Installation and Operating Manual TOST Aircraft Wheels
Contents
1. TB Rad 4 32 240 5TS 2a ES 5 HE Ss PERA O HA 260x85 3 00 4 4 6 A AAA 22021807 41800 2100 3300 S700 00 gt gt Ee EE q __Q_z_ a LRhrt L ri q o o 2 TB Rad 5 32 240 6TS 4a 760 6005 c O J T 2025 900 1400 2200 2640 3 50 5 5 00 5 350x135 380x150 6 003 E lt SS re 9 SB Rad aon 32 240 8TS 1a 20 25 soo 1400 ae O 5 AA A NA ABS 20 1 9005 214002 i Sa seral s 1322400018 da 2025 90 11300 1 N SB Rad 5 32 240978 4a 2025 900 1300 1750 2600 1 5 00 5 380x150 6 00 5 ei I 1 1 ab s085 1240 1850 2500 3700 4800 5 00 5 380x150 6 00 5 een I 40 3 1800 2700 3650 4800 1 5 00 5 380x150 6 00 5 iL I f aa awas 1240 1850 2500 3700 4800 5 00 5 380x150 6 00 5 ds EA A SS a PA OA A AAA PPP AI EA sinn 5 SB Rad _ 6 32 240 10TS 6 30 40 50 1400 2200 3500 6000 6 00 6 15x6 00 6 7 00 6 8 00 8 1 T J 5 30140150 1400 2200 3500 6000 _6 00 6 15x6 00 6 7 00 6 8 00 6 2 alle Lasten in daN op O ER Revision July 2003 Page 12 of 12 Issue December 19992. aircraft 10 Make sure that the wheel unit is mounted perfectly balanced to avoid vibration and excessive wear Note special instructions when mounting tires on very narrow wheels 9 3 Tire maintenance instructions 1 Maintain stipulated air pressure check at regular intervals Underpressure results in reduced load capacity and shortens service life 2 Inspect tires at regular intervals for damage shredding flat areas and foreign objects 3 Wheel units must be mounted perfectly balanced Wheel imbalance can result in damage to bearings and brake drums 4 Keep tires free of oil grease brake fluid and tar Clean tires with rag soaked with petrol then wash off with soap and water Caution Note on used inner tubes Aircraft tubes are made of natural rubber and they are slightly underdimensioned making them easier to install in new tires The layers of an aircraft tire are made of nylon and tend to stretch slightly with use The inner tube also increases in size adapting to the larger inside diameter of the tire If a tube enlarged in this way is later fitted in a new tire it may be too big for the tire with the result that the tube may wrinkle The wrinkles may rub through during operation causing the tube to lose pressure Rubbing through slowly results in gradual pressure loss the pilot is thus warned before a dangerous situation arises If the tube tears during a start the pilot will fail to notice that he is flyin
3. brake wheel in your efforts to achieve a pin point landing It is better to keep your brake in top condition for when you really need it 5 2 1 Brake shoes brake drum and brake linings Brake shoes are turned in pairs to the right diameter never replace a single brake shoe see above Replacement shoes are colour coded and must be fixed to the backing plate so that the mark is visible New brake shoes must be run in so make very careful use of the brake for the first 20 to 30 landings If brake linings glaze after prolonged or excessive use the braking action is significantly reduced clean scorched lining surface and brake drum with methylated spirits and emery paper Replace brake shoes when the lining is less than 1 5 mm thick at any point Warning Continued use of a brake shoe with a worn lining can damage the wheel You are strongly advised not to reline brake shoes 5 2 2 Adjustable brake lever When the brake lever is initially set or subsequently adjusted the nut must be tightened with the stipulated torque M 8x1 DIN 936 18t022 Nm M6 DIN 934 6to8 Nm Issue December 1999 Page 5 of 12 Revision July 2003 TOST GmbH FLUGZEUGGER TEBAU M NCHEN Operating manual Aircraft wheels Warning If the nut is not tightened properly the splined shaft could slip and damage the splines 5 2 3 Brake cables Ensure correct cable run as short and direct as possible but avoid
4. to 10 to 20 km h Allow brakes to cool for 10 to 15 min Work brakes and check whether the aircraft can be held with normal brake force when it has developed standing thrust at high motor rpm If yes the brake lining is conditioned run in If the aircraft cannot be held against the standing thrust repeat the procedure Issue December 1999 Page 7 of 12 Revision July 2003 TOST GmbH FLUGZEUGGER TEBAU M NCHEN Operating manual Aircraft wheels Gliders It takes 5 to 10 normally braked landings to condition the linings If you need maximum brake performance from the start brake the glider uniformly while towing it at 10 to 20 km h for about 500 m grass or 200 to 300 m runway Wear limits The total thickness of brake linings at any point must not be less than 2 5 mm for Cleveland or less than 1 5 for TOG disk brakes 5 3 3 Hydraulic hoses Do not twist hydraulic hoses as this may weaken them Twisted hydraulic hoses that are under pressure can work loose from their fittings When laying hydraulic hoses allow for sufficiently large bends to prevent pinching of the hose Pinching reduces the cross sectional area and impairs braking performance The life expectancy of a hydraulic hose is reduced significantly by small hose radii Use hoses made of steelflex if you cannot avoid tight bends Caution Hydraulic hoses laid horizontally should be inclined towards the rolling axis 6 Service instruction
