Installation of the Brake Manifold

TASK 32-44-17-400-001-A
Installation of the Brake Manifold

WARNING: PUT THE SAFETY DEVICES AND THE WARNING NOTICES IN POSITION BEFORE YOU START A TASK ON OR NEAR:

THE FLIGHT CONTROLS
THE FLIGHT CONTROL SURFACES
THE LANDING GEAR AND THE RELATED DOORS
COMPONENTS THAT MOVE.

MOVEMENT OF COMPONENTS CAN KILL OR CAUSE INJURY TO PERSONS AND/OR CAN CAUSE DAMAGE TO THE EQUIPMENT.

WARNING: BE CAREFUL WHEN YOU USE CONSUMABLE MATERIALS. OBEY THE MATERIAL MANUFACTURER'S INSTRUCTIONS AND YOUR LOCAL REGULATIONS.

WARNING: MAKE SURE THAT ALL THE CIRCUITS IN MAINTENANCE ARE ISOLATED BEFORE YOU SUPPLY ELECTRICAL POWER TO THE AIRCRAFT. UNWANTED ELECTRICAL POWER CAN BE DANGEROUS.

ZONE: 744
FIN: 3016GM

1. Reason for the Job
Self explanatory
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	2	WARNING NOTICE(S)
No specific	Torque wrench: range to between 1.3 and 1.2 m.daN (115.04 and 106.19 lbf.in )
No specific	Torque wrench: range to between 5.9 and 5.4 m.daN (43.51 and 39.82 lbf.ft )
No specific	Torque wrench: range to between 11.35 and 11.24 m.daN (83.70 and 82.89 lbf.ft )

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.02ABA1)	Phosphate Ester Hydraulic Fluid-General Power - -
(Material No.04JMD9)	Top Coat Polyurethane-- Decorative Furnishing
(Material No.06AEA1)	Polysulfide Sealant-Low Adhesion Brushable -
(Material No.06LCG9)	Non Hardening Jointing Putty-Medium Temp. Area - -
(Material No.14QFB1)	Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
744	MAIN DOOR

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
5	PACKING	AIPC 32-44-03-06-050
7	PACKING	AIPC 32-44-03-06-050
5	PACKING	AIPC 32-44-83-08-140

E. Referenced Information

REFERENCE	DESIGNATION
TASK 12-12-29-611-001-A	Fill the Hydraulic Fluid Reservoir with a Hand Pump
TASK 20-23-22-910-001-A	Marking of the Unions after Application of Standard or Specific Tightening Torque
TASK 29-00-00-910-002-A	Safety Procedures of the Hydraulic System
TASK 29-10-00-864-002-A	Depressurize the Yellow Hydraulic System
TASK 29-14-00-614-001-A	Depressurization of the Hydraulic Reservoirs
TASK 29-23-00-860-001-A	Disconnection of the Isolation Coupling of the Power Transfer Unit (PTU)
TASK 29-23-00-860-002-A	Connection of the Isolation Coupling of the Power Transfer Unit (PTU)
TASK 29-32-11-400-004-A	Installation of the Hydraulic Pressure Transducer
TASK 32-12-00-010-001-A	Open the Main Gear Doors for Access
TASK 32-12-00-410-001-A	Close the Main Gear Doors after Access
TASK 32-43-00-710-001-A	Operational Check of Alternate Braking System
TASK 32-43-00-870-002-A	Bleeding of the High Pressure Alternate Braking System
TASK 32-43-51-400-001-A	Installation of the Alternate Braking Selector Valve
TASK 32-44-15-400-001-A	Installation of the Pressure Relief Valve
TASK 51-75-13-916-002-A	Repair to a layer of Corrosion Preventive Compound
Alternate Brake Manifold 3016GM ** ON A/C NOT FOR ALL
Alternate Brake Manifold 3016GM ** ON A/C NOT FOR ALL

3. Job Set-up
Subtask 32-44-17-860-051-A

A. Aircraft Maintenance Configuration
(1) Make sure that the PTU isolation coupling is disconnected (Ref. AMM TASK 29-23-00-860-001).
(2) Make sure that the Yellow hydraulic system is depressurized (Ref. AMM TASK 29-10-00-864-002).
(3) Make sure that the reservoir of the Yellow hydraulic system is depressurized (Ref. AMM TASK 29-14-00-614-001).

