
en ~ men
m z 0
N > .... 0
"J
,,-, 5.535
(140,59) + 6.75
(171,45)
en 31 g
en> :::G
m ........
31 z n
.,,.,,
n,
ID -➔ ::c
r m>
C
-,
n,
------I+---+-♦ ~z
"" > m
z:::G
.,, no
,,r- > ..._ men
z ,,
m 31>
N >n
•".... I Z m
~
3.632 .... c
(92,25) >
UI
Nr
.,,::,
.b.
O') "mr-
00
·- 8.00 (203,3)
~
r-
m
".... 0.188 (4,77) DIA. THRU 2 X 0.500-13 UNC-38
0
::, 0.262 - 0.266 (6,65 - 6,75)
DIA. TO SHOWN
I ♦ 10 0.010 (0,25) I A IB I C
> -I
'O , ,
-, m
(0
0
0
r-
I ♦ 10 0.010 (0,25) A B C I I I I
NfD
c,. FIXTURE ASSY
.... ,0
,00
.... "'" ,_
....
"'l'I
0.512 - 0.521 0.50 (1,27) 1.50 (38,20)
co (13,00 - 13,23)
,
C
DIA. THRU
r
n,
0.240 (6,10)
,0
0.06 (1,52 X 45° 0.220 (5,59)
0
."" DIA.
.... t ,,enm
en
'::r
n,
n,
~ ...n> 31:
>n
... 0
r z 31:
"N 0.270 (6,86) -t m ~m
0 ::u z "'l'I
1.000 (25,4) ~ 0.268 (6,81) 0
~
....
0
0.050 (1,27) R DIA. r
en
> '"en
1" ZO
m -4 o
...,
N 1.875 (47,62) R (1,52 X 45°
,,, a.so c1,21>
...><
"'l'I
> 31: 0
en > ~
en ... n
n, -4 m z :1:
31: -4
C:
en ::u mm>
en r zm
,
C "' -< > ::u
n,
ITEM@ ITEM@ "" ZO
,, > .,, "en
m,,
31: ►
~ ,-.n
~
z
QJ
0
z""
u) "n, m N
I C:
I\) ...
:, ITEM QTY. NOMENCLATURE MATL.
ID
...
C: ....
VI
N
►
r
~ "
'111
en 3 00
1 1 PLATE STL. PLT. m
0) QJ
~
z
H.R.S. -4
~ ....
~
QJ
2 1 PLATE
I\) "0 3 4 PIN STEEL
:,
4 2 1/2-13 X 4.50 (114,3) LONG STUD STEEL
> -t
'0 ,,
, QJ
0
0 5 4 NEX NUT 1/2-13 STEEL
C0 ~
N n,
6 2 1/2 SPHERICAL WASHER SET STEEL
°'
..... ,0
-00
..a VI
1. PURPOSE
This section provides illustrations and parts breakdown of all
parts of the assemblyCies> shown on the title page which can be
disassembled, repaired or replaced, and reassembled.
Any modification, addition, or deletion in the parts list table
will be shown by an "R" at the beginning of the vertical line.
2. EXPLANATION AND USAGE OF SECTION
A. Item Numbers
The item number allows positive identification of the part
throughout the manual by making the part easy to find in
the parts list. The item number for a part normally does
not change, except for alpha variants explained below.
B. Alpha Variant Item Numbers
(1) Alpha variants A-Z <except I and O) are assigned to
existing item number when necessary to show:
Ca> Added items
Cb) Service Bulletin modifications
Cc) Configuration differences
Cd) Optional parts
Ce> Product improvement parts (non-Service Bulletin>
C2) Alpha variant item numbers are not shown on the
exploded view when the appearance and location of the
alpha variant item is the same as the basic item.
c. Items Not Illustrated
Items not illustrated are indicated by a dash C-) ahead of
the item number in the FIGURE & ITEM NUMBER column.
D. Assembly Order Indenture System
The Indenture System used in the parts list (NOMENCLATURE
column> shows the relationship of one part to another. For
a given item, the number of indentures depicts the
relationship of the item to the associated next higher
assembly as follows:
Page 1001
32-46-42 Apr 30/94
1234567
Assembly
.Detail Parts for Assembly
.Subassembly
.Attaching Parts for Subassembly
•• Detail Parts for Subassembly
••• Detail Installation Parts for Subassembly (Included only
if installation parts may be returned to shop as part of
the assembly.>
E. Parts Replacement Data
The interchangeability of the parts is described in the
NOMENCLATURE column by the following terms:
TERM ABBREVIATION DEFINITION
Alternate ALT This part will functionally replace
this item number noted, but has
different dimensions or mounting
provisions, and may require
additional parts.
Optional OPT This part is optional and inter-