5. 5 1 Landing wheels valid for all wheels 4 5 2 Shoe brake wheels 5 5 3 Disk brake wheels 6 6 Service instructions 8 7 Defects causes and remedies 9 8 Overhaul and check 10 9 Tire removal and replacement 10 Caution TOST aircraft wheels must only be used in accordance with the instructions and operating limits set out in this manual Once the wheel has been installed in the aircraft this manual must be added to the aircraft operating manual Issue December 1999 Page 2 of 12 Revision July 2003 TOST GmbH FLUGZEUGGER TEBAU M NCHEN Operating manual Aircraft wheels 1 General 1 1 Introduction This operating instruction manual is intended to provide pilots aircraft owners and workshop managers with the information needed for safe operation The manual includes all data that must be made available in connection with the technical specifications It also lists additional information and recommendations that in the view of the manufacturer may prove useful 1 2 Approval basis This aircraft wheel has been approved by the German aviation authority Luftfahrt Bundesamt on the basis of testing procedures for aircraft wheels and brakes dated 15 03 1956 alternatively TSO C26c requirements dated 28 12 1999 1 3 Warnings cautions notes There are three types of note in this manual and their importance for safe operation is defined as follows Warning Ignoring an instruction of this type res
6. TOST GmbH FLUGZEUGGER TEBAU M NCHEN Operating manual Aircraft wheels HST Installation and Operating Manual for TOST Aircraft Wheels Type Technical Series Serial number specification Landing wheel 32 240 TS Shoe brake wheel 32 240 TS Disk brake wheel 32 240 TS Technical Specification Issue 1 approved and registered by Luftfahrt Bundesamt 38020 Braunschweig Bundesrepublik Deutschland Braunschweig 28 12 99 signed Erckmann TOST GmbH Flugzeugger tebau M nchen Directors B D rflein e M D rflein P O Box 151924 e 80051 M nchen Germany Product organization EASA DE 21G 0065 Thalkirchner Strasse 62 80337 M nchen Company Register Munich No 59838 http www tost de e e mail info tost de EC Ident No DE 129481412 Issue December 1999 Page 1 of 12 Revision July 2003 TOST GmbH FLUGZEUGGER TEBAU M NCHEN 0 1 Document History Operating manual Aircraft wheels All changes to this operating manual must be recorded in the table below New or amended sections are identified by a vertical black line in the margin The revision number and the date are printed at the bottom left of the page Revision Section Revision Reference Approval Publication Reference number date date date Page s Signed 1 1 5 2002 May 02 Fenzl 0 2 Contents Section Page 1 General 3 2 Design 4 3 Operating limits 4 12 4 Installation note 4 5 Operating notes 4
7. ed through the bore it is impossible to put the bearings under strain by overtightening see above Note The spacer bush is visible through the bearing bore When you replace a wheel eg after changing a tire the bush should not be able to move axially If it can move this could mean that the inner tubing is being pinched or the wheel halves have not put been together correctly 5 Operating notes 5 1 Landing wheels valid for all wheels For all two part rims the two wheel halves are connected with high tensile DIN 912 M6 10 9 or better bolts Tighten bolts with a calibrated torque wrench 9 10 Nm Issue December 1999 Page 4 of 12 Revision July 2003 TOST GmbH FLUGZEUGGER TEBAU M NCHEN Operating manual Aircraft wheels Warning Do not use bolts of lower strength Always use a torque wrench The most frequent cause of bolt failure is tightening with too high a torque 5 2 Shoe brake wheels Shoe brake wheels are fitted with non servo brakes as the brake wrench turns the primary shoe is pressed outwards in the direction of rotation of the shoe the secondary shoe in the opposite direction The clutching effect on the primary shoe increases the contact pressure and results in a significantly higher braking action than for the secondary shoe This is the reason why the shoes wear differently Caution The brake wheel is designed for normal operation Do not use the
