Export Classification: C, ECCN 9E991

NORTHWEST DYNAMICS, INC.

DOCUMENT NO. B0249-OM

MAINTENANCE AND OVERHAUL MANUAL

WITH

ILLUSTRATED PARTS BREAKDOWN

FOR

ROTOR BRAKE ASSEMBLY

BELL HELICOPTER
MODEL 505 HELICOPTER

BHT: 206-340-301-101 (BRAKE DISC / NDI: D0143-1)

NDI: B0249-4 (CALIPER ASSEMBLY)
NDI: B0252-2 (MASTER CYLINDER)

REVISED ISSUE: 24 OCTOBER 2017

TECHNICAL PUBLICATION DEPARTMENT

REVISION: ORIGINAL
DATE: 18 APRIL, 2017

NORTHWEST DYNAMICS, INC.

6709 NE 131 AVENUE
VANCOUVER, WA 98682

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USA

REVISIONS
REV DESCRIPTION DATE APPROVAL
ORIGINAL Initial Release 18 APRIL 2017 S. KUNKLER
A Added B0252-2 configuration. 24 OCT 2017 S. KUNKLER

DESTINATION CONTROL STATEMENT

WARNING: This document contains technical data whose export is restricted by the Arms Export Control
Act (Title 22, U.S.C., Sec 2751, et. Seq.) or the Export Administration Act of 1979, as amended, Title 50,
U.S.C., App. 2401 et. Seq. Violations of these export laws are subject to severe criminal penalties.
Disseminate in accordance with provisions of DoD Directive 5230.25.

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TABLE OF CONTENTS
SECTION DESCRIPTION PAGE
1.0 SCHEDULED MAINTENANCE PROCEDURE 1-2
1.1 SCHEDULED MAINTENANCE 1-2
1.1.1 TOOLS 1-2
1.2 600 HOUR VISUAL AND FUNCTIONAL CHECK (Caliper) 1-2
1.3 1,200 HOUR INSPECTION (Rotor Brake Assembly) 1-3
1.3.1 1,200 HOUR INSPECTION (Caliper) 1-3
1.3.2 1,200 HOUR INSPECTION (Master Cylinder) 1-3
1.3.3 1,200 HOUR INSPECTION (Disc) 1-4
1.4 1,800 HOUR SCHEDULED MAINTENANCE (Caliper) 1-5
1.5 2,400 HOUR INSPECTION (Rotor Brake Assembly) 1-5
1.6 3,000 HOUR SCHEDULED MAINTENANCE (Rotor Brake Assembly) 1-5
1.7 MAINTENANCE INTERVALS 1-6
2.0 INSPECTION AND REPAIR 2-2
2.1 TOOLS 2-2
2.2 CALIPER INSPECTION AND REPAIR 2-2
2.2.1 EXTERNAL INSPECTION AND REPAIR (Caliper) 2-2
2.2.2 FRICTION PAD INSPECTION 2-3
2.2.3 CALIPER DAMAGE TOLERANCE 2-4
2.2.4 SWITCH ASSSEMBLY REPAIRS (Caliper) 2-5
2.2.5 FUNCTIONAL TEST (Caliper) 2-5
2.2.6 CALIPER PACKAGING AND PRESERVATION 2-7
2.3 MASTER CYLINDER INSPECTION AND REPAIR 2-8
2.3.1 EXTERNAL INSPECTION AND REPAIR (Master Cylinder) 2-8
2.3.2 MASTER CYLINDER DAMAGE TOLERANCE 2-8
2.3.3 FUNCTIONAL TEST (Master Cylinder) 2-9
2.3.4 MASTER CYLINDER PACKAGING AND PRESERVATION 2-11
2.4 DISC INSPECTION AND REPAIR 2-11
2.4.1 BRAKE DISC THICKNESS (Disc) 2-12
2.4.2 BRAKE SURFACE ROUGHNESS (Disc) 2-12
2.4.3 BRAKE SURFACE RUNOUT (Disc) 2-12
2.4.4 VISUAL INSPECTION (Disc) 2-13
2.4.5 DYNAMIC BALANCE (Disc) 2-13
2.4.6 DISC DAMAGE TOLERANCE (IN-SERVICE) 2-13
2.4.7 DISC PACKAGING AND PRESERVATION 2-14
3.0 OVERHAUL PROCEDURE 3-2
3.1 TOOLS 3-2
3.2 CALIPER ASSEMBLY 3-2
3.2.1 DISASSEMBLY PROCEDURE (Caliper) 3-3
3.2.2 CALIPER INSPECTION 3-5
3.2.3 ASSEMBLY PROCEDURE 3-6
3.2.4 PAINT 3-6
3.2.5 FUNCTIONAL TEST 3-7
3.2.6 CALIPER PACKAGNING AND PRESERVATION 3-7
3.3 MASTER CYLINDER 3-8
3.3.1 DISASSEMBLY PROCEDURE (Master Cylinder) 3-8
3.3.2 MASTER CYLINDER INSPECTION 3-11
3.3.3 ASSEMBLY PROCEDURE 3-11
3.3.4 PAINT 3-12
3.3.5 FUNCTIONAL TEST 3-13
3.3.6 MASTER CYLINDER PACKAGING AND PRESERVATION 3-13
3.4 DISC OVERHAUL 3-13

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SECTION 1
SCHEDULED MAINTENANCE PROCEDURE
FOR
ROTOR BRAKE ASSEMBLY
MODEL 505

CALIPER ASSEMBLY MASTER CYLINDER ASSEMBLY BRAKE DISC

NDI: BO249-4 NDI: B0252-2 BHT: 206-340-301-101 (NDI: D0143-1)

TABLE OF CONTENTS
1.0 INSPECTION AND REPAIR
1.1 SCHEDULED MAINTENANCE
1.1.1 TOOLS
1.2 600 HOUR VISUAL AND FUNCTIONAL INSPECTION (Caliper)
1.3 1,200 HOUR INSPECTION (Rotor Brake Assembly)
1.3.1 1,200 HOUR INSPECTION (Caliper)
1.3.2 1,200 HOUR INSPECTION (Master Cylinder)
1.3.3 1,200 HOUR INSPECTION (Disc)
1.4 1,800 HOUR SCHEDULED MAINTENANCE (Caliper)
1.5 2,400 HOUR INSPECTION (Rotor Brake)
1.6 3,000 HOUR SCHEDULED MAINTENANCE (Rotor Brake)
1.7 MAINTENANCE INTERVALS (Rotor Brake)

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1.0 SCHEDULED MAINTENANCE PROCEDURE

GENERAL: Each rotor brake assembly consists of two calipers, one master cylinder
and one disc (2 calipers, 1 master cylinder, 1 disc). The disc is connected to the
helicopter drive system and rotates in conjunction with the main and tail rotors. The
calipers are mounted stationary on the helicopter freewheeling unit and straddle the
brake disc. The master cylinder is fastened to a truss in the aft body area of the aircraft
and attached via a cable to the rotor brake lever located in the aircraft cockpit.
To decelerate the helicopter rotor, the master cylinder is actuated by the rotor brake
lever to supply 110 psig hydraulic pressure to the stationary calipers. When
pressurized, the calipers clamp the rotating disc, which induces braking. Each caliper
has two opposing friction pad assemblies. These opposing friction pads actuate when
the caliper is pressurized and clamp the disc. When pressure is released, the friction
pads retract back to their original position.
When the rotor brake is engaged (brake-on), the cockpit rotor brake indicator light will
illuminate thus indicating that one or more of the caliper friction pads is not in the brake-
off position.

1.1 SCHEDULED MAINTENANCE

GENERAL: Scheduled Maintenance shall be performed on a regular basis to assure
the rotor brake assembly is retained in a functional condition. The rotor brake assembly
requires the following Scheduled Maintenance:

1.1.1 TOOLS
GENERAL: As a minimum, the following tools are required to perform Scheduled
Maintenance. All inspection equipment shall be calibrated in accordance with ISO
17025 or equivalent.
Tools
- Standard Mechanics Tools
- 220 Grit Sandpaper (optional: 400 Grit)
- Lockwire Pliers

Inspection
- 0-6 inch Dial Caliper
- 0-1 inch Micrometer
- Dial Indicator and Magnetic Base
- Micro-Finish Roughness Comparator or equivalent

1.2 600 HOUR VISUAL AND FUNCTIONAL CHECK (Caliper)

GENERAL: Inspect to assure all fittings, fasteners and lockwire are intact and that the
caliper assemblies are leak free. Verify that the cockpit brake-on indication light
properly illuminates upon brake activation.
PROCEDURE: Operate and visually inspect rotor brake assembly.
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CORRECTIVE ACTION: Clean and remove any residual fluid which is present in areas
of the caliper bleed valves or fittings. If cockpit brake-on indication light fails to
illuminate upon brake activation or fails to turn off upon brake deactivation, refer to
Section 2.0, Inspection and Repair.