changeable with other parts in
the same item number variant
group or other item number if
designated.
Superseded by SUPSD BY The part in the part number
column is replaced by and is not
interchangeable with the item
number shown in the notation.
Supersedes SUPSDS The part in the part number
column replaces and is not inter-
changeable with the item number
shown in the notation.
Replaced by REPLD BY The part in the part number
column is replaced by and inter-
Replaces REPLS The part in the part number
column replaces and is inter-
Vendor Contractor and Government
I V
Entity No. (CAGE No.)
Page 1002
32-46-42 Apr 30/94
C F. Service Bulletin Incorporation
Assemblies, sub-assemblies and detail parts subject to
modification, deletion, addition or replacement by an
issued service bulletin are annotated to show both pre- and
post-service bulletin configuration. The term CPRE SB
xxxx> in the Nomenclature column designates the original
configuration, and the term (POST SB XXXX) identifies
assemblies and parts after service bulletin modification
has been completed.
C1) Subassemblies and detail parts used on assemblies
bearing the pre- or post-Service Bulletin notation
will not carry the same notation if the EFF. CODE
column clearly shows their pre- or post-Service
Bulletin status.
C2> End-item assemblies that are modified by a Service
Bulletin without assignment of a new part number (no
production equivalent of the modified assembly) will
not show pre- or post-Service Bulletin notation.
<3> A subassembly or detail part is modified by a Service
Bulletin, without assignment of a new part number,
will have the original part number shown with an
alpha-variant item number and the term (POST SB
xxxx>. The effectivity code remains the same as for
the pre-Service Bulletin configuration.
G. Effectivity Code
Reference Letters CA,B,C,etc.> are assigned in the EFF.
CODE column to each end-item. The reference letter of the
applicable end item assembly is also shown for each detail
part and subassembly. If the EFF. CODE column is blank,
the detail or subassemblies can be used on all assemblies
in this manual.
H. Quantity Per Assembly
The UNITS PER ASSY column normally shows the total number
of parts required per assembly, subassembly, or
sub-subassembly as applicable.
The letters "AR" indicate "as required" (for bulk items).
The letters "RF" indicate the item is listed for reference
purposes.
The letters "NP" indicate the item is "not procurable"
(Order its next higher assembly).
Page 1003
32-46-42 Apr 30/94
C
The letters "SP" indicate the item is a "service part" that
is not part of the end-item assembly.
I. Vendor Codes
Contractor and Government Entity No.
(CAGE No.) Name and Address
01178 Lourdes Industries Inc.
65 Hoffman Avenue
Hauppauge, New York 11788 U.S.A.
01556 Emhart Fastening Systems Group
Heli-Coil Div.
510 River Road.
Shelton, Connecticut 06484 U.S.A.
09257 Busak and Shamban Inc.
Seal Division
2531 Bremer Drive
P.O. Box 176
Fort Wayne, Indiana 46801 U.S.A.
63477 Cooper Industries Inc.
Wagner Brake Division Inc.
3700 Forest Park Blvd.
ST. Louis, Missouri 63018 U.S.A.
79136 Waldes Truarc, Inc.
Division of Seeger Inc.
500 Memorial Drive
Somerset, New Jersey 08875-6723 U.S.A.
92555 The Lee Company
2 Pettipaug Rd.
P.O. Box 424
Westbrook, Connecticut 06498-1543 U.S.A.
99017 Protective Closures Co. Inc.
Caplugs Division
2150 Elmwood Avenue
Buffalo, New York 14207-1910 U.S.A.
WARNING: BF GOODRICH ASSUMES NO LIABILITY WHATSOEVER, WHETHER