Subtask 32-44-17-865-051-A

B. Make sure that this(these) circuit breaker(s) is(are) open, safetied and tagged:

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C NOT FOR ALL
49VU	L/G/Y BRK/PRESS/IND	61GG	C10
** ON A/C NOT FOR ALL
49VU	ABCU &/Y BRK/PRESS IND	61GG	C10
** ON A/C NOT FOR ALL
121VU	HYDRAULIC/HYD POWER/Y	3803GX	N30
** ON A/C ALL
121VU	HYDRAULIC/BRAKING AND STEERING/SYS2/SPLY	4GG	M36
121VU	HYDRAULIC/BRAKING AND STEERING/SYS2/CTL	3GG	M35
121VU	HYDRAULIC/BRAKING AND STEERING/SYS1/CTL	1GG	M34
121VU	HYDRAULIC/BRAKING AND STEERING/SYS1/IND AND/SPLY	2GG	M33
121VU	HYDRAULIC/PARK BRK/CTL/STBY	71GG	N37
121VU	HYDRAULIC/PARK BRK/CTL/NORM	70GG	N36
121VU	HYDRAULIC/Y HYD/PUMP ENG2/MONG	3700GD	Q37
121VU	HYDRAULIC/Y HYD/PUMP ENG2/CTL	3701GD	Q36
** ON A/C NOT FOR ALL
121VU	HYDRAULIC/HYD POWER/Y	3803GX	N31
** ON A/C ALL
123VU	Y HYD/ELEC/PUMP	3802GX	AB06
123VU	Y HYD/ELEC/ELEC PUMP/NORM	3801GX	AB03

Subtask 32-44-17-941-053-A

C. Make sure the WARNING NOTICE(S) are in position to tell persons not to pressurize the Yellow hydraulic system:

On the panel 40VU in the cockpit
On the ground service panel of the Yellow hydraulic system.

Subtask 32-44-17-560-050-B ** ON A/C NOT FOR ALL

D. Preparation of the Replacement Component

WARNING: USE PROTECTIVE GOGGLES AND GLOVES WHEN YOU REMOVE OR INSTALL LOCKWIRE. EACH TIME YOU CUT LOCKWIRE, REMOVE AND DISCARD IT IMMEDIATELY. LOOSE LOCKWIRE CAN CUT YOU OR MAKE YOU BLIND, AND/OR CAN CAUSE DAMAGE.

(1) Remove and discard the lockwire from the check valve (6) on the removed manifold (2).
(2) Remove the check valve (6).
(3) Remove and discard the packing (7).

WARNING: OBEY THE HYDRAULIC SAFETY PROCEDURES.

(4) Apply clean Phosphate Ester Hydraulic Fluid-General Power - - (Material No.02ABA1) to the new AIPC 32-44-03-06-050 PACKING (7) and the threads of the check valve (6).
(5) Install the packing (7) on the check valve (6).
(6) Remove the blanking plugs and install the check valve (4) in the new manifold (2).
(7) TORQUE the check valve (6) to between 11.35 and 11.24 m.daN (83.70 and 82.89 lbf.ft )

.
(8) Safety the check valve (6) to the plug (20) with 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.

Subtask 32-44-17-560-052-A ** ON A/C NOT FOR ALL

E. Preparation for Installation
(1) Clean the component interfaces and the adjacent area.
(2) Do an inspection of the component interfaces and the adjacent area.
(3) Make sure that the parts retained from the removed component are clean and in the correct condition.
(4) Obey the hydraulic safety procedures (Ref. AMM TASK 29-00-00-910-002).

WARNING: BE CAREFUL WHEN YOU USE CONSUMABLE MATERIALS. OBEY THE MATERIAL MANUFACTURER'S INSTRUCTIONS AND YOUR LOCAL REGULATIONS.

(a) Apply Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) to the bolts (10) and the washers (11).

WARNING: BE CAREFUL WHEN YOU USE CONSUMABLE MATERIALS. OBEY THE MATERIAL MANUFACTURER'S INSTRUCTIONS AND YOUR LOCAL REGULATIONS.