CAUTION

DO NOT USE ISOPROPYL ALCOHOL AS IT MAY CAUSE THE

FORMATION OF RESINOUS PRECIPITATE AND DEPOSIT OF
GUMMY RESIDUES ON MOVING PARTS. USE PD-680
(STODDARD SOLVENT), TRICHLOROTHENE OR ALIPHATIC
NAPHTA.

1.3 1,200 HOUR INSPECTION (Rotor Brake Assembly)

The rotor brake assembly shall be inspected after 1,200 hours of helicopter service life.
The assembly shall meet all inspection and maintenance criteria as specified. Any unit
that fails to meet criteria shall be subjected to Inspection and Repair procedures per
Section 2.0.

1.3.1 1,200 HOUR INSPECTION (Caliper)

GENERAL: Inspect to assure all fittings, fasteners and lockwire are intact and that the
caliper assemblies are leak free. Inspect the friction pad assembly to verify adequate
liner thickness (refer to Section 2.0, Figure 2-2). Verify that the cockpit brake-on
indication light properly illuminates upon brake activation.
PROCEDURE: Operate and visually inspect rotor brake assembly common with drive
system inspections. Measure the friction pad to ensure liner thickness is greater than
.100 inch (refer to Figure 2-2).
CORRECTIVE ACTION: Clean and remove any residual fluid which is present in areas
of the caliper bleed valves or fittings. If cockpit brake-on indication light fails to
illuminate upon brake activation or fails to turn off upon brake deactivation, refer to
Section 2.0, Inspection and Repair. If friction pad thickness does not meet .100 inch
minimum thickness refer to Section 2.0, Inspection and Repair.

CAUTION

DO NOT USE ISOPROPYL ALCOHOL AS IT MAY CAUSE THE

FORMATION OF RESINOUS PRECIPITATE AND DEPOSIT OF
GUMMY RESIDUES ON MOVING PARTS. USE PD-680
(STODDARD SOLVENT), TRICHLOROTHENE OR ALIPHATIC
NAPHTA.

1.3.2 1,200 HOUR INSPECTION (Master Cylinder)

GENERAL: Inspect to assure all fittings, fasteners and lockwire are intact and that the
master cylinder is leak free. Verify that the caliper assembly friction pads clamp disc
when the master cylinder is extended (rotor brake lever moved to brake-on position)
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and caliper friction pads disengage disc when the master cylinder piston is retracted
(rotor brake lever returned to brake-off position).
PROCEDURE: Operate and visually inspect rotor brake assembly.
CORRECTIVE ACTION: Clean and remove any residual fluid which is present in areas
of the master cylinder piston rod and fittings. If caliper friction pad assemblies fail to
clamp disc when master cylinder is actuated, refer to Section 2.0, Inspection and
Repair.

CAUTION

DO NOT USE ISOPROPYL ALCOHOL AS IT MAY CAUSE THE

FORMATION OF RESINOUS PRECIPITATE AND DEPOSIT OF
GUMMY RESIDUES ON MOVING PARTS. USE PD-680
(STODDARD SOLVENT), TRICHLOROTHENE OR ALIPHATIC
NAPHTA.

1.3.3 1,200 HOUR INSPECTION (Disc)

GENERAL: Monitor disc wear, surface finish and runout specifications. See illustration
below (FIGURE 1-1).
Parameter
Minimum Thickness: 0.290 inch (7.366 mm)
Maximum Brake Surface Runout: 0.004 inch (.102 mm)
Maximum Brake Surface Roughness: 125 RMS

PROCEDURE: Verify the specification parameters.

FIGURE 1-1

A Measure disc thickness using calibrated micrometer. Disc thickness shall be

within specification limits.

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B Slowly rotate the disc pilot shaft and measure the brake surface runout using a
calibrated dial indicator. Total indicated runout shall not exceed .004 inch
maximum.
C Measure the brake surface roughness using a micro-finish comparator (or
equivalent). Surface roughness shall not exceed 125 RMS.
CORRECTIVE ACTION: Out of tolerance conditions of disc thickness and surface
runout cannot be remedied without removal from aircraft. If surface roughness is locally
out of tolerance, it is permissible to smooth using 220 Grit (optional: 400 Grit)
sandpaper. The disc shall meet all specification and dimensional parameters
(paragraph 1.3.3) after surface finish repair.
For other Corrective Action, remove the unit from the aircraft and refer to Section 2,
Paragraph 2.4 Inspection and Repair.

1.4 1,800 HOUR SCHEDULED MAINTENANCE (Caliper)

GENERAL:
Calipers – overhaul calipers in accordance with Paragraph 3.2.

PROCEDURE: Remove the brake calipers from the aircraft and refer to Section 3,
Paragraphs 3.2 for overhaul procedure.

1.5 2,400 HOUR INSPECTION (Rotor Brake Assembly)

GENERAL:
Calipers – inspect calipers in accordance with Paragraph 1.3.1.
Master Cylinder – inspect master cylinder in accordance with Paragraph 1.3.2.
Disc – inspect Disc in accordance with Paragraph 1.3.3.

1.6 3,000 HOUR SCHEDULED MAINTENANCE (Rotor Brake Assembly)

GENERAL:
Calipers – inspect calipers in accordance with Paragraph 1.3.1.
Master Cylinder – overhaul master cylinder in accordance with Paragraph 3.3.
Disc – inspect Disc in accordance with Paragraph 1.3.3.
PROCEDURE: Remove the master cylinder from the aircraft and refer to Section 3,
Paragraphs 3.3 for overhaul procedure. Inspect Calipers per Paragraph 1.3.1. Inspect
Disc per Paragraph 1.3.3.

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1.7 MAINTENANCE INTERVALS (Rotor Brake Assembly)

GENERAL: The rotor brake assembly shall be subjected to maintenance intervals in

accordance with the following Procedure.

PROCEDURE:
STEP SERVICE MAINTENANCE TASK HARDWARE SPECIFIC MANUAL
HOURS DESCRIPTION TASK PARA.
A 600 VISUAL AND FUNCTIONAL CHECK CALIPER INSPECT 1.2
B 1,200 INSPECTION CALIPER INSPECT 1.3.1
MASTER CYL. INSPECT 1.3.2
DISC INSPECT 1.3.3
C 1,800 SCHEDULED MAINTENANCE CALIPER OVERHAUL 3.2
D 2,400 INSPECTION CALIPER INSPECT 1.3.1
MASTER CYL. INSPECT 1.3.2
DISC INSPECT 1.3.3
E 3,000 SCHEDULED MAINTENANCE CALIPER INSPECT 1.3.1
MASTER CYL. OVERHAUL 3.3
DISC INSPECT 1.3.3
F 3,600 SCHEDULED MAINTENANCE CALIPER OVERHAUL 3.2
G 4,200 INSPECTION CALIPER INSPECT 1.3.1
MASTER CYL. INSPECT 1.3.2
DISC INSPECT 1.3.3
H 4,800 INSPECTION CALIPER INSPECT 1.3.1
MASTER CYL. INSPECT 1.3.2
DISC INSPECT 1.3.3
I 5,400 SCHEDULED MAINTENANCE CALIPER OVERHAUL 3.2
J 6,000 SCHEDULED MAINTENANCE CALIPER INSPECT 1.3.1
MASTER CYL. OVERHAUL 3.3
DISC INSPECT 1.3.3
K 6,600 INSPECTIION CALIPER INSPECT 1.3.1
MASTER CYL. INSPECT 1.3.2
DISC INSPECT 1.3.3
L 7,200 SCHEDULED MAINTENANCE CALIPER OVERHAUL 3.2
M 7,800 INSPECTION CALIPER INSPECT 1.3.1
MASTER CYL. INSPECT 1.3.2
DISC INSPECT 1.3.3
N 8,400 INSPECTION CALIPER INSPECT 1.3.1
MASTER CYL. INSPECT 1.3.2
DISC INSPECT 1.3.3
O 9,000 SCHEDULED MAINTENANCE CALIPER OVERHAUL 3.2
MASTER CYL. OVERHAUL 3.3
DISC INSPECT 1.3.3
P 9,600 VISUAL AND FUNCTIONAL CHECK CALIPER INSPECT 1.2
Q 10,200 INSPECTION CALIPER INSPECT 1.3.1
MASTER CYL. INSPECT 1.3.2
DISC INSPECT 1.3.3
R 10,800 SCHEDULED MAINTENANCE CALIPER OVERHAUL 3.2
S 11,400 INSPECTION CALIPER INSPECT 1.3.1
MASTER CYL. INSPECT 1.3.2
DISC INSPECT 1.3.3
T 12,000 SCHEDULED MAINTENANCE CALIPER OVERHAUL 3.2
MASTER CYL. OVERHAUL 3.3
DISC OVERHAUL 3.4
U REPEAT STEPS A THROUGH T UNTIL HARDWARE IS REMOVED FROM SERVICE.