CONTRACTUAL, WARRANTY, TORT OR OTHERWISE, FOR ANY FEDERAL
AVIATION ADMINISTRATION SANCTIONS, PRODUCT MALFUNCTIONS,
PROPERTY DAMAGE, PERSONAL INJURIES, OR SIMILAR INCIDENTS
OCCURRING AFTER ANY SUBSTITUTION OF ANY PARTS NOT APPROVED
BY BF GOODRICH, OR SUBSTITUTION OF ANY PARTS WITH
ALTERATIONS NOT AUTHORIZED BY BF GOODRICH MANUALS OR OTHER
WRITTEN PROCEDURES ISSUED BY BF GOODRICH.
r---
Page 1004
32-46-42 Apr 30/94
-
.....,, so 60~
ss53--p.--s
r
.,, 5 40~~--35
350 'f.R ~ 3 6 5
.... I q, -375
10
280~ 9()". ~80 45-._i -pji-20
.,
C
Cl) 29~ )35 60~~:r-=-25 i360_:::Ji~355

380315
3l
> n
.
...a
30~ 105 7~s..., § .... 0
Z3
m 305~.\ / 110 72- :/~-'cl.:::::-65 180 .... ~m
170 175 160 r CD
)C
90~1/1 ----p W 10 135 130 ,- .., z "Tl
~•
'O ,.. "'G')
,- C
en ~ Zo
0
a. 95, -· /325 ,'-J,..~65
,-.. 70 ..,-4 m -to
Cl)
a. -- --. >
-4
> :s 0
en >:
330 en..,. n
..
....
< 190 115~ .
m
0
.,,
"' -4
:s z :c
\\~~- ~·:r--\;~
C: m m>
..,> r zm
-< ,.. ..,
31: -4 "' Zo
....::,
a,
([) en
,-
....
.,, nen
~
m .,,
3
:,.n
>
I
m en
u) ., -4 N
I C:
zm
I\)
CD 1 ~ 2 ~ 2 ~ 230 10 15 ., ...a:,,,
'/If:'
VI r
.- I \ I 125 - -
Cl) N
200 215 225 210
l=.
CJ)
>
fl>
/
/320 185 140 145 155 165 310
00
fl>
315 L,
l=.
Cl)
51
C"
I\) ,-
33/JO~~~~
.
"<
260 255 250 270 265 245 275 240 235
> -0
'tJ m
., 10
Cl)
llll
0 ...a
,o
-00
"""'
C
FIGURE AIRLINE UNITS
& ITEM PART STOCK NOMENCLATURE EFF PER
NO. NUMBER NUMBER 1234567 CODE ASSY
1-1 2-1528-1 BRAKE-MULTIPLE DISK ••••••• A RF
1-1 A 2-1528-2 BRAKE-MULTIPLE DISK ••••••• B RF
1-1 B 2-1528-3 BRAKE-MULTIPLE DI SK • •••••• C RF
R 1-1c 2-1528-4 BRAKE-MULTIPLE DISK ••••••• D RF
R 1-1D 2-1528-5 BRAKE-MULTIPLE DI SK •• ••••• E RF
R 1-1 E 2-1528-6 BRAKE-MULTIPLE DI SK •• ••••• F RF
5 MS20995C32 .WIRE - LOCK •••••••••••••• AR
10 43-1343 • BOLT • •••••••••••••••••••• 6
15 MS20002C6 • WASHER - CSK ••••••••••••• 6
R 20 324-28 .CAP - PLUG CREPLD BY
ITEM 20A) ••••••• CV99017) 1
R 20A ASC4DN .THREADED CAP AND GASKET
CREPLS ITEM 20) •• CV99017) 1
25 274-212 .FITTING - UNION •••••••••• 1
30 68-404 .PACKING - PREFORMED •••••• 1
R 35 324-32 .CAP - PLUG CREPLD BY
ITEM 35A) •••••••• CV99017) 1
R 35A ASC6DN .THREADED CAP AND GASKET
(REPLS ITEM 35) CV99017) 1
40 274-211 .FITTING - UNION •••••••••• 1
R 48 F6446 .BLEEDER SCREW ••••• (63477) D,E,F 1
R 50 NAS1304-4H • BOLT • •••••••••••••••••••• A,B,C 2
R 53 NAS1304-15H • BOLT • •••••••••••••••••••• D,E,F 2
55 AN960-416 .WASHER - FLAT •••••••••••• 2
60 195-183 .SHUTTLE VALVE ASSEMBLY ••• 1
R 65 56-627 .RETAINER - PACKING ••••••• A,B,C 1
R 65A 56-627 .RETAINER - PACKING ••••••• D,E,F 2
R 70 68-1330 .PACKING - PREFORMED •••••• A,B,C 1
R 70A 68-1330 .PACKING - PREFORMED •••••• D,E,F 2
R 72 60-862 • SPACER ••••••••••••••••••• D,E,F 2
R 73 95-578 .ADAPTER •••••••••••••••••• D,E,F 1
75 379-18 .GASKET ••••••••••••••••••• 1
80 NAS1304-4H .BOLT .................... 2
85 AN960-416 .WASHER - FLAT •••••••••••• 2
- Items Not Illustrated.