1 Apply Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) to the component interface.

Subtask 32-44-17-560-050-C ** ON A/C NOT FOR ALL

F. Preparation of the Replacement Component

(1) Remove and discard the lockwire from the check valve (4) on the removed manifold (10).
(2) Remove the check valve (4).
(3) Remove and discard the packing (5).
(4) Apply the hydraulic fluid:

WARNING: OBEY THE HYDRAULIC SAFETY PROCEDURES.

(a) Apply the clean Phosphate Ester Hydraulic Fluid-General Power - - (Material No.02ABA1) to the new AIPC 32-44-03-06-050 PACKING (5) or the new AIPC 32-44-83-08-140 PACKING (5) and the threads of the check valve (4).
(5) Install the packing (5) on the check valve (4).
(6) Remove the blanking plugs and install the check valve (4) in the manifold (10).
(7) TORQUE the check valve (4) to between 11.35 and 11.24 m.daN (83.70 and 82.89 lbf.ft )

.
(8) Safety the check valve (4) to the plug (9) with 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.

Subtask 32-44-17-560-052-B ** ON A/C NOT FOR ALL

G. Preparation for Installation
(1) Clean the component interfaces and the adjacent area.
(2) Do an inspection of the component interfaces and the adjacent area.
(3) Make sure that the parts retained from the removed component are clean and in the correct condition.
(4) Obey the hydraulic safety procedures (Ref. AMM TASK 29-00-00-910-002).
(5) Apply the special material and the sealant:

WARNING: BE CAREFUL WHEN YOU USE CONSUMABLE MATERIALS. OBEY THE MATERIAL MANUFACTURER'S INSTRUCTIONS AND YOUR LOCAL REGULATIONS.

(a) Apply the zinc chromate putty Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) to the bolts (7) and the washers (8).
(b) Apply the Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) between the manifold (10) and the aircraft structure.

4. Procedure
Subtask 32-44-17-420-051-B ** ON A/C NOT FOR ALL

A. Installation of the Brake Manifold 3016GM
(1) Put the manifold (2) in position and install the washers (11) and the bolts (10).
(2) Remove the PLUG-BLANKING from each disconnected line end.
(3) Connect the T-assembly (4) to the manifold (2).
(4) TORQUE the T-assembly (4) to between 5.9 and 5.4 m.daN (43.51 and 39.82 lbf.ft )

.
(5) Connect the elbow assembly (9) to the manifold (2).
(6) TORQUE the elbow assembly (9) to between 5.9 and 5.4 m.daN (43.51 and 39.82 lbf.ft )

.
(7) Connect the pipe (1) to the manifold (2).
(8) TORQUE the pipe (1) to between 1.3 and 1.2 m.daN (115.04 and 106.19 lbf.in )

.
(9) Connect the pipe (5) to the check valve (6).
(10) Connect the pipes (3) and (8) to the manifold (2).
(11) TORQUE the pipes (3), (5) and (8) to between 5.9 and 5.4 m.daN (43.51 and 39.82 lbf.ft )

.
(12) Apply paint to the pipe connectors:
(a) Put marks on the pipe connectors with Top Coat Polyurethane-- Decorative Furnishing (Material No.04JMD9)
(13) Make sure that the pipes (13), (15) and (16) are in the correct position in the bottom half of the clamp (17).
(14) Put the top half of the clamp (17) in position.
(15) Install the washers (18), the bolts (19), the washers (14) and the nuts (12).

Subtask 32-44-17-560-053-A ** ON A/C NOT FOR ALL

B. Installation of the Removed Components
(1) Install the pressure relief valve 3067GM (Ref. AMM TASK 32-44-15-400-001).
(2) Install the hydraulic pressure transducer 3068GN (Ref. AMM TASK 29-32-11-400-004).