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SECTION 2
INSPECTION AND REPAIR PROCEDURE
FOR
ROTOR BRAKE ASSEMBLY
MODEL 505
CALIPER ASSEMBLY MASTER CYLINDER ASSEMBLY BRAKE DISC
NDI: BO249-4 NDI: B0252-2 BHT: 206-340-301-101 (NDI: D0143-1)

TABLE OF CONTENTS
2.0 INSPECTION AND REPAIR
2.0 TOOLS
2.1 CALIPER INSPECTION AND REPAIR
2.2.1 EXTERNAL INSPECTION AND REPAIR (Caliper)
2.2.2 FRICTION PAD INSPECTION
2.2.3 CALIPER DAMAGE TOLERANCE
2.2.3.1 HOUSING DAMAGE TOLERANCE
2.2.4 SWITCH ASSEMBLY REPAIRS (Calipers)
2.2.5 FUNCTIONAL TEST (Caliper)
2.2.5.1 HYDRAULIC – SET UP
2.2.5.2 PROOF PRESSURE (Caliper)
2.2.5.3 FUNCTIONAL OPERATION (Caliper)
2.2.5.4 ELECTRICAL INDICATION TEST (Caliper)
2.2.6 CALIPER PACKAGING AND PRESERVATION
2.2.6.1 SHORT TERM
2.2.6.2 LONG TERM
2.3 MASTER CYLINDER INSPECTION AND REPAIR
2.3.1 EXTERNAL INSPECTION AND REPAIR (Master Cylinder)
2.3.2 MASTER CYLINDER DAMAGE TOLERANCE
2.3.2.1 CYLINDER DAMAGE TOLERANCE (Master Cylinder)
2.3.2.2 AFT BRACKET DAMAGE TOLERANCE (Master Cylinder)
2.3.3 FUNCTIONAL TEST (Master Cylinder)
2.3.3.1 HYDRAULIC SET UP
2.3.3.2 PROOF PRESSURE (Master Cylinder)
2.3.3.3 FUNCTIONAL OPERATION (Master Cylinder)
2.3.4 MASTER CYLINDER PACKAGING AND PRESERVATION
2.3.4.1 SHORT TERM
2.3.4.2 LONG TERM
2.4 DISC INSPECTION AND REPAIR
2.4.1 BRAKE DISC THICKNESS (Disc)
2.4.2 BRAKING SURFACE ROUGHNESS (Disc)
2.4.3 BRAKING SURFACE RUNOUT (Disc)
2.4.4 VISUAL INSPECTION (Disc)
2.4.5 DYNAMIC BALANCE
2.4.6 DISC DAMAGE TOLERANCE (In Service)
2.4.7 DISC PACKAGING AND PRESERVATION

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2.0 INSPECTION AND REPAIR

GENERAL: Rotor brake assemblies (Caliper, Master Cylinder and Disc) that fail to meet
acceptance criteria of Section 1 (Scheduled Maintenance) shall be removed from the
aircraft and subjected to the following inspection and repair procedure:

2.1 TOOLS
GENERAL: As a minimum, the following tools are required to perform the Inspection
and Repair procedures. All inspection equipment shall be calibrated in accordance with
ISO 17025 or equivalent.

Tools
- Standard Mechanics Tools
- Lockwire Pliers
- 220 Grit Sandpaper (optional: 400 Grit)
- Hydraulic Power Supplier (280 psi min.) MIL-PRF-87257 Hydraulic Oil
- Pressure Gauge (280 psi min.)
- Pressure Gauge (60 psi max.)
- Block-Switch Test: See Figure 2-8
- Block-Operational See Figure 2-9 or equivalent
- Misc. Hydraulic Fittings, Etc.: See Figure 2-3 and 2-5
- Balancing Arbor: See Figure 2-7

Inspection Tools
- 0-6 inch Dial Caliper
- Torque Wrench (300 in-lb max.)
- 0-1 inch Micrometer
- Surface Plate (12in. x 18in. min.)
- Dial Indicator with Base
- Dynamic Balancing Test Apparatus (ISO 17025) or equivalent
- Micro-Finish Roughness Comparator or equivalent
- Multi-Meter, Continuity Tester or equivalent

2.2 CALIPER INSPECTION AND REPAIR

GENERAL: All Calipers shall be subjected to the following Inspection and Repair
procedure prior to being returned to service. If a Caliper fails to meet requirements of
Section 2.0, refer to Section 3.0 for Overhaul Procedures.

2.2.1 EXTERNAL INSPECTION AND REPAIR (Caliper)

PROCEDURE: The external components of the caliper assembly shall be visually
inspected to assure all items are intact and in conformance with the Figure 2-1. All
cotter pins shall be in place and lockwire intact. There shall be no evidence of
corrosion or mechanical damage.
CORRECTIVE ACTION: Replace or install any missing or damaged external
components. See Section 3.0 for part numbers and installation torque of replacement
parts. If the caliper housing exhibits scratches, nicks or evidence of corrosion, refer to
paragraph 2.2.3 for repair procedure.

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FIGURE 2-1
REFER TO TABLE 3-1 FOR PART NUMBERS

2.2.2 FRICTION PAD INSPECTION

PROCEDURE: Inspect friction pad thickness to monitor allowable pad wear. See
Figure 2-2 below. It is recommended that the friction pads be replaced if the exposed
friction pad of either caliper pad is less than .100 inch (2.54 mm) beyond friction pad
assembly wear indicator. Fully worn pads will exhibit .080 inch (2.03 mm) of pad
exposure.
CORRECTIVE ACTION: Replace friction pad assemblies if friction pads have worn
beyond their allowable limit. See Section 3, Paragraph 3.2, Sub-Paragraph 3.2.1 for
disassembly procedure to replace friction pad assemblies (Paragraph 3.2.1 Steps D –
G and F.) Reverse steps to reassemble with new friction pad assemblies.

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FIGURE 2-2

2.2.3 CALIPER DAMAGE TOLERANCE

GENERAL: A caliper assembly may become slightly damaged as the result of minor
mishaps that occur during maintenance, operation or handling. The following criteria
shall be used to evaluate and repair mishap damage.
2.2.3.1 HOUSING DAMAGE TOLERANCE
PROCEDURE: Visually inspect the caliper housings to detect damaged surfaces as
evident by deformations or material/paint anomalies. See Figure 2-1.
- No material nicks or imperfections are permitted in the sealing area of the hydraulic
port (Inspect Item 5).
- There shall be no material imperfections in the area of the caliper mounting surface.
The caliper mounting pads shall be clean and flat (Inspect Item 5).
- Minor nicks and imperfections on the remaining external housing surfaces can be
repaired if less than .025 inch (.635 mm) in depth. (Inspect Items 2 and 5).
CORRECTIVE ACTION: Replace caliper housing if damage is not repairable. Painted
surfaces within damage tolerance can be repaired by lightly sanding by hand* the
imperfection (400 grit, optional 220 grit sandpaper) to remove any corrosion. Following
surface preparation, apply a dab of primer paint (MIL-PRF-23377 or similar) and after
adequate drying time, dab with top coat (MIL-PRF-85285 or similar) to seal the
imperfection.

*NOTE
Use of powered tools is prohibited.

Non-painted surfaces within damage tolerance can be repaired by lightly sanding* the
imperfection using 400 grit (optional: 200 grit) sandpaper to smooth the material. The
surface finish shall be 63 RMS maximum following smoothing. Apply Chemical

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Conversion treatment per MIL-C-5541, Alodine treatment, or equivalent to the damaged

surface.

2.2.4 SWITCH ASSEMBLY REPAIRS (Caliper)

GENERAL: If an electrical indication malfunction is suspected, subject the caliper to
Switch Indication Test in accordance with paragraph 2.2.5.4.

2.2.5 FUNCTIONAL TEST (Caliper)

GENERAL: caliper assembly shall be subjected to and successfully pass the following
Functional Test requirements.
CORRECTIVE ACTION: Any unit that fail to conform to all test requirements shall be
subjected to Overhaul in accordance with Section 3.0 of this manual.
2.2.5.1 HYDRAULIC SET UP (Caliper)
PROCEDURE: Configure the caliper assembly in accordance with the hydraulic
schematic per Figure 2-3. Thoroughly bleed hydraulic set up including pressure
gauges. Loosen the caliper bleed valves and slowly apply flow (20 psi) to completely
purge the system of entrapped air. Once the air has been removed, tighten the bleed
valves to 50 in-lb ± 5 in-lb and reduce pressure.

FIGURE 2-3

2.2.5.2 PROOF PRESSURE (Caliper)

SET UP: Position a rotor brake disc, spacer block (See Figure 2-9) or equivalent,
between the two friction linings of the caliper assembly. This simulates rotor brake
installation.