8. g with a flat tire This can result in extremely hazardous landing situations In view of the considerable risks involved in fitting an old tube into a new tire you are advised always to fit new inner tubes in new tires Issue December 1999 Page 11 of 12 Revision July 2003 Betriebsgrenzen Spezifikationen und zugeordnente Bereifungen zu 3 TL 50 S an rete Techn Spex Baureihe Lagor star Lastfeyn Last max Last Bruchiast m gliche Bereifung bei Breit es lo TT mm techn TBB mm OE Lauraa 3 32 240175 2a 20 200 30 2t0xw s co o A Jesse er 25 20 ee ee ee ee a 2 OR SO _ _ __ou _ P nme aa S a Laufrad 4 32 200278 2a 17 625 975 1540 2665 2 80 2 50 4 al S A A A bl 37607 a a 260x85 3 00 4 4 00 4 85 zus O I J Y 2c 2025 900 1400 2200 3800 6000 330x130 355x150 5 00 4 100 zus Se ee ee EEE ES SE SEA SEE GEE EEE Gee ee ee ee ea Laufrad 5 32 240 3TS 4a 17 760 1200 1900 3200 5 00 5 380x150 6 00 5 350x135 rT 1 J 20725 900 1300 1750 2600 5 00 5 380x150 6 00 5 350x135 1 rT 4c 20wsors5 1240 1850 2500 3700 4800 5 00 5 380x150 6 00 5 350x135 1 aE a EE ES SS BS ee ES nl Eee rn ILaufrad 6 32 240 4TS 5a 1400 2200 3500 6000 1 Sa en Ee A es lt er Ze NE EZ Lu SDSS WETS ae eS nun ere AA 5
9. h 5 mm hexagon key remove bolts and washers split hub halves 9 2 Replacement 1 Tires and wheel hubs must be clean and dry 2 Do not apply excessive force when replacing a wheel 3 4 Remove dirt sand labels etc from the tire Apply a moderate Apply a dehesive agent or talcum powder to the hub shoulder amount of talcum powder to reduce friction between tube and tire Caution Too much talcum has the opposite effect Fill air into tube tube placed in the tire until it is evenly round Remove nut and washer from valve Replace tire red mark at valve hole and tube on the wheel half with the valve hole push valve through valve hole Push other wheel part onto tire match bolt holes with centring shaft Insert wheel bolts washers and any nuts and tighten to the correct torque M6 9 to 10 Nm Tighten bolts diagonally Issue December 1999 Page 10 of 12 Revision July 2003 TOST GmbH FLUGZEUGGER TEBAU M NCHEN Operating manual Aircraft wheels 9 Place a tire in a safety cage when inflating it to mounting pressure for the first time If you do not have a safety cage take great care when inflating the tire Inflate the tire to mounting pressure The mounting pressure is 10 more than the specified operating pressure Check carefully for leaks Leave to adjust at this pressure for 12 to 24 hours Once the tire shows no leaks and is at operating pressure the wheel unit can be mounted on the
10. pect for damage Rigid hoses inhibit free movement Use flexible hoses Corroded brake plate bolts Clean and grease or replace Bent cracked brake plate Replace High wear of disk Locked brakes See above and lining Poor conditioning See page 7 Excessive rust grooves or Clean or replace holes in brake disk Incorrect linings or disk Replace by original parts Brake slips Contaminated or scorched Clean see page 7 or replace linings Poor conditioning See page 7 Linings or disk less than minimum thickness Replace see page 7 Insufficient brake pressure See above New linings installed on used disk Replace disk Issue December 1999 Page 9 of 12 Revision July 2003 TOST GmbH FLUGZEUGGER TEBAU M NCHEN Operating manual 8 Aircraft wheels Overhaul and check An overhaul is not stipulated annual check see Section 6 for capability test 9 Tire removal and replacement Warning Tires under pressure can be dangerous if they are not handled carefully and with the correct equipment 9 1 Removal an 1 Jack up aircraft at specified point 2 3 Do not unscrew the valve insert until the tire pressure has Deflate tire completely before removing the wheel unit dropped to 0 2 bar Remove wheel from axle Loosen wheel bead from the hub shoulder with a rubber or plastic hammer Undo wheel bolts wit
11. s Adjust shoe brakes regularly to compensate for the shoe wear Clean wheels regularly to ensure that all parts can move freely and to inhibit corrosion At the same time check wheels for corrosion cracks and visible damage also check the brake lining or disk for minimum thickness If you are flying in areas where airborne salt is a problem there may be corrosion The solution is to clean the brake wheel sandblast it and cover the damaged areas with clear varnish Issue December 1999 Page 8 of 12 Revision July 2003 TOST GmbH FLUGZEUGGER TEBAU M NCHEN 7 Defects causes and remedies Operating manual Aircraft wheels After a hard landing check wheel for damage Replace the ball bearings if you notice ball bearing noise Caution Also check the axis even 0 1 to 0 2 mm wobble can cause the brake to block and destroy the wheel Landing with a blocked wheel eg by activating the valve lever damages the brake and can destroy the brake plate Disk brakes Problem Possible cause Remedy Insufficient brake pressure or excessive travel Air in system Locate error bleed air Leaky system Locate and fix Defective master cylinder Repair or replace Brakes lock Piston jammed in cylinder Repair or replace Foreign object Remove Water in hydraulic system Evacuate and purge Piston does not return Evacuate remove piston and ins
