This document provides maintenance procedures and time limits for a Pilatus PC-6 aircraft that has been modified with a BERINGER brake system. It outlines scheduled maintenance checks that are in addition to the original PC-6 maintenance manual. These include preflight inspections of brake disc safety wires and additional checks at 100 hour intervals or annually of components like the brake fluid level, hoses for leaks, disc wear and pad wear. The document also provides time limits before overhaul is required for different brake system components ranging from 3500 hours or 7 years for items like the master cylinder to 7000 hours or 14 years for the wheel unit.
This document provides maintenance procedures and time limits for a Pilatus PC-6 aircraft that has been modified with a BERINGER brake system. It outlines scheduled maintenance checks that are in addition to the original PC-6 maintenance manual. These include preflight inspections of brake disc safety wires and additional checks at 100 hour intervals or annually of components like the brake fluid level, hoses for leaks, disc wear and pad wear. The document also provides time limits before overhaul is required for different brake system components ranging from 3500 hours or 7 years for items like the master cylinder to 7000 hours or 14 years for the wheel unit.
This document provides maintenance procedures and time limits for a Pilatus PC-6 aircraft that has been modified with a BERINGER brake system. It outlines scheduled maintenance checks that are in addition to the original PC-6 maintenance manual. These include preflight inspections of brake disc safety wires and additional checks at 100 hour intervals or annually of components like the brake fluid level, hoses for leaks, disc wear and pad wear. The document also provides time limits before overhaul is required for different brake system components ranging from 3500 hours or 7 years for items like the master cylinder to 7000 hours or 14 years for the wheel unit.
This document provides maintenance procedures and time limits for a Pilatus PC-6 aircraft that has been modified with a BERINGER brake system. It outlines scheduled maintenance checks that are in addition to the original PC-6 maintenance manual. These include preflight inspections of brake disc safety wires and additional checks at 100 hour intervals or annually of components like the brake fluid level, hoses for leaks, disc wear and pad wear. The document also provides time limits before overhaul is required for different brake system components ranging from 3500 hours or 7 years for items like the master cylinder to 7000 hours or 14 years for the wheel unit.
1 General BERINGER brake system functioning is similar to original brake system except when dual (pilot + copilot brakes) are installed.
On original system only one of the two pilots can have the brake action due to shuttle valves. With BERINGER there is no shuttle valve and both pilots can brake simultaneously. The brake pressure at the wheel is then the highest reached by pilot or co-pilot
CAUTION: Both pilot and co-pilot can brake simultaneously
2 Time limit / overhaul schedule
Partial overhaul Complete overhaul
Component Time limit interval interval Flexible stainless braided hoses
3500 flying hours
Brake master cylinder or 7 years 3500 flying hours Brake regulator or 7 years 3500 flying hours Brake unit 4 years or 7 years 3500 flying hours 7000 flying hours Wheel unit or 7 years or 14 years
Refer to maintenance and overhaul manual with procedures and IPL.
Next maintenance checks replace corresponding ones into the PC-6 maintenance manual.
Inspection Operation Wear Component 100h Annual inspection limit Check brake fluid level Brake system - Apply brakes, examine system for leaks 0.6 mm Brake system Check play between disc and key disc drive 0.024 in Examine Main wheel tires - Check inflation pressure
Hydraulic Hoses - Examine
6.4 mm Examine Brake Discs Check disc wear 0.252 in Check for wear Visual Brake Pads Check brake pad wear Check brake pad wear inspection Remove from axle Examine bearings, valve, axles and Main wheels - Examine wheels, lubricate bearings, change lip seal Examine Brake unit - Examine Disassemble, check pistons movement, check bolts Examine Tail wheel tire - Check inflation pressure Remove from landing gear Tail wheel - Examine Examine bearings, axle and wheel
Main Wheel lip seal - 1 year - annual inspection On condition Main wheel disc clips - If found worn, all key disc must be replaced
Brake caliper seals and pistons b 4 years
On condition Brake assembly screws b 4 years On condition Brake pad guides b 4 years On condition Brake pads c After each brake disc change 4 years On condition Brake discs b 7 years
NOTE:
a All screws of the assembly must be changed at the same time. It is not allowed to change only few of them.
b Brake parts must be changed by pair on both left and right sides.
c Brake pads must be changed all 4 at the same time even if not worn out (the 2 on left side and the 2 on right side). When new brake discs are installed brake pads must be changed to new ones even if not worn out.
When new brake pads have been installed, it is important to condition them properly to obtain the service life designed into them. Rated brake torque value is reached only after a full conditioning of brake pads and disc.
CAUTION: Brake torque value can be only 50% of rated brake torque before the conditioning. It means that even with full brake effort aircraft will not stop as usual. Pilot must take into consideration this parameter to avoid loose of aircraft control during the conditioning procedure.
CONDITIONNING PROCEDURE: 1. Taxi aircraft for 500m (1500 feet) with light brake effort. 2. Perform two (2) consecutive stops from 30 – 35 knots down to 5 knots. Apply light brake effort during these two stops; do not try to apply full brake effort. 3. Allow the brakes to cool for 10 to 15 minutes. 4. Apply brakes and check for restraint at high static throttle. If brakes hold, conditioning is complete. 5. If brakes cannot hold aircraft during static run-up, allow the brakes to cool completely and repeat steps 1 through 4.
This conditioning procedure will wear off high spots and prepare pads and disc friction surfaces. A visual inspection of disc will indicate the pads condition: a smooth surface with light and regular grooves indicates that pads and disc are properly conditioned.
NOTE: A rough surface of disc with deep grooves and isolated bumps indicates that an excessive brake effort has been applied during conditioning. In this case, bumps must be sanded and conditioning procedure repeated.
CAUTION: A wrong conditioning may affect brake performances and increase