NOTE
Close low pressure gauge valve before
applying pressure to Caliper Assembly.

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PROCEDURE:
A. Slowly apply 280 +20/-0 psi hydraulic pressure using MIL-PRF-87257 hydraulic fluid
to caliper inlet port and hold for a period of 2 minutes. As pressure is applied, the
friction pads, Figure 2-2, shall actuate smoothly and clamp the brake disc or
equivalent spacer block.
B. Following the 2 minute hold, reduce pressure.
ACCEPTANCE: Caliper actuation shall be smooth and continuous. There shall be no
evidence of external leakage, loosening of fasteners, deformation or any abnormalities.
2.2.5.3 FUNCTIONAL OPERATION (Caliper)
SET UP: Remove the rotor brake disc or spacer block to allow the caliper friction pads
to actuate to their maximum stroke.

NOTE
Close low pressure gauge valve before
applying pressure to Caliper Assembly.

PROCEDURE:
A. Slowly apply 110 ± 10 psi hydraulic pressure using MIL-PRF-87257 hydraulic fluid
to caliper inlet port. Observe the motion of the friction pads. Actuation shall be
smooth and continuous.
B. Slowly release hydraulic pressure until within the range of low pressure gauge.
Open low pressure gauge valve when in its range. Lower hydraulic pressure to 5
psi minimum and both friction pads shall fully retract.
ACCEPTANCE:
A. Friction lining motion shall be smooth and continuous.
B. There shall be no evidence of external leakage, loosening of any fasteners or
deformation.
2.2.5.4 ELECTRICAL INDICATION TEST (Caliper)
SET UP: Install spacer block (see Figure 2-8) between the two caliper halves to
precisely position the clamping surface between the two friction pads.
Using a multi-meter, continuity tester or equivalent, measure the continuity between
connector pins 1 and 2 (see connector Schematic Figure 2-10) of the two connectors.

NOTE
Close low pressure gauge valve before
applying pressure to Caliper Assembly.

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PROCEDURE:
A. The continuity between connector pins 1 and 2 shall exhibit a closed circuit (less
than 2 ohm).
B. Apply 110 ± 10 psi hydraulic pressure using MIL-PRF-87257 hydraulic fluid to the
caliper inlet port. Upon application of hydraulic pressure, the continuity between
connector pins 1 and 2 shall exhibit an open circuit (infinite resistance).
C. Reduce the hydraulic pressure to 5 psi minimum, (open valve to low pressure
gauge when in range) and verify that the continuity between connector pins 1 and 2
exhibits a closed circuit (less than 2 ohms).
D. Repeat procedure A-C on opposite caliper connector.
ACCEPTANCE:
A. Continuity conditions shall be in accordance with steps A-C for both caliper
connectors.
CORRECTIVE ACTION:
If caliper switches do not meet requirements, refer to section 3.0, paragraph 3.2.3.2-D
through 3.2.3.2-L for installation and adjustment procedure. Note: new lock washers
(21) are required to perform this procedure.

NOTE
If caliper switches do not meet
requirement following adjustment, they
should be replaced.

2.2.6 CALIPER PACKAGING AND PRESERVATION

PROCEDURE: Drain the assembly of excess oil. Install protective plug (NAS 815-4)
and gasket (M83461/2-904) or equivalent in the caliper inlet port. Install dust covers or
similar over the caliper switch receptacles. Package to prevent handling damage.
2.2.6.1 SHORT TERM
PROCEDURE: Wipe the caliper assembly to remove any residual fluids. Box or
package the caliper to prevent damage. As a minimum, caliper packaging shall be
identified as follows:
A. “Inspection and Repair; Accepted”
B. “Name of Repair Facility”
C. “Year-Month-Day”
2.2.6.2 LONG TERM
PROCEDURE: Package and identify the caliper assembly in accordance with
paragraph 2.2.6.1. Note that the maximum shelf life of the caliper assembly is 10 years
following overhaul – refer to manufacturing date on nameplate to establish overhaul
interval. Add the following information to the package identification:
A. Expires: “Year-Month-Day”
B. “If Expired, subject to Overhaul Procedure”

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2.3 MASTER CYLINDER INSPECTION AND REPAIR

GENERAL: All Master Cylinders shall be subjected to the following Inspection and
Repair procedure prior to being returned to service. If a Master Cylinder fails to meet
requirements of Section 2.0, refer to Section 3.0 for Overhaul Procedures.

2.3.1 EXTERNAL INSPECTION AND REPAIR (Master Cylinder)

PROCEDURE: The external components of the master cylinder assembly shall be
visually inspected to assure all items are intact and in conformance with the Figure 2-4.
Retaining ring and lockwire are to be intact (Inspect Items 21 and 31). There shall be
no evidence of corrosion or mechanical damage. (Inspect Items 7, 12, 22 and 35).
CORRECTIVE ACTION: Replace or install any missing or damaged external
components. See Section 3.0 for part numbers and installation torque of replacement
parts. If the cylinder and / or aft bracket exhibits scratches, nicks or evidence of
corrosion, refer to paragraph 2.3.2 for repair procedure. (Inspect Items 12 and 35).

FIGURE 2-4
REFER TO TABLE 3-3 FOR PART NUMBERS

2.3.2 MASTER CYLINDER DAMAGE TOLERANCE

GENERAL: A master cylinder may become slightly damaged as the result of minor
mishaps that occur during maintenance, operation or handling. The following criteria
shall be used to evaluate and repair mishap damage.
2.3.2.1 CYLINDER DAMAGE TOLERANCE
PROCEDURE: Visually inspect the cylinder to detect damaged surfaces as evident by
deformations or material/paint anomalies. See Figure 2-4.
- Minor nicks and imperfections on the external cylinder surfaces can be repaired if
less than .025 inch (.635 mm) in depth. (Inspect Item 12).
CORRECTIVE ACTION: Replace cylinder if damage is not repairable. Painted surfaces
within damage tolerance can be repaired by lightly sanding by hand* the imperfection (400 grit,
optional 220 grit sandpaper) to remove any corrosion. Following surface preparation, apply a
dab of primer paint (MIL-PRF-23377 or similar) and after adequate drying time, dab with top coat
(MIL-PRF-85285 or similar) to seal the imperfection.

*NOTE
Use of power tools is prohibited.

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2.3.2.2 AFT BRACKET DAMAGE TOLERANCE

PROCEDURE: Visually inspect the aft bracket to detect damaged surfaces as evident
by deformations or material/paint anomalies. See Figure 2-4.
- Minor nicks and imperfections on the aft bracket surfaces can be repaired if less
than .025 inch (.635 mm) in depth.
CORRECTIVE ACTION: Replace aft bracket if damage is not repairable. Painted
surfaces within damage tolerance can be repaired by lightly sanding by hand* the
imperfection (400 grit, optional 220 grit sandpaper) to remove any corrosion. Following
surface preparation, apply a dab of primer paint (MIL-PRF-23377 or similar) and after
adequate drying time, dab with top coat (MIL-PRF-85285 or similar) to seal the
imperfection.

*NOTE
Use of power tools is prohibited.

2.3.3 FUNCTIONAL TEST (Master Cylinder)

GENERAL: Master cylinder shall be subjected to and successfully pass the following
Functional Test requirements. Any unit that fail to conform to all test requirements shall
be subjected to Overhaul in accordance with Section 3.0 of this manual.

2.3.3.1 HYDRAULIC SET UP (Master Cylinder)

PROCEDURE: Configure the master cylinder in accordance with the hydraulic
schematic per Figure 2-5.

FIGURE 2-5

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2.3.3.2 PROOF PRESSURE (Master Cylinder)

SET UP:
A. Open the HYDRAULIC RESERVOIR SHUT OFF VALVE.
B. Close the SYSTEM SHUT OFF VALVE.
C. Open the EXTERNAL PRESSURE SHUT OFF VALVE.
D. Bleed the master cylinder by slowly apply external hydraulic pressure using MIL-
PRF-87257 hydraulic fluid (do not exceed 280 psi) to the master cylinder high
pressure port until the master cylinder reservoir port begins to exhaust fluid.
Continue applying pressure until the unit is fully bled with the master cylinder
reservoir port elevated upward.
E. Reduce pressure to 0 PSIG.
F. Close the HYDRAULIC RESERVOIR SHUT OFF VALVE
PROCEDURE:
G. Slowly apply 280 +20/-0 psi external hydraulic pressure using MIL-PRF-87257
hydraulic fluid to the master cylinder high pressure port and hold for a period of 2
minutes.
H. Following the 2 minute hold, reduce pressure.
ACCEPTANCE: There shall be no evidence of external leakage, loosening of fasteners,
deformation or any abnormalities.
2.3.3.3 FUNCTIONAL OPERATION (Master Cylinder)
2.3.3.3.1 SYSTEM BLEED OPERATION (Master Cylinder)
PROCEDURE:
A. Open the HYDRAULIC RESERVOIR SHUT OFF VALVE and apply a low pressure
of approximately 5 - 10 psi at the HYDRAULIC RESERVOIR port (refer to Figure 2-
5).
B. Close the EXTERNAL PRESSURE SHUT OFF VALVE.
C. Open the SYSTEM SHUT OFF VALVE.
D. Loosen the bleed valves located on the B0249 Caliper Assemblies to exhaust fluid.
E. Bleeding shall be accomplished by extending and retracting the Master Cylinder
piston to draw in fluid from the reservoir port and exhausting fluid from the Caliper
Assembly bleed ports.
F. Continue bleeding until there is no evidence of air expelling from the Caliper
Assembly bleed ports.
G. Tighten the Caliper Assembly bleed valves to 50 in-lb ± 5 in-lb.
H. Reduce pressure.
2.3.3.3.2 FUNCTIONAL TEST (Master Cylinder)
PROCEDURE:
A. Following the Bleeding operation described in Paragraph 2.3.3.3.1 ensure that the
HYDRAULIC RESERVOIR SHUT OFF VALVE is open.
B. Close the EXTERNAL PRESSURE SHUT OFF VALVE.
C. Open the SYSTEM SHUT OFF VALVE.