* Do Not Remove Unless Damaged.
+ Total of 22 Wear Plates are Require to Overhaul Brake Assembly.
AR - As Required
r--
NP - Not Procurable (Order Next Higher Assembly).
Page 1006
32-46-42 Apr 30/94
(
FIGURE AIRLINE UNITS
& ITEM PART STOCK NOMENCLATURE EFF PER
NO. NUMBER NUMBER 1234567 CODE ASSY
90 95-567 .ADAPTER •••••••••••••••••• 1
95 379-18 .GASKET ••••••••••••••••••• 1
*100 50-491-23 .IDENTIFICATION PLATE ••••• A 1
*100A 50-622 .IDENTIFICATION PLATE ••••• B 1
*1008 50-491-30 .IDENTIFICATION PLATE ••••• C 1
R *100C 50-633 .IDENTIFICATION PLATE ••••• D 1
R *100D 50-635 .IDENTIFICATION PLATE ••••• E, F 1
105 56-627 .RETAINER - PACKING ••••••• 1
115 463-9 .ROD AND INSERT ASSEMBLY •• 2
120 534-2 • STUD ASSEMBLY •••••••••••• 2
125 309-32-1 .PRESSURE PLATE AND
WEAR PLATE ASSEMBLY ••••• 1
130 78-265 •• RIVET ••••••••••••••••••• 22
+135 93-919-1 •• PLATE - WEAR (REPLD BY
ITEM 135A) •••••••••••••• 11
+135A 93-919-2 •• PLATE - WEAR (REPLS
ITEM 135) •••••••••••••• 11
*140 3585-2CN0164 •• INSERT - HELICAL COIL
(V01556) •••••••••••••••• 2
145 93-921-1 •• PLATE - PRESSURE •••••••• NP
R 150 244-641-1 .CARRIER & LINING - ASSY
(COLOR-WHITE) ••••••••••• A,B,C 3
D,E
R 150A 244-641-4 .CARRIER & LINING - ASSY
(COLOR-WHITE) ••••••••••• F 3
R 155 133-893-1 .DISK-STATOR (COLOR-WHITE) A,B,C
D,E 2
R 155A 133-893-2 .DISK-STATOR.(COLOR-WHITE) F 2
160 4-322-1 .TORQUE PLATE ASSEMBLY •••• 1
*165 3591-6CN0375 •• INSERT - HELICAL COIL
••••••••••••••••• (V01556 6
170 78-265 •• RIVET ••••••••••••••••••• 22
+175 93-919-1 •• PLATE - WEAR (REPLD BY
ITEM 175A) •••••••••••••• 11