Subtask 32-44-17-420-051-C ** ON A/C NOT FOR ALL

C. Installation of the Brake Manifold 3016GM
(1) Put the manifold (10) in position and install the washers (8) and the bolts (7).
(2) Remove the PLUG-BLANKING from each disconnected line end.
(3) Connect the T-assembly (2) to the manifold (10).
(4) TORQUE the T-assembly (2) to between 5.9 and 5.4 m.daN (43.51 and 39.82 lbf.ft )

.
(5) Connect the pipe (1) to the manifold (10).
(6) TORQUE the pipe (1) to between 5.9 and 5.4 m.daN (43.51 and 39.82 lbf.ft )

.
(7) Connect the pipe (3) to the check valve (4).
(8) Connect the pipe (6) to the manifold (10).
(9) TORQUE the pipes (3) and (6) to between 5.9 and 5.4 m.daN (43.51 and 39.82 lbf.ft )

.
(10) Identify the tightened union nuts with a red line
(Ref. AMM TASK 20-23-22-910-001).
(11) Make sure that the pipes (14), (17) and (18) are in the correct position in the bottom half of the clamp (13).
(12) Put the top half of the clamp (13) in position.
(13) Install the washers (12), the bolts (11), the washers (16) and the nuts (15).

Subtask 32-44-17-560-053-B ** ON A/C NOT FOR ALL

D. Installation of the Removed Components
(1) Install the pressure relief valve 3067GM (Ref. AMM TASK 32-44-15-400-001).
(2) Install the hydraulic pressure transducer 3068GN (Ref. AMM TASK 29-32-11-400-004).
(3) Install the selector valve 99GG (Ref. AMM TASK 32-43-51-400-001).

Subtask 32-44-17-860-052-A

E. Preparation for Test
(1) Connect the PTU isolation coupling (Ref. AMM TASK 29-23-00-860-002).
(2) Bleed the alternate brake system (Ref. AMM TASK 32-43-00-870-002).
(3) If necessary fill the reservoir of the Yellow hydraulic system to the correct level (Ref. AMM TASK 12-12-29-611-001).
(4) Open the right MLG door (Ref. AMM TASK 32-12-00-010-001).

Subtask 32-44-17-865-052-A

F. Remove the safety clip(s) and the tag(s) and close this(these) circuit breaker(s):

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C NOT FOR ALL
49VU	L/G/Y BRK/PRESS/IND	61GG	C10
** ON A/C NOT FOR ALL
49VU	ABCU &/Y BRK/PRESS IND	61GG	C10
** ON A/C NOT FOR ALL
121VU	HYDRAULIC/HYD POWER/Y	3803GX	N30
** ON A/C ALL
121VU	HYDRAULIC/BRAKING AND STEERING/SYS2/SPLY	4GG	M36
121VU	HYDRAULIC/BRAKING AND STEERING/SYS2/CTL	3GG	M35
121VU	HYDRAULIC/BRAKING AND STEERING/SYS1/CTL	1GG	M34
121VU	HYDRAULIC/BRAKING AND STEERING/SYS1/IND AND/SPLY	2GG	M33
121VU	HYDRAULIC/PARK BRK/CTL/STBY	71GG	N37
121VU	HYDRAULIC/PARK BRK/CTL/NORM	70GG	N36
121VU	HYDRAULIC/Y HYD/PUMP ENG2/MONG	3700GD	Q37
121VU	HYDRAULIC/Y HYD/PUMP ENG2/CTL	3701GD	Q36
** ON A/C NOT FOR ALL
121VU	HYDRAULIC/HYD POWER/Y	3803GX	N31
** ON A/C ALL
123VU	Y HYD/ELEC/PUMP	3802GX	AB06
123VU	Y HYD/ELEC/ELEC PUMP/NORM	3801GX	AB03

Subtask 32-44-17-710-050-A

G. Test
(1) Do an operational test of the alternate braking with anti-skid (Ref. AMM TASK 32-43-00-710-001).
(2) Make sure that there is no hydraulic fluid leakage from the brake manifold 3016GM.

NOTE: Leaks are not permitted.

5. Close-up
Subtask 32-44-17-410-050-A

A. Close Access
(1) Apply corrosion protection to the bolt heads, pipe connections and the adjacent areas (Ref. AMM TASK 51-75-13-916-002).
(2) Remove the container.
(3) Remove the WARNING NOTICE(S).
(4) Remove the access platform(s).
(5) Make sure that the work area is clean and clear of tools and other items.
(6) Close the right MLG door (Ref. AMM TASK 32-12-00-410-001).
(7) Remove the ground support and maintenance equipment, the special and standard tools and all other items.

[Rev.10 from 2021] 2026.04.01 07:51:22 UTC