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D. Extend the master cylinder piston and monitor the pressure at the SYSTEM
PRESSURE GAUGE and motion of caliper assembly friction pads. System
pressure shall be 110 ± 10 psi and friction pad actuation shall be smooth and
continuous.

ACCEPTANCE:
• System pressure shall build up to 110 ± 10 psi during extension of master cylinder
piston.
• Friction lining motion shall be smooth and continuous.
• There shall be no evidence of external leakage, loosening of any fasteners or
deformation.

CORRECTIVE ACTION:
• If the master cylinder fails to meet pressure acceptance criteria, the
internal poppet valve spring force may need to be adjusted. If pressure is
low, the spring shim (refer to Figure 3-3, Item 39) thickness may need to
be increased. If pressure is high, the spring shim thickness may need to
be decreased. The overhaul kit (B0252-K) includes three shim sizes that
can be used individually or in combination to adjust the master cylinder
pressure. Refer to Section 3.0, sub-paragraph 3.3 for master cylinder
disassembly and assembly instruction.
2.3.4 MASTER CYLINDER PACKAGING AND PRESERVATION
PROCEDURE: Drain the assembly of excess oil. Install protective plug (TPN-1) or
equivalent into reservoir port. Install protective cap (CD-4) or equivalent onto system
pressure port.
2.3.4.1 SHORT TERM
PROCEDURE: Wipe the master cylinder to remove any residual fluids. Box or package
the master cylinder to prevent damage. As a minimum, master cylinder packaging shall
be identified as follows:
A. “Inspection and Repair; Accepted”
B. “Name of Repair Facility”
C. “Year-Month-Day”
2.3.4.2 LONG TERM
PROCEDURE: Package and identify the master cylinder in accordance with paragraph
2.3.4.1. Note that the maximum shelf life of the caliper assembly is 10 years following
overhaul – refer to manufacturing date on nameplate to establish overhaul interval. Add
the following information to the package identification:
A. Expires: “Year-Month-Day”
B. “If Expired, subject to Overhaul Procedure”

2.4 DISC INSPECTION AND REPAIR

GENERAL: Brake Discs shall be subjected to the following Inspection and Repair
procedure.

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2.4.1 BRAKE DISC THICKNESS (Disc)

PROCEDURE: Measure the braking surface thickness as depicted below.
Measurements shall be taken using a calibrated micrometer. See Figure 2-6
CORRECTIVE ACTION: If brake disc has worn beyond its minimum allowable limit, it
shall be removed from service and a new unit installed.

FIGURE 2-6

2.4.2 BRAKE SURFACE ROUGHNESS (Disc)

PROCEDURE: Measure the surface roughness of the disc braking surface using a
micro-finish roughness comparator or equivalent. The maximum allowable roughness
is 125 RMS. See Figure 2-6.
CORRECTIVE ACTION: Using 400 grit (Optional: 220 grit) sandpaper or lapping
method to hand* rework and/or polish the braking surface until a 32 RMS is obtained.

*NOTE
Use of power tools is prohibited.

During this procedure, the following criteria shall be maintained:

A. The braking surface (both sides) shall be parallel to the hub mounting surface within
.002 inch. See Figure 2-6.
B. The brake disc shall be within the thickness requirements of Figure 2-6.
If brake disc cannot be reworked to meet specification requirements, remove the disc
from service and replace with a new unit. See Section 3.0, Overhaul.

2.4.3 BRAKE SURFACE RUNOUT (Disc)

PROCEDURE: Inspect the parallelism between the two braking surfaces and hub
mounting surface. These three planes shall be parallel within 0.002 inch. See Figure
2-6.

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CORRECTIVE ACTION: Using lapping or surface grinding techniques, rework the

braking surface until .002 inch parallelism is obtained. Both sides of the disc braking
surface and mounting hub surface shall meet these criteria. Also, minimum Disc
thickness of Figure 2-6 shall be maintained.

2.4.4 VISUAL INSPECTION (Disc)

PROCEDURE: Visually inspect the disc to insure that it exhibits quality workmanship.
There shall be no corrosion of the braking surface. All non-braking surfaces shall be
adequately painted for corrosion protection.
CORRECTIVE ACTION: If slight handling nicks, scratches or imperfections are present,
repair in accordance with paragraph 2.4.6 (Disc Damage Tolerance).

2.4.5 DYNAMIC BALANCE (Disc)

PROCEDURE: The brake disc shall be subjected to a dynamic balance test while
installed on a balancing arbor in accordance with Figure 2-7. Balance tests shall be
performed using a calibrated dynamic balance machine and associated test apparatus.
The combined imbalance of the brake disc and balancing arbor shall not exceed 0.03
in-oz.
CORRECTIVE ACTION: If brake disc does not meet balancing test criteria, see Section
3.0, Overhaul.

FIGURE 2-7

2.4.6 DISC DAMAGE TOLERANCE (IN-SERVICE)

PROCEDURE: Visually inspect the brake disc for evidence of small nicks as the result
of minor mishap.
- There shall be no material chipping or imperfections on the braking surface of the
disc.

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- There shall be no material imperfections on the mounting surface interface or pilot

shaft bore.
CORRECTIVE ACTION: If either of the imperfections exist, replace the brake disc.
Minor nicks and imperfections are acceptable if they are minor, infrequent (3
imperfections maximum) and less than .010 inch in depth. Lightly sand by hand* the
material imperfection using 400 grit (optional: 220 grit) sandpaper to remove corrosion.
Apply a dab of primer paint** (MIL-PRF-23377 or similar) to the sanded area. Following
the repair, subject the disc to procedures in accordance with Paragraph 2.4 (Disc
Inspection and Repair).

*NOTE
Use of powered tools is prohibited.

**NOTE
DO NOT apply primer paint to the braking surfaces of the disc. Primer is only
allowed on the mounting surfaces and circumference of disc. Refer to Figure 2-6.

2.4.7 DISC PACKAGING AND PRESERVATION

PROCEDURE: To prevent corrosion, apply a light film of oil or grease to the non-
painted braking surfaces. Package to prevent handling damage and label as follow:
A. “Inspection and Repair; Accepted”
B. “Name of Repair Facility”
C. “Year-Month-Day”

FIGURE 2-8

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FIGURE 2-9

FIGURE 2-10

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SECTION 3
OVERHAUL PROCEDURE
FOR
ROTOR BRAKE ASSEMBLY
MODEL 505
CALIPER ASSEMBLY MASTER CYLINDER ASSEMBLY BRAKE DISC
NDI: BO249-4 NDI: B0252-2 BHT: 206-340-301-101 (NDI: D0143-1)

TABLE OF CONTENTS
3.0 OVERHAUL PROCEDURE
3.1 TOOLS
3.2 CALIPER ASSEMBLY
3.2.1 DISASSEMBLY PROCEDURE
3.2.2 CALIPER INSPECTION
3.2.2.1 VISUAL INSPECTION (Caliper)
3.2.2.2 DIMENSIONAL INSPECTION (Caliper)
3.2.3 ASSEMBLY PROCEDURE (Caliper)
3.2.3.1 OVERHAUL KIT (Caliper)
3.2.3.2 ASSEMBLY (Caliper)
3.2.4 PAINT (Caliper)
3.2.5 FUNCTIONAL TEST (Caliper)
3.2.6 CALIPER PACKAGING AND PRESERVATION
3.3 MASTER CYLINDER
3.3.1 DISASSEMBLY PROCEDURE
3.3.2 MASTER CYLINDER INSPECTION
3.3.2.1 VISUAL INSPECTION (Master Cylinder)
3.3.2.2 DIMENSIONAL INSPECTION (Master Cylinder)
3.3.3 ASSEMBLY PROCEDURE (Master Cylinder)
3.3.3.1 OVERHAUL KIT (Master Cylinder)
3.3.3.2 ASSEMBLY (Master Cylinder)
3.3.4 PAINT (Master Cylinder)
3.3.5 FUNCTIONAL TEST (Master Cylinder)
3.3.6 MASTER CYLINDER PACKAGING AND PRESERVATION
3.4 DISC OVERHAUL

TABLE 3-1 PARTS BREAKDOWN FOR CALIPER ASSEMBLY

TABLE 3-2 CALIPER ASEMBLY OVERHAUL KIT
TABLE 3-3 PARTS BREAKDOWN FOR MASTER CYLINDER
TABLE 3-4 MASTER CYLINDER OVERHAUL KIT

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3.0 OVERHAUL PROCEDURE

GENERAL: Rotor Brake Calipers shall be overhauled at intervals of 1,800 hours of
service life. The Master Cylinder shall be overhauled at intervals of 3,000 hours of
service life per Section 1.0, Paragraph 1.7.
The Rotor Brake Disc shall be overhauled upon accumulating a maximum of 12,000
hours of service and at each subsequent 12,000 hours interval, providing the Disc
specification parameters are met. Refer to Section 1.0, Paragraph 1.7.

3.1 TOOLS
GENERAL: As a minimum, the following tools are required to overhaul the rotor brake
assembly. All inspection equipment shall be calibrated in accordance with ISO 17025 or
equivalent.

Tools
- Standard Mechanics Tools
- Lockwire Pliers
- Snap Ring Pliers, Truarc Model 0309: 90 degrees, .070 inch tip (Long Island City, NY) or
equivalent
- Standard Hydraulic Technician Tools (o-ring pick, etc…)
- 220 Grit Sandpaper (optional: 400 Grit)
- Hydraulic Power Supplier (280 psi min.) MIL-PRF-87257 Hydraulic Oil
- Pressure Gauge (250 psi min.)
- Pressure Gauge (60 psi max.)
- Shut off valves
- Block-Switch Test: See Figure 2-8
- Block-Operational See Figure 2-9 or equivalent
- Misc. Hydraulic Fittings, Etc.: See Figures 2-3 and 2-5
- Balancing Arbor: See Figure 2-7
- Master Cylinder Pin Tool - 00-90 screw, McMaster Carr P/N 92482A235 or equivalent.

Inspection Tools
- 0-6 inch Dial Caliper
- Torque Wrench (300 in-lb max.)
- Bore Gauge or equivalent (1 3/16 inch)
- 0-1 inch Micrometer
- 1-2 inch Micrometer
- Surface Plate (12in. x 18in. min.)
- Dial Indicator with Base
- Dynamic Balancing Test Apparatus (MIL-STD-45662) or equivalent
- Micro-Finish Roughness Comparator or equivalent
- Inspection Pin Gauges
- Multi-Meter, Continuity Tester or equivalent

3.2 CALIPER ASSEMBLY

GENERAL: All Calipers shall be subjected to the following Overhaul Procedure upon
achieving intervals of 1,800 hours of service life.

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3.2.1 DISASSEMBLY PROCEDURE (Caliper)

PROCEDURE: Remove the Caliper Assembly from the aircraft and refer to Figure 3-1.
A. Remove lockwire (42) installed on switch assemblies (20) and torque pins (13).
B. Remove switch assemblies, lock washers (21), and pins (12) from spacer (19).
C. Remove 4 each bleed valves (22) using socket wrench. Install torque is 50 ± 5 in-lb.
D. Remove 2 each cotter pins (38), 5/16 inch castle nuts (37) and washers (36) (39).
Installation torque on castle nut is 150 to 100 in-lb.
E. Remove 2 each 5/16 inch bolt, washers (35) (36) and bracket (26).
F. Separate the caliper housings (2) (5) as shown in Figure 3-1.
G. Remove transfer tube (14) and 2 each o-rings (30).

NOTE:
EXERCISE CARE NOT TO SCORE OR DAMAGE SEAL
GLANDS WHILE REMOVING 0-RINGS. USE SOFT METAL
OR PLASTIC TOOL TO EXTRACT O-RINGS.

H. Remove 2 each rod wipers (43) from spacer (19).

I. Remove 2 each friction pad assemblies (15).
J. Remove 4 each torque pins (13) from housings (2) (5).
K. Remove 2 each retaining rings (34) using snap ring pliers from housings.
L. Remove 2 each piston assemblies (8) (9) (10) (11) (23) (27) (30) (33) from housings.
M. Remove 2 each packing retainers (32) and 2 each packing (29) from housings.
N. Restrain piston assembly (8) (9) (10) (11) (23) (27) (30) (33) by the flats on rod (10).
Remove deformation of lock washer (11) then remove nut (27). Installation torque on
nut (27) is 30 ± 15 in-lb.

CAUTION
WHILE REMOVING NUT (27), NOTE THAT THE INTERNAL SPRING IS LOADED
(COMPRESSED). DO NOT POSITION BODY OR FACE IN FRONT OF COMPONENTS.

O. Disassemble piston assembly and remove packing (30) and rod wiper (33).
P. Discard packings (29) (30), retainer packings (32), rod wipers (33) (43), friction pad
assemblies (15), cotter pins (38) and lock washers (11) (21).

CAUTION
CLEANING SOLVENTS ARE TOXIC AND VOLATILE. USE ONLY IN WELL VENTILATED AREAS.
AVOID PHYSICAL CONTACT WITH SOLVENT AND DO NOT INHALE VAPORS.

Q. Thoroughly clean all components using Acetone, Stoddard solvent or equivalent. Do

not use Isopropyl Alcohol.

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FIGURE 3-1

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3.2.2 CALIPER INSPECTION

3.2.2.1 VISUAL INSPECTION
PROCEDURE: Visually inspect the caliper housings, torque pins, pistons, rods, rod
bearings, springs, transfer tube, spacer, bleed valves, switch assemblies, pins, bracket,
ring retainers and fasteners (2) (5) (13) (8) (10) (9) (23) (14) (19) (22) (20) (12) (26) (27)
(34) (35) (37) for condition and security. All items shall be free of nicks, burrs, gouges
or imperfections. Visually inspect the condition of the fastener hardware. All items shall
be in good condition and security.
If minor external imperfections are present on housings (2) (5), refer to Section 2.0,
Caliper Damage Tolerances for allowable imperfections and repair procedure. Internal
housing inspection criteria shall be performed per paragraph 3.2.2.2.1.
Replace items, which do not meet visual inspection criteria.
3.2.2.2 DIMENSIONAL INSPECTION
3.2.2.2.1 HOUSING INSPECTION

PROCEDURE:

• Examine the hydraulic bore of the caliper housings (2) (5) for evidence of
wear. Measure the bore diameter at the location of maximum wear.
Measurements shall be taken using a calibrated bore gauge or equivalent.
The maximum allowable bore diameter is 1.189 inch. There shall be no
evidence of nicks or gouges in the hydraulic bore and the surface finish shall
not exceed 32 RMS.
• Inspect surface finish of internal o-ring glands using a surface finish
comparator or equivalent. The groove shall exhibit a 32 RMS max finish and
the side walls 63 RMS max.
3.2.2.2.2 PISTON INSPECTION

PROCEDURE:

• Examine the O.D. of the caliper pistons (8) for evidence of wear. Using a
calibrated micrometer, measure the piston at the location of maximum wear.
The minimum allowable piston diameter is 1.183 inch with surface finish of 32
RMS maximum.
• There shall be no gouges or imperfections on this surface.
3.2.2.2.3 ROD BEARING INSPECTION

PROCEDURE:

• Examine the O.D. of the rod bearing (9) for evidence of wear. Using a
calibrated micrometer, measure the rod bearing at the location of maximum
wear. The minimum allowable piston diameter is 1.183 inch.
• Examine the I.D. of the rod bearing for evidence of wear. Measure the bore
diameter at the location of maximum wear. Measurements shall be taken
using a calibrated bore gauge or equivalent. The maximum allowable bore
diameter is .563 inch. There shall be no evidence of nicks or gouges on the
hydraulic bore.
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3.2.3 ASSEMBLY PROCEDURE

3.2.3.1 OVERHAUL KIT
PROCEDURE: Obtain Caliper Overhaul Kit Number B0249-K. One (1) Kit contains
component parts needed to overhaul one (1) rotor brake caliper. See Table 3-2 for
breakdown of Kit components.
3.2.3.2 ASSEMBLY
PROCEDURE: See Figure 3-1.
A. Reverse disassembly procedure of paragraph 3.2.1.
B. It is recommended that a light coating of petroleum jelly or MIL-PRF-87257
hydraulic oil be applied to o-rings and their mating bores/rods prior to installation.
C. When installing castle nuts (37), it may be necessary to add shim washers (39) to
provide alignment of cotter pin (38). Shim washers are included in the Overhaul Kit.
A maximum of 2 Shim Washers may be used under each nut.
D. Install lock washer (21) onto switch assembly (20) and thread switch assembly two
full turns into caliper spacer (19). Snug jam nut with 15 in-lb max toque. Do not
lockwire nut.
E. Connect an ohm meter, continuity tester or equivalent between connector pins 1
& 2 of the limit switch.
F. Loosen jam nut to allow for rotation of switch. Rotate the switch counterclockwise
until a closed circuit is achieved (less than 2 ohms).
G. Slowly turn switch clockwise into the housing until an open circuit is achieved
(infinite resistance).
H. Slowly turn the switch counter-clockwise until a closed circuit is achieved (less
than 2 ohms).
I. Continue counter-clockwise rotation a minimum of 90° and maximum of 180°
until the lock tab washer matches with the locking flats on the housing spacer.
J. Tighten the jam nut (15-30 in-lb) onto the tab washer, bend the tab washer flaps
over the housing spacer edges to lock.
K. Repeat steps D through J on the second switch assembly.
L. Secure the switch nuts by lockwiring both switch nuts together to prevent them from
rotating counterclockwise.

3.2.4 PAINT
GENERAL: The caliper assembly shall be adequately primed and painted to prevent
corrosion of external surfaces. Restore finish as required to prevent corrosion.
PROCEDURE: For minor restoration, lightly sand surface using 400/220 grit
sandpaper* and clean sanded surfaces with Acetone or similar solvent. Dab the
restoration surfaces with primer. Following application of primer and suitable drying
time, apply a dab of top coat paint to the primed surfaces. Primer shall be in
accordance with MIL-PRF-23377 and top coat per MIL-PRF-85285 or equivalent
substitutes.

*NOTE
Use of power tools is prohibited.

For major restoration of the caliper assembly, the following procedure shall be followed:

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A. Thoroughly clean the external surfaces of the caliper assembly using a clean rag
and Acetone solvent or equivalent.
B. Lightly sand the painted caliper by hand* using 400/220 grit sandpaper.
C. Wipe all surfaces with a clean rag and Acetone solvent.
D. Mask the caliper assembly in accordance with Figure 3-2.

FIGURE 3-2
E. Mask the caliper nameplate and hydraulic inlet port.
F. Lightly prime the caliper assembly using MIL-PRF-23377 paint or similar substitute.
Allow to dry a minimum of 90 minutes.
G. Apply top coat 1 to 3 mills thick and allow to dry 24 hours minimum or until fully
cured.
H. Remove masking material from caliper surfaces.
I. Install gasket (M83461/2-904) onto protective closure plug (NAS 815-4) and install
into caliper inlet hydraulic port.

3.2.5 FUNCTIONAL TEST

GENERAL: Each caliper assembly shall be subjected to and successfully pass
functional test requirements in accordance with Section 2.0, (Paragraph 2.2.5
Functional Test). Any unit that fails to meet all test criteria shall be subjected to
Overhaul in accordance with Section 3.0.

3.2.6 CALIPER PACKAGING AND PRESERVATION

PROCEDURE: Remove the hydraulic power supply from the caliper inlet port and drain
the unit of excess oil. Install a protective plug (NAS 815-4) or equivalent into the inlet
port.
Wipe the caliper of residual fluids. Box and package the caliper to prevent damage.
Note that the maximum shelf life of the caliper assembly is 10 years following overhaul
– refer to manufacturing date on nameplate to establish overhaul interval. As a
minimum, the caliper packaging shall be identified as follows:
A. Overhaul Procedure: Accepted
B. Overhaul Kit Part No.: B0249-K
C. Name of Overhaul Facility
D. “Year – Month – Day”
E. “expires_____________”
F. “If Expired, subject to Overhaul Procedure”

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3.3 MASTER CYLINDER

GENERAL: All Master Cylinders shall be subjected to the following Overhaul Procedure
upon achieving intervals of 3,000 hours of service life.

3.3.1 DISASSEMBLY PROCEDURE (Master Cylinder)

PROCEDURE: Remove the Master Cylinder from the aircraft and refer to Figure 3-3.
A. Remove protective cap (33) and protective cap (34) and drain out any residual
hydraulic fluid.
B. Remove lockwire (31) installed between jam nut (15) and end cap (9). Remove
lockwire (31) installed between end cap (9) and cylinder (12).
C. Remove jam nut (15) (Installation torque is 100 to 85 in-lb) and washer (16).
D. Remove aft bracket (35) from end cap (9).
E. Remove turnbuckle (37) and drilled nut (36) from piston (7).
F. Remove end cap (9) from cylinder (12).
G. Remove piston assembly (3) (4) (5) (6) (7) (8) (13) (14) (17) (19) (20) (25) (26) (27)
(39) (40) from cylinder (12).
H. Remove retaining ring (21) using Truarc Pliers (#0309) from cylinder (12).
I. Remove support (11) from cylinder (12).
J. Remove hydraulic fitting (22) from cylinder (12) and rod bearing (10).
K. Remove rod bearing (10) from cylinder (12).
L. Remove retaining ring (20) from piston assembly.
M. Remove floating piston (8) from piston assembly.
N. Remove 2 each bearing rings (13), 2 each packing retainers (26), packing (25) and
packing (27) from floating piston (8).

NOTE:
EXERCISE CARE NOT TO SCORE OR DAMAGE SEAL
GLANDS WHILE REMOVING 0-RINGS. USE SOFT
METAL OR PLASTIC TOOL TO EXTRACT O-RINGS.

O. Remove rod wiper (29) from support (11).

P. Remove spacer (38), 2 each packing retainer (24), packing (23) and packing (30)
from rod bearing (10).
Q. Remove teflon tape from hydraulic fitting (22).
R. Remove packing (28) from end cap (9).

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S. Apply compressive load on end of spring retainer (14) to compress spring (17).
Remove pin (19) from piston assembly using a master cylinder pin tool (00-90
screw).

CAUTION
WHILE REMOVING SPRING RETAINER (14), NOTE THAT THE INTERNAL SPRING IS LOADED
(COMPRESSED). DO NOT POSITION BODY OR FACE IN FRONT OF COMPONENTS.

T. Gently reduce the compressive force applied to the spring retainer (14) and allow
the internal spring to smoothly separate the spring retainer from the piston
assembly.
U. Remove spring retainer (14), spring (17), spring shim (39), spring seat (40), poppet
assembly (3) from piston (7).
V. Discard packings (23) (30) (25) (27) (28), retainer packings (24) (26), rod wipers
(29), ring bearings (13).

CAUTION
CLEANING SOLVENTS ARE TOXIC AND VOLATILE. USE ONLY IN WELL VENTILATED AREAS.
AVOID PHYSICAL CONTACT WITH SOLVENT AND DO NOT INHALE VAPORS.

W. Thoroughly clean all components using Acetone, Stoddard solvent or equivalent.

Do not use Isopropyl Alcohol.

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FIGURE 3-3

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3.3.2 MASTER CYLINDER INSPECTION

3.3.2.1 VISUAL INSPECTION
PROCEDURE: Visually inspect the master cylinder piston, floating piston, cylinder, rod
bearing, hydraulic fitting, spring, pin, spring retainer and poppet assembly (7) (8) (12)
(10) (22) (17) (19) (14) (3) for condition and security. All items shall be free from nicks,
burrs, gouges or imperfections. All items shall be in good condition and security.
If minor external imperfections are present on cylinder (12) or aft bracket (35), refer to
Section 2.0, Master Cylinder Damage Tolerance for allowable imperfections and repair
procedure. Cylinder bore inspection criteria shall be performed per paragraph
3.3.2.2.1.
Replace items, which do not meet visual inspection criteria.
3.3.2.2 DIMENSIONAL INSPECTION
3.3.2.2.1 CYLINDER INSPECTION

PROCEDURE:

• Examine the hydraulic bore of the cylinder (12) for evidence of wear.
Measure the bore diameter at the location of maximum wear. Measurements
shall be taken using a calibrated bore gauge or equivalent. The maximum
allowable bore diameter is .927 inch. There shall be no evidence of nicks or
gouges in the hydraulic bore and the surface finish shall be not exceed 16
RMS.
3.3.2.2.2 PISTON INSPECTION

PROCEDURE:

• Examine the rod of the piston (7) for evidence of wear. Measure the rod
diameter at the location of maximum wear. Measurements shall be taken
using a calibrated micrometer (0 – 1 inch) or equivalent. The minimum
allowable diameter is .247 inch. There shall be no evidence of nicks or
gouges on the rod diameter and the surface finish shall be not exceed 16
RMS.
• Examine the rod of the piston for evidence of bending. Place the piston on a
flat surface plate with the piston head extending over the edge of the plate.
Roll the piston rod and visually inspect for gaps between the surface plate
and the rod. There shall be no evidence of a bent piston rod.

3.3.3 ASSEMBLY PROCEDURE

3.3.3.1 OVERHAUL KIT
PROCEDURE: Obtain Master Cylinder Overhaul Kit Number B0252-K. One (1) Kit
contains component parts needed to overhaul one (1) rotor brake master cylinder. See
Table 3-4 for breakdown of Kit components.
3.3.3.2 ASSEMBLY
PROCEDURE: See Figure 3-3.

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A. Reverse disassembly procedure of paragraph 3.3.1.

B. Refer to Figure 3-4 for orientation of Spring Seat (40) relative to Poppet Assembly
(3), Spring Shim (39) and Spring (17).

FIGURE 3-4

NOTE - Refer to Section 2.0, sub-paragraph 2.3.3.3.2 for Spring Shim (39)
adjustment to achieve 110 +/- 10 PSIG reseat pressure.
C. It is recommended that a light coating of petroleum jelly or MIL-PRF-87257
hydraulic oil be applied to packings and their mating bores/rods prior to installation.
D. Permissible to sipe rod wiper (29) 8 places, 50% through part, from aft face prior to
installation.
E. Prior to installation of hydraulic fitting (22) place teflon tape on tapered thread that
mates with rod bearing (10) thread.
F. Install lockwire between end cap (9) and cylinder (12).
G. Install lockwire between jam nut (15) and end cap (9).

3.3.4 PAINT
GENERAL: The master cylinder shall be adequately primed and painted to prevent
corrosion of external surfaces. Restore finish as required to prevent corrosion.
PROCEDURE: For minor restoration, lightly sand surface using 400/220 grit
sandpaper* and clean sanded surfaces with Acetone or similar solvent. Dab the
restoration surfaces with primer. Following application of primer and suitable drying
time, apply a dab of top coat paint to the primed surfaces. Primer shall be in
accordance with MIL-PRF-23377 and top coat per MIL-PRF-85285 or equivalent
substitutes.

*NOTE
Use of power tools is prohibited.

For major restoration of the caliper assembly, the following procedure shall be followed:
A. Thoroughly clean the external surfaces of the caliper assembly using a clean rag
and Acetone solvent or equivalent.
B. Lightly sand the painted master cylinder by hand* using 400/220 grit sandpaper.
C. Wipe all surfaces with a clean rag and Acetone solvent.
D. Mask the Master Cylinder Assembly in accordance with Figure 3-5.

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FIGURE 3-5

E. Lightly prime the master cylinder using MIL-PRF-23377 paint or similar substitute.
Allow to dry 90 minutes minimum.
F. Apply top coat 1 to 3 mills thick and allow to dry 24 hours minimum or until fully
cured.
G. Remove masking material from master cylinder surfaces.
H. Install protective cap (TPN-1) or equivalent into hydraulic port located in end cap.
I. Install protective cap (CD-4) or equivalent onto hydraulic fitting.

3.3.5 FUNCTIONAL TEST

GENERAL: Each master cylinder shall be subjected to and successfully pass functional
test requirements in accordance with Section 2.0, (Paragraph 2.3.3 Functional Test).

3.3.6 MASTER CYLINDER PACKAGING AND PRESERVATION

PROCEDURE: Remove hydraulic lines from the master cylinder and drain the unit of
excess oil. Install protective plugs (TPN-1 and CD-4) or equivalent into the hydraulic
ports.
Wipe the master cylinder of residual fluids. Box and package the master cylinder to
prevent damage. Note that the maximum shelf life of the caliper assembly is 10 years
following overhaul – refer to manufacturing date on nameplate to establish overhaul
interval. . As a minimum, the master cylinder packaging shall be identified as follows:
A. Overhaul Procedure: Accepted
B. Overhaul Kit Part No.: B0252-K
C. Name of Overhaul Facility
D. “Year – Month – Day”
E. “expires______________”
F. “If Expired, subject to Overhaul Procedure”

3.4 DISC OVERHAUL

PROCEDURE:
A. The rotor brake disc shall be subjected to Inspection and Repair procedures in
accordance with Section 2.0, paragraph 2.4.
B. Any unit that fails to meet all acceptance criteria shall be removed from service.
Using ¼ inch steel letter stamps, stamp “SCRAP” on the disc braking surface.
C. Install new disc if existing Disc is scrapped.

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TABLE 3-1 PARTS BREAKDOWN FOR CALIPER ASSEMBLY

B0249-4 CALIPER ASSEMBLY
Item No Qty/Assy Nomenclature Part No.
2 1 Housing Assembly D0490-1
5 1 Housing Assembly D0491-1
8 2 Piston D0442-2
9 2 Rod Bearing D0443-1
10 2 Rod D0444-1
11 2 Lock Washer D0445-1
12 2 Pin D0446-1
13 4 Torque Pin D0459-1
14 1 Transfer Tube D0448-2
15 2 Friction Pad Assembly D0449-3
19 1 Spacer D0460-1
20 2 Switch Assembly D0489-1
21 2 Lock Washer D0198-1
22 4 Bleeder Valve D0151-1
23 2 Spring D0453-1
26 1 Bracket D0499-1
27 2 Nut 92101A430
29 2 Packing MS28775-123
30 4 Packing MS28775-010
32 4 Packing Retainer BUT-123
33 2 Rod Wiper 959-2
34 2 Ring Retaining 98409A226
35 2 Bolt AN5-33
36 A/R Washer AN960C516L
37 2 Nut AN310-5
38 2 Cotter Pin MS24665-229
39 A/R Shim B11870
42 A/R Lockwire MS20995
43 2 Rod Wiper SHU-312

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TABLE 3-2 CALIPER ASSEMBLY OVERHAUL KIT (P/N B0249-K)

B0249-4 OVERHAUL KIT
Item No Qty Nomenclature Part No.
11 2 Lock Washer D0445-1
15 2 Friction Pad Assembly D0449-3
29 2 Packing MS28775-123
30 4 Packing MS28775-010
32 4 Packing Retainer BUT-123 (Opt. MS28774-123)
33 2 Rod Wiper 959-2
36 4 Washer AN960C516L
38 2 Cotter Pin MS24665-229
39 4 Shim B11870
40 1 Protective Plug NAS 815-4 or Equivalent
41 1 Gasket M83461/2-904 or Equivalent
42 A/R Lockwire MS20995
43 2 Rod Wiper SHU-312

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TABLE 3-3 PARTS BREAKDOWN FOR MASTER CYLINDER

B0252-2 MASTER CYLINDER
Item No Qty/Assy Nomenclature Part No.
3 1 Poppet Assembly D0462-1
7 1 Piston D0463-1
8 1 Floating Piston D0464-1
9 1 End Cap D0465-1
10 1 Rod Bearing D0466-1
11 1 Support D0467-1
12 1 Cylinder D0468-1
13 2 Ring Bearing D0469-1
14 1 Spring Retainer D0470-1
15 1 Jam Nut D0316-1
16 1 Washer AN960C1216L
17 1 Spring C0420-048-1000S
19 1 Pin D0472-1
20 1 Retaining Ring 96363A546
21 1 Retaining Ring 98409A211
22 1 Hydraulic Fitting AN816-4D
23 1 Packing MS28775-010
24 2 Packing Retainer MS28774-010
25 1 Packing MS28775-116
26 2 Packing Retainer MS28774-116
27 1 Packing MS28775-014
28 1 Packing MS28775-120
29 1 Rod Wiper 4615SHD00250
30 1 Packing MS28775-019
31 A/R Lockwire MS20995
32 1 Nameplate D0480-1
33 1 Protective Cap TPN-1
34 1 Protective Cap CD-4
35 1 Aft Bracket D0474-1
36 1 Drilled Nut NAS509-3
37 1 Turnbuckle MS21251-3S
38 1 Spacer D0483-1
39 A/R Spring Shim D0485-1/-2/-3
40 1 Spring Seat D0503-1

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TABLE 3-4 MASTER CYLINDER OVERHAUL KIT (P/N B0252-K)

B0252-2 MASTER CYLINDER
Item No Qty Nomenclature Part No.
3 1 Poppet Assembly D0486-1
13 2 Ring Bearing D0469-1
23 1 Packing MS28775-010
24 2 Packing Retainer MS28774-010
25 1 Packing MS28775-116
26 2 Packing Retainer MS28774-116
27 1 Packing MS28775-014
28 1 Packing MS28775-120
29 1 Rod Wiper 4615SHD00250
30 1 Packing MS28775-019
31 A/R Lockwire MS20995
33 1 Protective Cap TPN-1
34 1 Protective Cap CD-4
39 2 Spring Shim (.14 in thick) D0485-1
39 2 Spring Shim (.10 in thick) D0485-2
39 2 Spring Shim (.06 in thick) D0485-3

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