( + Total of 22 Wear Plates are Require to Overhaul Brake Assembly.
AR - As Required
Page 1007
I 32-46-42 Apr 30/94
FIGURE AIRLINE EFF UNITS

& ITEM PART STOCK NOMENCLATURE CODE PER
NO. NUMBER NUMBER 1234567 ASSY.
+175A 93-919-2 ..PLATE - WEAR (REPLS
ITEM 175) •••••••••••••• 11
180 184~852-1 •• TORQUE PLATE •••••••••••• NP
185 5100-75 .RING - RETAINING (V79136) 4
190 107-372 • ADJUSTER ASSEMBLY •••••••• A 4
R 190A 107-372-1 .ADJUSTER ASSEMBLY •••••••• B,C,D 4
E, F
195 MS21042L04 •• NUT - SELF-LOCKING •••••• 1
200 130-24 •• BALL •••••••••••••••••••• 1
205 45-226 •• TUBE - ADJUSTER ••••••••• 1
210 20-616 •• PIN - ADJUSTER •••••••••• 1
215 N5000-75 •• RING - RETAINING(V79136) 1
220 56-883 •• RETAINER - TUBE ••••••••• 1
225 40-654 •• SPRING - HELICAL •••••••• A 1
R 225A 40-672 •• SPRING - HELICAL •••••••• B,C,D 1
E,F
230 260-844 •• HOUSING - ADJUSTER •••••• 1
R 235 115-325 .INSULATOR (REPLD BY ITEM
235A) ••.••...•.••••••••• 5
R 235A 115-325-1 .INSULATOR (REPLS ITEM
235 >•••••••••••••••••••• 5
240 60-819 • SPACER ••••••••••••••••••• 5
245 54-457 • SLEEVE ••••••••••••••••••• 5
250 74-850 .PISTON ••••••••••••••••••• 5
255 S12587-222 • PACKING - BACKUP (V09257) 5
260 68-1328 .PACKING - PREFORMED ••••••
265 MS28774-225 .RETAINER - PACKING BACKUP 5
(SUPSD BY ITEM 265A) ••••
265A 68-1389 • RETAINER - PACKING BACKUP 5
(SUPSDS ITEM 265) ••••••
265B MS27595-225 .RETAINER - PACKING BACKUP 5
(OPT TO ITEM 265A) ••••• 5
275 S11065-17-1 .SCRAPER RING •••• (V09257) 1
280 155-11 .BLEEDER SCREW ASSEMBLY ••• 1
285 MS51958-60 •• SCREW MACHINE .......... 1
+ Total of 22 Wear Plates are Require to Overhaul Brake Assembly. (
AR - As Required '
Page 1008
32-46-42 Apr 30/94
(
FIGURE AIRLINE EFF UNITS
& ITEM PART STOCK NOMENCLATURE CODE PER
NO. NUMBER NUMBER 1234567 ASSY.
290 MS35338-100 • • WASHER •••••••••••••••••• 1
295 84-28 •• VALVE - BLEEDER ••••••••• 1
300 274-36 .FITTING - BLEEDER •••••••• 1
305 68-404 .PACKING - PREFORMED ..... 1
310 60-824 • SPACER ••••••••••••••••••• 1
315 266-235-1 • PISTON HOUSING ASSY •••••• 4
320 PLGA2180010 •• LEE PLUG ••••••• CV92555)
325 3591-4CN0250 •• INSERT - HELICAL COIL 4
••••••••••••••• CV01556)
330 3591-3CN0380 •• INSERT - HELICAL COIL
•••••••••••••• • CV01556) 2
335 260-842-1 •• HOUSING - PISTON ....... NP
R -340 380-90 PARTS KIT (To Convert
The 2-1528-1 To The
2-1528-2) •••••••••••••••• AR
R -345 380-110 OVERHAUL KIT - SHUTTLE
VALVE •••••••••••••••••••• AR
R 350 80375-1 .BODY - SHUTTLE VALVE
•••••••••••••••• CV01178) NP
R 355 80387-1 .CAP - END •••••••• CV01178) NP
R 360 80306-1 .POPPET ASSEMBLY •• CV01178) 1
R 365 NAS1611-014 .PACKING - PREFORMED •••••• 1
R 370 NAS1612-8 .PACKING - PREFORMED •••••• 1
R 375 T4-6 • BALL • •••••••••••••••••••• 2
R 380 80373 .SPRING •••••••••• CV01178) 1