12. s water this is the reason why old brake fluid has a corrosive effect Replace fluid once a year according to the manufacturer s stipulations 5 3 1 Brake disks Check brake disks for fracture excessive wear grooves corrosion and deformation Brake disks are given application specific surface treatment so they will be subject to varying amounts of rust Rust dust is removed from the disk by one or two parking brake operations In the event of more serious rusting it may be necessary to remove the disk from the wheel and to clean both brake surfaces properly First clean the disk with a wire brush then rub it off with sandpaper 220 grain Finally polish with fine sandpaper 400 grain This treatment may make it possible to continue using the brake disk Replace the brake disk if wear has progressed beyond the permissible limit Measure the minimum at two or three places Also replace the brake disk if the wobble is 2 0 2 mm Disk thickness Wear limit Application 3mm 2 6 Synthetic disk brake wheels 4mm 3 5 TOG brake calliper 5mm 4 3 Cleveland calliper 30 9 6 mm 5 2 Cleveland calliper 30 63A 6 5 mm 5 5 Dual brake calliper 30 41B 5 3 2 Brake linings Brake linings are made of asbestos free organic material For top performance and long service life this material must be correctly conditioned Powered aircraft Roll aircraft at 1700 motor rpm over a distance of 500 m braked down
13. tight radii Use a Bowden cable recommended cable Y 2 to 3 mm with adjusting screw for exact clearance adjustment Readjust brake cable depending on wear 5 3 Disk brake wheels TOST disk brake wheels are a combination of the proven landing wheels and brake disks turned from heat treated steel The special heat treatment ensures that these wheels achieve very high braking deceleration outstanding strength and minimal tendency to scoring Caution Modern high performance gliders are no longer equipped with skids applying full brake capacity could cause the aircraft s nose to make ground contact and damage the underside of the aircraft We can supply TOG fixed yoke disk brakes or a range of floating yoke disk brakes from Cleveland Caution Floating yoke disk brakes must move freely in order to operate correctly check bolts regularly for corrosion and contamination The brake callipers are fastened to a torque plate and backing plate or a combination of both type dependent For pressure transfer use either hydraulic fluid MIL H 5606 or DOT 4 brake fluid in TOG brake callipers and Cleveland callipers identified by Issue December 1999 Page 6 of 12 Revision July 2003 TOST GmbH FLUGZEUGGER TEBAU M NCHEN Operating manual Aircraft wheels Caution Use only the fluid approved for your aircraft s brake system DOT 4 brake fluid is strongly hygroscopic ie it absorb
14. ults in either immediate danger or considerable risk to flight safety Caution Ignoring an instruction of this type leads to a minor or a more or less long term reduction of flight safety Note This heading draws attention to an item which is important or unusual although it may not be directly related to safety Issue December 1999 Page 3 of 12 Revision July 2003 TOST GmbH FLUGZEUGGER TEBAU M NCHEN Operating manual Aircraft wheels 2 Design TOST aircraft wheels except tail wheels consist of two parts for easier assembly and are die cast from a light metal alloy Special heat treatment increases the strength and improves the alternating flexural strength for optimal endurance The rim flange with integrated segment chambers serves as a crumple zone in the event of overloading load peaks are dissipated but the emergency rolling characteristics remain unaffected The coefficient of friction is improved by casting perlitic brake rings into shoe brake wheels The ball bearings with sealing rings are maintenance free tension of the bearings is prevented through the use of spacer bushes Each wheel is embossed with the manufacturer logo and serial number and also displays the specification and part number on a stick on label 3 Operating limits cf table on page 12 4 Installation note TOST aircraft wheels are all installed without axial tension The hollow axle is simple push
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