+ Total of 22 Wear Plates are Require to Overhaul Brake Assembly.
AR - As Required
Page 1009
32-46-42 Apr 30/94

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l

Keep this record in front of the manual. On receipt of revision,

REV. REV. DATE REV. REV. DATE

32-46-42 Page RR-1

32-1 701, 801 Jan 29/90 Apr 26/91

32-46-42 Page TR-1

SERVICE SERVICE DATE OF

32-46-42 Page TC-2

• A "WARNING" statement is given to prevent personal injury.

WARNING: THE USE OF REPLACEMENT PARTS THAT ARE NOT AUTHORIZED BY

I the indicator rod protrudes from the piston housing

SHUTTLE VALVE ASSY. (60)

BOLT (50> BLEEDER SCREW ASSY (280)

CARRIER & LINING

Figure 1. Description of Main Brake Assembly

I WARNING: PUT A PROTECTIVE SHIELD AROUND THE BRAKE ASSEMBLY WHEN

I NOTE: Malfunctioning shuttle valves (60) can be overhauled or

FAULT PROBABLE CAUSE CORRECTION

Worn preformed packing

NUT (195) RING RETAINER

ADJUSTER TUBE\ HELICAL SPRING

BALL (200) ADJUSTER HOUSING

TUBE RETAINER (220)

Figure 302. Exploded View of Adjuster Assembly

ARBOR PRESS RETAINER RING (215)

3/8 (9 mm) O.D. PLUG

Figure 303. Adjuster Disassembly Procedure

Figure 304. Shuttle Valve Disassembly

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I USUAL HEAT CHECKING 0.070

INITIAL WEAR PLATE

Figure 501. Wear Plate Examination

PITTING -.I ~0.275

Figure 502. Carrier and Lining Assembly Examination

ITEM NO. PART NUMBER DIMENSION A II II

DIMENSION C 11 11 INSPECTION SCHEDULE

not have to be removed unless greater than 0.255 inch

Figure 504. Disk Examination

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Figure 507. Adjuster Housing Examination

I a dry adjuster pin (210) as far as possible by hand. If

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DIAL INDICATOR MOUNTED

WARNING: A SPRING THAT IS NOT PUT IN THE CORRECT POSITION CAN BE

BRAKE PART SPRING PART SPRING HEIGHT SPRING LOAD LIMIT

Figure 508. Spring Load Check

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Figure 509. Examination of Shuttle Valve End Cap

I CHECK FOR MINIMUM

Figure 509. Piston Housing Examination

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SPACER BRAKE PART

CLAMP PARTS IN FIXTURE AND PLACE IN FURNACE

Repair nicks, gouges, grooves and scratches by hand filing or

AREA SERVICE REPAIR

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Figure 604. Piston Housing - Removal of Lee Plugs

(5) Second Rework: