To All Holders of Hamilton Sundstrand'S Component Maintenance Manual 21-32-20 Applicability: Emb135, Emb145 This Sheet Transmits Revision No. 4 Date Aug 29/07 Highlights

COMPONENT MAINTENANCE MANUAL
816601
TO ALL HOLDERS OF HAMILTON SUNDSTRAND’S

COMPONENT MAINTENANCE MANUAL 21-32-20
APPLICABILITY: EMB135, EMB145
THIS SHEET TRANSMITS REVISION NO. 4 DATE AUG 29/07
HIGHLIGHTS
We recommend that you put this revision into your manual without delay. After you have put the
revised pages in your manual, mark the Record of Revisions sheet with the new revision number and
date, and write the date that you insert the revised pages into your manual and your initials on the
Record of Revisions sheet in the appropriate spaces.
The revised pages of this manual were reprinted. Please replace these pages of your manual with
the pages of this revision. General format and layout changes were made in addition to these
technical changes:
If you have questions about this manual, you can contact Technical Publications by email at
mailto:tech.pubs@hs.utc.com or fax at (860) 660-9014.
The changes made to the manual during this revision are described in the table that follows:
Change Driver
Page Description of Change
References
All Affected Pages Revised the special tools and consumable Non-technical change;
materials notes. no substantiation data
required.
SBL-1 Added Service Bulletin 21-2197. IH-07726-124433
SB 21-2197
1001 Revised paragraph 1.A.(4) and added paragraph Non-technical change;
1.A.(5). no substantiation data
required.
1003 Added the definition of REFER TO SB XX. Non-technical change;
no substantiation data
required.
1011 Added Service Bulletin 21-2197 reference to item IH-07726-124433
110. SB 21-2197
1021 Added Change Code 3. IH-07726-124433
SB 21-2197
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THIS IS A BLANK PAGE
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HIGH-STAGE BLEED VALVE
PART NUMBER:
816601-1
© 1996, 1997, 2000, 2003, 2007 Hamilton Sundstrand Corporation

PROPRIETARY
THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN ARE THE PROPERTY OF HAMILTON SUNDSTRAND CORPORATION (HSC).
RECIPIENT AGREES TO HOLD ALL SUCH INFORMATION IN CONFIDENCE AND AGREES IT SHALL BE USED ONLY FOR RECIPIENT’S INTERNAL
PURPOSES TO MAINTAIN RECIPIENT’S EQUIPMENT OR AS MAY OTHERWISE BE PERMITTED IN AN APPLICABLE AGREEMENT BETWEEN
RECIPIENT AND HSC. THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN SHALL NOT BE USED FOR ANY OTHER PURPOSE,
INCLUDING THE CREATION, MANUFACTURE, DEVELOPMENT, OR DERIVATION OF ANY REPAIRS, MODIFICATIONS, SPARE PARTS, DESIGN, OR
CONFIGURATION CHANGES, OR TO OBTAIN FAA OR ANY OTHER GOVERNMENT OR REGULATORY APPROVAL FOR SAME. RECIPIENT AGREES
NOT TO DISCLOSE SUCH INFORMATION TO ANY THIRD PARTY, EXCEPT AS MAY OTHERWISE BE PROVIDED FOR IN AN APPLICABLE AGREEMENT
BETWEEN RECIPIENT AND HSC. COPYING OR DISCLOSURE OF THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN BY ANYONE
WITHOUT HSC’S PRIOR WRITTEN PERMISSION IS NOT AUTHORIZED AND MAY RESULT IN CRIMINAL AND/OR CIVIL LIABILITY.
Information Subject to Export Control Laws

Export Permitted Under NLR.
The data in this document were developed only to maintain systems and/or parts manufactured by or for Hamilton Sundstrand or approved
by Hamilton Sundstrand. The data may not be applicable to any other systems and/or parts, regardless of their apparent similarity to
systems and/or parts manufactured by or for Hamilton Sundstrand or approved by Hamilton Sundstrand. Do not rely in any way on data in
this document to maintain or otherwise support systems and/or parts that were not manufactured by or for Hamilton Sundstrand or
approved by Hamilton Sundstrand without evidence that the Federal Aviation Administration or other regulatory agency has determined
that the data in this document is valid for such use.

WITH
ILLUSTRATED PARTS LIST
Page T-1
Basic Issue: Oct 30/96
CAGE Code: 73030 21-32-20 Revision 4 Aug 29/07
816601
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SAFETY SUMMARY
1. Scope
A. This publication describes processes that may require the use of chemicals, solvents,
paints, or other materials that can affect a person’s health or safety. It may also cover
high energy procedures that can affect a person’s health or safety. Warnings are placed
just ahead of these procedures to bring attention to the existence of a procedure or
material that can be dangerous.
2. Significance of Material Safety Data Sheets (MSDS) and How to Obtain MSDS
WARNING: BEFORE USING ANY OF THE MATERIALS SPECIFIED IN HAMILTON
SUNDSTRAND MAINTENANCE PUBLICATIONS, BE AWARE OF ALL
HANDLING, STORAGE, AND DISPOSAL PRECAUTIONS RECOMMENDED
BY THE MANUFACTURER OR SUPPLIER. FAILURE TO COMPLY WITH
MANUFACTURER’S OR SUPPLIER’S RECOMMENDATIONS MAY RESULT
IN PERSONAL INJURY OR DISEASE.
THE USER OF THIS PUBLICATION SHOULD OBTAIN THE MATERIAL

SAFETY DATA SHEETS (OCCUPATIONAL SAFETY AND HEALTH ACT
(OSHA) FORM 20 OR EQUIVALENT) FROM THE MANUFACTURERS OR
SUPPLIERS OF MATERIALS TO BE USED. THE USER MUST BECOME
COMPLETELY FAMILIAR WITH THE MANUFACTURER OR SUPPLIER
INFORMATION AND ADHERE TO THE PROCEDURES,
RECOMMENDATIONS, WARNINGS, AND CAUTIONS OF THE
MANUFACTURER OR SUPPLIER FOR THE SAFE USE, HANDLING,
STORAGE, AND DISPOSAL OF THESE MATERIALS.
A. Refer to the materials list at the beginning of each section of this manual for materials
used to repair and maintain the covered equipment.
B. If you do not have a copy of the manufacturer’s MSDS for the materials covered in the
materials list, contact the manufacturer and request that a MSDS be supplied before you
use the material.
3. Purpose
A. The warnings bring your attention to the existence of a procedure that can affect a
person’s health or safety.
B. Short warnings are provided in this maintenance publication to alert operating and
maintenance personnel of potential hazards that could result in personal injury or health
hazards. The warnings do not replace the manufacturer’s recommendations. When
there is a reference to the Warnings Registry 341-006, that publication will provide more
information about the dangers of the material. The information contained in the
Warnings Registry is a summary of the manufacturer’s MSDS. The full-length warnings
provide three principle parts of safety: (1) a listing of the known dangers, (2) what is
needed to do to protect you from the dangers, and (3) what to do if the dangers occur.
C. The detailed warnings in Warnings Registry 341-006 are a summary of the
manufacturer’s MSDS and are not intended to replace the material on the sheet, but are
intended to supplement them.
Page SA-1
21-32-20 Aug 1/03
816601
D. Cautions are provided in the maintenance publication or service bulletin to alert

operating and maintenance personnel to conditions that could result in equipment
damage.
4. Definitions Applying to Warnings
A. Flammable: a material that can catch fire easily and can be explosive. These materials
are labeled according to the flash point of the material.
B. Flash Point: the lowest temperature at which a flammable liquid gives off fumes that can
burn.
C. Ignition Source: includes flames, sparks, or heat.
(1) Flames: materials that are burning such as lit matches, propane torches, or pilot
lights.
(2) Sparks: materials such as lighted cigarettes, electrical motors, or static electricity.
(3) Heat: any source of energy that will raise the temperature of a flammable material to
its flash point and could include hot parts, heated tools, or direct sunlight.
D. Corrosive: acidic or alkaline material that will remove human tissue or create chemical
reactions with other materials.
E. Toxic: material that is poisonous.
F. Reactive: material that will make fumes, burn, or can be explosive when mixed with
certain other materials.
G. Shock (Electrical): the result of any source of electricity more than 50 volts that causes
current to flow through a person and can result in dangerous burns to human tissues or
death.
H. Exposure: contact with the material or physical process without protection. Contact may
be by the eyes, breathing, touch, skin absorption, or swallowing.
I. Irritation: any sense of pain, soreness, rash, or general discomfort.
5. Reporting Materials or Processes Not Covered
A. Please call Bruce D. Gulick, (815) 226-6000, FAX: (815) 966-8525, or write to Hamilton
Sundstrand, Technical Publications, Department 768, 4747 Harrison Avenue, P.O. Box
7002, Rockford, IL 61125-7002, if you find a material in a Hamilton Sundstrand
maintenance document that is known to be covered by a material data safety sheet
(MSDS) but is not covered by a warning in the procedure.
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816601
RECORD OF REVISIONS
BASIC ISSUE: Oct 30/96
REV. ISSUE DATE REV. ISSUE DATE

NO. DATE INSERTED BY NO. DATE INSERTED BY
1 Oct 30/97
2 Jan 15/00 Jun 27/03 HS
3 Aug 1/03 Sep 4/03 HS
4 Aug 29/07 Aug 30/07 HS
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RECORD OF TEMPORARY REVISIONS
REV. ISSUE DATE DATE

NO. DATE INSERTED BY INCORPORATED
Page RTR-1
21-32-20 Jan 15/00
816601
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816601
SERVICE BULLETIN LIST
DATE
SERVICE BULLETIN ISSUE DATE INCORPORATED
21-2197 Jul 17/02 Aug 29/07
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21-32-20 Jan 15/00
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LIST OF EFFECTIVE PAGES
Subject Page Date Subject Page Date
Title Page T-1 Aug 29/07 Testing and 115 Aug 1/03
T-2 Aug 1/03 Trouble-Shooting Continued 116 Aug 1/03
Safety Summary SA-1 Aug 1/03 Disassembly 301 Aug 29/07
SA-2 Aug 1/03 302 Jan 15/00
Record of Revisions RR-1 Jan 15/00 303 Jan 15/00
RR-2 Jan 15/00 304 Jan 15/00
305 Jan 15/00
Record of Temporary RTR-1 Jan 15/00 306 Jan 15/00
Revisions RTR-2 Jan 15/00 307 Jan 15/00
Service Bulletin List SBL-1 Aug 29/07 308 Jan 15/00
SBL-2 Jan 15/00 309 Jan 15/00
List of Effective Pages LEP-1 Aug 29/07 310 Jan 15/00
LEP-2 Aug 29/07 311 Jan 15/00
312 Jan 15/00
Table of Contents T/C-1 Aug 29/07
T/C-2 Aug 1/03 Cleaning 401 Aug 29/07
402 Aug 1/03
List of Figures LOF-1 Aug 29/07
LOF-2 Aug 29/07 Check 501 Jan 15/00
502 Jan 15/00
List of Tables LOT-1 Aug 29/07 503 Jan 15/00
LOT-2 Aug 1/03 504 Jan 15/00
Introduction INTRO-1 Jan 15/00 505 Jan 15/00
INTRO-2 Jan 15/00 506 Jan 15/00
Description and 1 Jan 15/00 507 Jan 15/00
Operation 2 Jan 15/00 508 Jan 15/00
3 Jan 15/00 509 Jan 15/00
4 Jan 15/00 510 Jan 15/00
5 Jan 15/00 511 Jan 15/00
6 Jan 15/00 512 Jan 15/00
513 Jan 15/00
Testing and 101 Aug 29/07 514 Jan 15/00
Trouble-Shooting 102 Aug 29/07 515 Jan 15/00
103 Aug 29/07 516 Jan 15/00
104 Aug 1/03 517 Jan 15/00
105 Aug 1/03 518 Jan 15/00
106 Aug 1/03
107 Aug 1/03 Repair-General 601 Aug 29/07
108 Aug 1/03 602 Aug 29/07
109 Aug 1/03 603 Aug 29/07
110 Aug 1/03 604 Jan 15/00
111 Aug 1/03 Repair 1-1 601 Aug 1/03
112 Aug 1/03 602 Aug 1/03
113 Aug 1/03 Repair 2-1 601 Jan 15/00
114 Aug 1/03 602 Jan 15/00
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Subject Page Date Subject Page Date

Repair 3-1 601 Jan 15/00 Illustrated Parts List 1019 Aug 1/03
602 Jan 15/00 (Continued) 1020 Aug 1/03
Repair 3-2 601 Jan 15/00 1021 Aug 29/07
602 Jan 15/00 1022 Aug 1/03
Assembly 701 Aug 29/07
702 Aug 1/03
703 Aug 1/03
704 Aug 1/03
705 Aug 1/03
706 Aug 1/03
707 Aug 1/03
708 Aug 1/03
709 Aug 1/03
710 Aug 1/03
711 Aug 1/03
712 Aug 1/03
713 Aug 1/03
714 Aug 1/03
715 Aug 1/03
716 Aug 1/03
717 Aug 1/03
718 Aug 1/03
719 Aug 1/03
720 Aug 1/03
721 Aug 1/03
722 Aug 1/03
723 Aug 1/03
724 Aug 1/03
Fits and Clearances 801 Jan 15/00
802 Jan 15/00
Special Tools, Fixtures, 901 Aug 29/07
and Equipment 902 Jan 15/00
Illustrated Parts List 1001 Aug 29/07
1002 Aug 29/07
1003 Aug 29/07
1004 Aug 29/07
1005 Aug 1/03
1006 Aug 1/03
1007 Aug 1/03
1008 Aug 1/03
1009 Aug 1/03
1010 Aug 1/03
1011 Aug 29/07
1012 Aug 1/03
1013 Aug 1/03
1014 Aug 1/03
1015 Aug 1/03
1016 Aug 1/03
1017 Aug 1/03
1018 Aug 1/03
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816601
TABLE OF CONTENTS
Subject Page
SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-1
1. Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-1
2. Significance of Material Safety Data Sheets (MSDS) and How to Obtain MSDS. SA-1
3. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-1
4. Definitions Applying to Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-2
5. Reporting Materials or Processes Not Covered . . . . . . . . . . . . . . . . . . . . . . . . . . SA-2
RECORD OF REVISIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RR-1
RECORD OF TEMPORARY REVISIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .RTR-1
SERVICE BULLETIN LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SBL-1
LIST OF EFFECTIVE PAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEP-1
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T/C-1
LIST OF FIGURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOF-1
LIST OF TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOT-1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRO-1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Description (Refer to Figure 1 and Figure 2.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Operation (Refer to Figure 3 and Figure 4.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TESTING AND TROUBLE-SHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2. Dielectric Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3. Insulation Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4. Proof Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5. Leakage Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
6. Performance Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
7. Tests to do Again if the Valve is Disassembled . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
8. Trouble-shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
2. Disassembly of the Electrical Group (Refer to Figure 301). . . . . . . . . . . . . . . . . . . 302
3. Disassembly of the Actuator Linkage Group (Refer to Figure 302). . . . . . . . . . . . . 304
4. Disassembly of the Lock and Filter Group (Refer to Figure 303).. . . . . . . . . . . . . . 306
5. Disassembly of the Valve Group (Refer to Figure 304). . . . . . . . . . . . . . . . . . . . . . 308
6. Disassembly of the Actuator Housing (Refer to Figure 305). . . . . . . . . . . . . . . . . . 310
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Specific Cleaning Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
2. Spring Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
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Subject Page
REPAIR-GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Replace the Screw Thread Inserts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
3. Replace the Identification Plate (60, IPL Figure 1). . . . . . . . . . . . . . . . . . . . . . . . . 604
4. Special Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
CONNECTOR - REPAIR 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Replace the Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
VALVE HOUSING-REPAIR 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Replace the Plain Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
ACTUATOR HOUSING-REPAIR 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Replace the Split Bushing (10, IPL Figure 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
ACTUATOR HOUSING-REPAIR 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Replace the Studs (Refer to Figure 601) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
2. Actuator Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
3. Assemble the Valve Group (Refer to Figure 701). . . . . . . . . . . . . . . . . . . . . . . . . . 704
4. Install the Valve Group (Refer to Figure 703). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710
5. Install the Locking Screw (Refer to Figure 704). . . . . . . . . . . . . . . . . . . . . . . . . . . 712
6. Install the Air Filter (Refer to Figure 705). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714
7. Assemble the Actuator (Refer to Figure 706). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716
8. Install the Electrical Group (Refer to Figure 707). . . . . . . . . . . . . . . . . . . . . . . . . . 720
9. Calibration and Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 723
10. Completion of Assembly After Calibration and Test. . . . . . . . . . . . . . . . . . . . . . . . 723
11. Installation of the Identification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 723
12. Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 723
FITS AND CLEARANCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Fits and Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Assembly Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
1. Special Tools, Fixtures, and Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901
ILLUSTRATED PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
2. Numerical Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1007
3. Detailed Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1009
4. Configuration Change Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1021
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LIST OF FIGURES
Figure Page
Figure 1. High-Stage Bleed Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 2. High-Stage Bleed Valve (External View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 3. Mechanical/Pneumatic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 4. Electrical Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 101. Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Figure 102. Proof Pressure Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Figure 103. Internal Leakage Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Figure 104. Leakage Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Figure 105. External Leakage Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Figure 106. Minimum and Maximum Pressure Operation Test Setup . . . . . . . . . . . . . 115
Figure 301. Electrical Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Figure 302. Actuator Linkage Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Figure 303. Lock and Filter Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Figure 304. Valve Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Figure 305. Actuator Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Figure 501. Actuator Cover and Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
Figure 502. Pull Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
Figure 503. Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
Figure 504. Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
Figure 505. Piston Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
Figure 506. Piston Ring-Helix, Wear and Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
Figure 507. Piston Ring-Wear Pattern and Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
Figure 508. Disc and Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
Figure 509. Locking Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
Figure 510. Linkage Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
Figure 511. Valve Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
Figure 512. Butterfly Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
Figure 513. Seal Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
Figure 514. Valve Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
Figure 601. Connector Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair 1-1 601
Figure 601. Install the Plain Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair 2-1 601
Figure 601. Replace the Split Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair 3-1 602
Figure 601. Actuator Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair 3-2 602
Figure 701. Valve Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 705
Figure 702. Measure the Dimensions Necessary to Calculate the Thickness
of the Shims That Hold the Valve Shaft in Position . . . . . . . . . . . . . . . . . . 706
Figure 703. Install the Valve Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711
Figure 704. Install the Locking Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713
Figure 705. Install the Air Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715
Figure 706. Assemble the Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 717
Figure 707. Install the Electrical Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721
Figure 708. Positions of the Insulation Sleeving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 722
Page LOF-1
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816601
Figure Page
Figure 901. Crimping Tool M22520/1-01
Turret Head AssemblyM22520/1-04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
Figure 902. Insertion/Removal Tool M81969/14-02. . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
IPL Figure 1. High-Stage Bleed Valve (Electrical Group). . . . . . . . . . . . . . . . . . . . . . . . 1010
IPL Figure 2. Actuator Linkage Group
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1012
IPL Figure 3. Lock and Filter Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1014
IPL Figure 4. Valve Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1016
IPL Figure 5. Actuator Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1018
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816601
LIST OF TABLES
Table Page
Table 101. Special Tools, Fixtures, and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 102. Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Table 103. Test To Be Done Again . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Table 104. Trouble-Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Table 401. Cleaning Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Table 501. Special Checks for the Electrical Connector, Identification Plate,
and Actuator Cover and Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
Table 502. Special Checks for the Pull Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
Table 503. Special Checks for the Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
Table 504. Special Checks for the Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
Table 505. Special Checks for the Piston Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
Table 506. Special Checks for the Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
Table 507. Special Checks for the Link Retainer, Link Connector,
Sleeve Bushing, Air Filter, Actuator Housing,
and the Disc and Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
Table 508. Special Checks for the Locking Crank. . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
Table 509. Special Checks for the Linkage Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
Table 510. Special Checks for the Valve Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
Table 511. Special Checks for the Butterfly Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
Table 512. Special Checks for the Seal Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
Table 513. Special Checks for the Valve Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
Table 514. Spring Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
Table 601. Special Tools, Fixtures, and Equipment . . . . . . . . . . . . . . Repair-General 601
Table 602. Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair-General 602
Table 702. Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
Table 703. Thicknesses Of The Plain Solid Disks That Set The Butterfly Disc
In The Center Of The Valve Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708
Table 801. Fits And Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Table 802. Assembly Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
IPL Table 1. Configuration Change Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1021
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INTRODUCTION
1. This Component Maintenance Manual gives the maintenance instructions for the
High-Stage Bleed Value PN 816601-1. The maintenance instructions include tests which
show if the unit is serviceable. There are also procedures to repair or replace parts which
are not serviceable.
2. This manual was written by the Customer Support Department of Hamilton Sundstrand,
a United Technologies Company, One Hamilton Road, Windsor Locks, CT 06096-1010.
This manual includes:
• Title Page
• Record of Revisions
• Record of Temporary Revisions
• Service Bulletin List
• List of Effective Pages
• Table of Contents
• List of Figures
• List of Tables
• Introduction
• Description and Operation
• Testing and Fault Isolation Procedures
• Disassembly and Assembly Procedures
• Cleaning, Check, and Repair Procedures
• Fits and Clearances, and Special Tools, Fixtures, and Test Equipment
• Ilustrated Parts List
3. Refer to the Table of Contents to find the applicable section. The Repair section includes a
list of the repair procedures.
4. The Introduction of the Illustrated Parts List tells how to use the Illustrated Parts List.
5. The unit has an identification plate which shows the:
• Part Name, which identifies the unit with words
• Part No., which identifies the unit with a number
• Serial No., which identifies each unit
• HS Ref, which identifies the parts list used for the initial assembly of the unit
• Mod Data, which identifies the engineering changes which were made to the unit.
Numbers in this block can be divided by slashes (/) or dashes(-). For example, L5-8/
10-11 shows that changes L5 thru L8 and L10 and L11 were made. The L9 change was
not made.
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816601
6. All measured quantities in this manual are given in English units with metric equivalents in
parentheses ().
7. Verification: Testing and Troubleshooting Verified by simulation
Disassembly Verified by simulation
Assembly Verified by simulation
8. Abbreviations and Acronyms:
°C Degrees Centigrade Pvi Valve inlet pressure
cps Cycles per second °R Degrees Rankine
°F Degrees Fahrenheit rms Root mean square
ma Milliamperes Tc Calibrated flowmeter temperature
ppm Pounds per minute Tfm Flowmeter temperature
Pamb Ambient pressure vac Alternating current voltage
Pc Calibrated flowmeter pressure vdc Direct current voltage
Pfm Flowmeter pressure Wfm Measured flow from the flowmeter
psia Pounds per square inch absolute Wfmc Corrected flow
psig Pounds per square inch gage
Page INTRO-2
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816601
DESCRIPTION AND OPERATION

1. Description (Refer to Figure 1 and Figure 2.)
A. There are two high stage bleed valves, one for each bleed system.
B. The high-stage bleed valve opens to let engine high-pressure bleed air supply the
environmental control system (ECS).
C. The high-stage bleed valve is a butterfly type valve. It operates pneumatically. It also has
an enclosed position switch, a pull solenoid and a pneumatic actuator.
D. The butterfly valve has a shaft and disc set installed in the valve housing. The valve
shaft is connected to the actuator by a crank and linkage.
E. The pull solenoid has a plunger that operates a ball shutoff valve in the servo air supply
of the actuator housing.
F. The servo air on the upstream side of the valve goes through a filter to the guide piston.
The air then goes through the ball shutoff valve to the diaphragm and piston.
G. The actuator has a piston that moves in the bore of the actuator housing. It also has a
rider plate that moves in the bore of the actuator cover. There is a diaphragm between
these to prevent leakage. A linkage connects the actuator to the butterfly valve.
H. The closed position switch is attached to the actuator housing.
I. The lock plug is installed in the actuator housing.
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816601
Figure 1. High-Stage Bleed Valve
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816601
Figure 2. High-Stage Bleed Valve (External View)
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816601
2. Operation (Refer to Figure 3 and Figure 4.)

A. The high-stage bleed valve opens to let engine high-pressure into the ECS when the
high pressure bleed air pressure is less than 43 to 48 psig.
B. When the unit gets a 28 vdc electrical signal, the pull solenoid energizes and the ball
valve opens. This pressurizes the larger surface area of the servo actuator. This
pressure pushes against the pressure on the smaller surface of the servo actuator and
the spring pressure and moves the valve to a more open position.
C. When the 28 vdc electrical signal is not on, the pull solenoid goes off and the ball shutoff
valve closes. The pressure on the larger side of the servo actuator bleeds to ambient
and the valve closes.
D. The valve shaft moves an actuator arm when the valve opens or closes. The actuator
arm operates the closed position switch. The switch energizes an indicator when the
valve is closed.
E. You can lock the valve in the closed position with the lock plug as follows:
(1) Remove the locking screw from the actuator housing. It has a retaining cable.
(2) Turn the valve to the closed position. The locking crank has a hex head so you can
put a wrench on it to turn the valve.
(3) Install the locking screw in the hole in the actuator housing that is nearest to the
locking crank. This will lock the valve in the closed position.
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816601
Figure 3. Mechanical/Pneumatic Diagram
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Figure 4. Electrical Diagram
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816601
TESTING AND TROUBLE-SHOOTING

1. General
A. These conditions are applicable during the tests unless the instructions show differently.
(1) Temperature: Air temperature between 50 and 120 °F (10 to 48.9 °C).
(2) Pressure: ambient air pressure
(3) Humidity: No specification
(4) Gas: Clean, filtered, dry air between 50 and 120 °F (10 to 48.9 °C). The maximum
pressure must be 360 psig.
(5) Power Supply:
(a) 28 ±1 vdc (25 watts) to energize the solenoid
(b) 500 ±50 vac rms at 50 to 60 cps for the dielectric test
(c) 500 ±50 vdc for the insulation resistance test.
B. The special tools, fixtures, and equipment necessary to do the tests are specified in
Table 101.
NOTE: Equivalent tools, fixtures, and equipment can be used if they agree with the
requirements of ARINC Report 668.
NOTE: Unless otherwise specified, the items specified are available from: Hamilton
Sundstrand, a United Technologies Company, One Hamilton Road, Windsor
Locks, CT 06096-1010.
Table 101. Special Tools, Fixtures, and Equipment
TOOL NO. NAME USE
GS20985-1 Pressure Test Cap Cap the valve inlet and outlet
(2 required) flanges during proof pressure
and leakage testing.
GS21162-2 Microswitch Cable Assembly Adapt between the timing test
box, GS22907-1, and the
timing test adapter
GS24193-1, during operational
test.
GS22907-1 Timing Test Box Measures and records the
valve actuation time.
GS24192-1 Timing Test Cable Adapt between the timing test
valve electrical connector
during operational test.
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Table 101. Special Tools, Fixtures, and Equipment (Continued)
TOOL NO. NAME USE
GS24193-1 Timing Test Adapter Adapt between the timing test

cable, GS24192-1, and the
timing test box GS22907-1,
GS24194-1 Protractor Measure the valve angle
during testing.
GS24195-1 Position Switch Test Box Do a functional test on the
position switch.
C. The test equipment necessary to do the tests to the unit are specified in Table 102.
Table 102. Test Equipment
EQUIPMENT PARAMETER MINIMUM RANGE PRECISION
Flowmeter WFM 0.1 to 1.0 ppm at ±2% of full scale

14.7 psia and
50 to 120 °F
(10 to 48.9 °C)
Flowmeter WFM 0.01 to 0.10 ppm at ±2% of full scale
40 psig and
50 to 120 °F
(10 to 48.9 °C)
Milliammeter - 0 to 0.5 ma ±1 ma
Ohmmeter - 1 to 100 megohms ±20 megohms
Pressure Gage PFM 0 to 100 psig ±1 psig
Pressure Gage PVI 0 to 11 psig ±0.5 psig
Pressure Gage PVI 0 to 62 psig ±1 psig
Pressure Gage PVI 0 to 250 psig ±5 psig
Pressure Gage PVI 0 to 456 psig ±2.5 psig
Quadrant and Pointer - 0 to 90° ±1°

Thermocouple and TFM 50 to 120 °F ±5 °F
Readout (10 to 48.9°C) (2.8 °C)
Timer - 0 to 120 seconds ±0.1 second
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Table 102. Test Equipment (Continued)
EQUIPMENT PARAMETER MINIMUM RANGE PRECISION
Voltmeter - 0 to 550 vac ±20 vac

Voltmeter - 0 to 30 vdc ±1 vdc
D. You can do the tests in any sequence, but you must do the dielectric test (when
necessary), insulation resistance test, and proof pressure test before the other tests.
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2. Dielectric Test
CAUTION: DO A DIELECTRIC TEST ONLY IF THE SOLENOID OR THE ENVIRONMENT
FREE SWITCH IS REPLACED.
CAUTION: DO NOT USE MORE THAN 500 VAC TO DO THE TEST. THIS WILL HELP
TO PREVENT DAMAGE TO THE ELECTRICAL COMPONENTS.
A. Attach the pins A, B, C, D, E, F together in one group. Attach the ground clamp to the
solenoid case. Refer to Figure 101 for the pin identification.
B. Connect the pin group to a 500 ±50 vac rms, 50 to 60 cps, power supply. The valve
chassis must be electrically isolated from the power supply. The valve can be in any
position when you do the test.
C. Connect an ac milliammeter in series between the power supply and the pin group.
CAUTION: APPLY AND REMOVE THE VOLTAGE AT A CONSTANT RATE OF 250 TO
500 VOLTS PER SECOND. DO THIS UNTIL YOU GET THE SPECIFIED
VOLTAGE. THIS HELPS TO PREVENT DAMAGE TO THE ELECTRICAL
COMPONENTS.
D. Apply 500 ±50 vac between the connector pin group and the solenoid case. Do this for a
minimum of 1 minute. There must be no electrical failure, sparks, flashover, or current
leakage more than 0.5 ma.
E. Decrease the voltage to zero.
3. Insulation Resistance Test
A. Attach the pins A, B, C, D, E, F together in one group. Attach the ground clamp to the
solenoid case. Refer to Figure 101 for the pin identification.
B. Connect the pin group to a 500 ±50 vdc power supply. The valve chassis must be
electrically isolated from the power supply. The valve can be in any position when you do
the test.
C. Connect an ohmmeter between the pin group and the solenoid case.
CAUTION: APPLY AND REMOVE THE VOLTAGE AT A CONSTANT RATE OF 250 TO
500 VOLTS PER SECOND. DO THIS UNTIL YOU GET THE SPECIFIED
VOLTAGE. THIS HELPS TO PREVENT DAMAGE TO THE ELECTRICAL
COMPONENTS.
D. Apply 500 ±50 vdc between the connector pin group and the solenoid case. Measure the
insulation resistance. The resistance must be greater than 20 megohms.
E. Decrease the voltage to zero.
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816601
Figure 101. Wiring Diagram
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816601
4. Proof Pressure Test

WARNING: PUT THE VALVE IN A SAFE CHAMBER DURING THE PROOF PRESSURE
TEST. THIS HELPS TO PREVENT INJURY.
NOTE: Do the proof pressure test only when the actuator housing, butterfly disc or valve
housing is replaced.
A. Do a proof pressure test of the valve body and actuator supply chamber as follows:
(1) Install the valve in the test setup shown in Figure 102.
(2) Make sure the solenoid (120, IPL Figure 1) is not energized.
(3) Make sure that valve A is open.
(4) Increase the inlet pressure (PVI) to 451 ±5 psig. Keep this pressure for a minimum of
60 seconds.
(5) Decrease the pressure to zero.
(6) Examine the valve for damage or deformation. There must be no signs of damage or
deformation.
B. Do a proof pressure test of the actuator servo chamber as follows:
(1) Apply 28 ±1 vdc between pins A and B of the electrical connector (10, IPL Figure 1)
to energize the solenoid (120).
60 seconds.
deformation.
C. Do a proof pressure test of the disc and shaft as follows:
(1) Remove the pressure test cap from the side of the valve that does not have the air
supply or pressure gage. Do not apply the 28 vdc to the electrical connector.
60 seconds.
deformation.
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816601
Figure 102. Proof Pressure Test Setup
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816601
5. Leakage Tests
A. Do an internal leakage test as follows:
NOTE: If your flow measuring device compensates for temperature, it is not
necessary to measure the flowmeter pressure (PFM), and the flowmeter
temperature (TFM). or correct for temperature as specified in steps (3) and
(4).
(2) Increase the inlet pressure (PVI) to 60 ±2 psig.
(3) Measure and write the measured flow (WFM), flowmeter pressure (PFM), and the
flowmeter temperature (TFM).
Figure 103. Internal Leakage Test Setup

(4) Calculate the corrected leakage rate as shown in Figure 104.
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816601
Figure 104. Leakage Correction

(5) The corrected leakage must not be more than 0.36 ppm.
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816601
B. Do an external leakage test as follows:

NOTE: If your flow measuring device compensates for temperature, it is not
necessary to measure the flowmeter pressure (PFM), and the flowmeter
temperature (TFM) or correct for temperature as specified in steps (3) and
(4).
(2) Increase the inlet pressure (PVI) to 60 ±2 psig.
(3) Measure and write the measured flow (WFM), flowmeter pressure (PFM), and the
flowmeter temperature (TFM).
(4) Calculate the corrected leakage rate as shown in Figure 104.
(5) The corrected leakage must not be more than 0.10 ppm.
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816601
Figure 105. External Leakage Test Setup
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816601
6. Performance Tests
A. Position Switch Function Test
(1) Install a protractor, GS24194-1, to measure the angle of the valve.
(2) Refer to the wiring diagram in Figure 101.
NOTE: You can use an ohmmeter, indicator lights or position switch test box for the
position switch function test. A maximum resistance of 0.500 ohms should
be measured when contacts are closed.
(3) With the valve closed, do a check to make sure there is continuity between pins C
and D.
(4) Turn the valve to the open position. The continuity between pins C and D must stop
and the continuity between pins E and F must start when the valve is between 3 and
9 degrees from closed as shown on the protractor.
(5) If the continuity between pins C and D does not stop when the valve is between 3
and 9, you can adjust the position as follows:
(a) Loosen the nuts on the environment free (position) switch (110, IPL Figure 1).
(b) Adjust the position of the switch with the position of the two nuts.
(c) Tighten the nuts.
(d) Do step (4) again.
(6) Turn the valve to the closed position. The continuity between pins C and D must
start and the continuity between pins E and F must stop when the valve is between 9
and 3 degrees as shown on the protractor.
(7) Adjust the environment free (position) switch (110) as necessary to get the
conditions in steps (4) and (6). The test result is satisfactory when you can do steps
(4) and (6) with no adjustment between the steps.
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B. Minimum Pressure Operation Test

(2) Increase the inlet pressure (Pvi) to 10 ±1 psig and the solenoid shall be
de-energized.
(3) The valve shall remain closed.
(4) Apply 28 ±1 vdc to pins A and B of the electrical connector to energize the solenoid.
The valve must open within 5.0 seconds.
(5) Remove the electrical power from the electrical connector. The valve must close
within 3.0 seconds.
C. Maximum Pressure Operation Test
(2) Increase the inlet pressure (Pvi) to 200 ±4 psig and the solenoid shall be
de-energized.
(3) The valve shall remain closed.
(4) Apply 28 ±1 vdc to pins A and B of the electrical connector to energize the solenoid.
The valve must open within 3.0 seconds.
(5) Remove the electrical power from the electrical connector. The valve must close
within 2.0 seconds.
7. Tests to do Again if the Valve is Disassembled
A. If you disassemble the valve to correct a malfunction, do the tests specified in Table 103
again.
Table 103. Test To Be Done Again
DISASSEMBLY TEST TO BE DONE AGAIN
Removal of Solenoid Dielectric Test

Insulation Resistance Test
Leakage Test
Performance Test
Disassembly of the Actuator Proof Pressure Test
Leakage Test
Performance Test
Removal of the Position Switch Dielectric Test
Insulation Resistance Test
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Figure 106. Minimum and Maximum Pressure Operation Test Setup
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8. Trouble-shooting
A. Trouble-shooting procedures for the valve are given in Table 104.
Table 104. Trouble-Shooting
TROUBLE POSSIBLE CAUSE WHAT TO DO
The valve is not in the limits The insulation on the wires or Examine the wires and the
given in the dielectric test. contacts are damaged. contacts. If you can find that
there is damage, repair the
damage as specified in
REPAIR. If you cannot repair
the damage, replace the
solenoid (120, IPL Figure 1) or
environment free switch (110),
as necessary.
The valve is not in the limits The insulation on the wires is Replace the solenoid (120, IPL
given in the insulation damaged or the wires are Figure 1) or environment free
resistance test. broken. switch (110), as necessary.
The valve is not in the limits The split ring or the butterfly Replace the split ring or the
given in the internal leakage disc is worn or damaged. butterfly disc. Refer to
test. ASSEMBLY. Do the tests that
are specified in Table 103.
The valve is not in the limits The split bushings in the valve Replace the split bushings.
given in the external leakage housing are worn or damaged. Refer to REPAIR. Do the tests
test. that are specified in Table 103.
The valve is not in the limits The environment free switch or Replace the environment free
given in the position switch the wiring is damaged. switch. Refer to ASSEMBLY.
function test. Do the tests that are specified
in Table 103.
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DISASSEMBLY
1. General
NOTE: Refer to TESTING AND TROUBLE-SHOOTING to find the condition of the unit or
the cause of a malfunction. Find the level of disassembly and repair necessary if the
unit does not have to be fully disassembled.
A. Discard the preformed packings, cotter pins, and diaphragms during disassembly.
B. Keep the matched parts together.
C. Remove the identification plate, inserts, and plain bearings only if replacement is
necessary.
D. Put parts in different envelopes (or equivalent). Identify the envelopes with labels.
E. Cut and remove all the lockwire before disassembly.
F. The special tools, fixtures and equipment necessary to do the disassemble the unit are
specified in Table 301.
Locks, CT 06096-1010.
TOOL NO. NAME USE
GS24180-1 Power Arm Fixture Hold the valve in the

necessary position.
M81969/14-02 Insertion/Removal Tool Used to install or remove
contacts from the electrical
connector.
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2. Disassembly of the Electrical Group (Refer to Figure 301).

NOTE: The environment-free switch (110, IPL Figure 1), push solenoid (120) and electrical
connector (10) are connected by wires. Disassembly of these components is only
necessary if one of the components is replaced.
A. Remove four screws (20A) and washers (30) to remove the electrical connector (10)
from the unit.
B. Use the removal tool, M81969/14-02, to remove the pins A, B, C, D, E, and F from the
electrical connector (10). These pins attach the wires from the environment-free switch
(110) and push solenoid (120) to the electrical connector (10).
C. Install a wood wedge between the butterfly disc (140, IPL Figure 3) and the valve
housing (160).
D. Remove eight screws (40, IPL Figure 1) which attach the mounting plate (80) and
actuator cover and tube (90) to the unit. Remove the mounting plate. Carefully hit the
actuator cover and tube with a plastic mallet to loosen it. Remove the cover.
E. Remove the clamp (50) from the bracket.
F. Remove the identification plate (60) and instruction plate (70) from the actuator cover
and tube (90) only if replacement is necessary. Refer to REPAIR-GENERAL.
G. Pull the flange of the diaphragm (50, IPL Figure 2) away from the actuator housing to get
access to the preformed packing (100, IPL Figure 1). Remove the packing from the unit.
H. Loosen the nuts on the environment-free switch (110). Remove the switch (120) from the
unit.
CAUTION: BE CAREFUL NOT TO DROP THE SOLENOID PLUNGER AND SPRING
DURING REMOVAL OF THE PUSH SOLENOID (120). THE PLUNGER AND
SPRING CAN FALL OUT OF THE SOLENOID.
I. Remove the screws (130, 140) which attach the push solenoid (120) to the unit. Lift off
push solenoid.
J. Temporarily put masking tape on the end of the plunger of the push solenoid (120).
Attach the tape to the sides of the solenoid. This is done to keep the plunger and spring
in the solenoid.
K. Pull the valve seat (160) from its hole. Turn the unit to remove ball (180) and spring
(190). Remove preformed packing (170) from the valve seat.
L. Lift the valve body (200) and spring (220) out their the hole. Remove preformed packing
(210) from the valve body.
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Figure 301. Electrical Group
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3. Disassembly of the Actuator Linkage Group (Refer to Figure 302).

A. Remove the two screws (30, IPL Figure 2) and washers (40). Remove the rider plate
(20), diaphragm (50), piston (60), and piston guide (70). Remove the piston from the
diaphragm. Remove the rider ring (10) from the rider plate (20). Remove the piston ring
(80) from the piston guide.
B. Remove the wood wedge between the (140, IPL Figure 3) and the valve housing (160).
CAUTION: MAKE SURE THAT YOU KEEP THE SPRING (130, IPL Figure 2)
COMPRESSED TO RELEASE TENSION WHEN YOU REMOVE THE
HEADLESS STRAIGHT PIN (100). YOU CAN DAMAGE THE LINK RETAINER
(90) IF THE SPRING IS NOT COMPRESSED.
C. Compress the spring (130) and at the same time remove headless straight pin (100)
from link retainer (90). Remove the link retainer. Remove the spring (130) and spring
retainer (140).
D. Remove the cotter pin (160), washer (170), headed straight pin (180) and connector link
(150).
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Figure 302. Actuator Linkage Group
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4. Disassembly of the Lock and Filter Group (Refer to Figure 303).

CAUTION: THE LOCKING CRANK (80, IPL Figure 4), LINKAGE CRANK (90), VALVE
SHAFT (100), AND BUTTERFLY DISC (110) ARE MATCHED PARTS. KEEP
THEM TOGETHER.
A. Remove the cotter pin (10, IPL Figure 3) and headed straight pin (20). Remove the
locking crank (110, IPL Figure 4).
CAUTION: BE CAREFUL NOT TO CAUSE DAMAGE TO THE LINKAGE CRANK (90)
DURING THE REMOVAL OF THE VALVE GROUP FROM THE ACTUATOR
HOUSING. THE LINKAGE CRANK MOVES LOOSELY ON THE SHAFT
AFTER YOU REMOVE THE HEADED STRAIGHT PIN.
B. Remove the cotter pin (30, IPL Figure 3) and headed straight pin (40). This loosens the
linkage crank (90, IPL Figure 4). You cannot remove it until you remove the valve shaft
(100).
C. Remove the valve group (50) as follows:
(1) Remove the nuts (60, 100, 120) washers (70, 90, 110), and screws (80).
(2) Carefully pull the valve group (50) from the actuator housing (260). Remove the
linkage crank (90, IPL Figure 4) from the hole in the actuator.
D. Remove packing backup retainer (130, IPL Figure 3) and preformed packing (140) from
the hole for the valve shaft in the actuator housing (260).
E. Remove the five solid shims (150).
F. Remove sleeve bushing (160) and preformed packing (170) from the actuator housing
(260).
G. Remove the locking screw (180), preformed packing (190), retaining cable and terminal
(200), and retaining chain (210) from the actuator housing (260).
H. Remove the plug and bleeder (220), preformed packing (230), compression spring (240)
and air filter (250) from the actuator housing (260).
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Figure 303. Lock and Filter Group
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5. Disassembly of the Valve Group (Refer to Figure 304).

A. Remove the plug and bleeder (10, IPL Figure 4), preformed packing (20), and solid plain
discs (30).
B. Remove the cotter pin (50) and headed straight pin (60). This loosens the butterfly disc
(110).
CAUTION: THE LOCKING CRANK (80), LINKAGE CRANK (90), VALVE SHAFT (100),
AND BUTTERFLY DISC (110) ARE MATCHED PARTS. KEEP THEM
TOGETHER.
C. Remove the valve shaft (100) and butterfly disc (110).
D. Remove the seal ring (120) from the butterfly disc (110).
E. Remove the plain bearings (140, 150) from the valve housing (160) only if replacement
is necessary. Refer to REPAIR 2-1.
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Figure 304. Valve Group
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6. Disassembly of the Actuator Housing (Refer to Figure 305).

A. Do not remove the split bushing (10, IPL Figure 5) from the actuator housing unless
replacement is necessary. Refer to REPAIR 3-1.
B. Do not remove the inserts (20, 30, 40, 50, 60) from the actuator housing unless
replacement is necessary. Refer to REPAIR-GENERAL.
C. Do not remove the two studs (70) from the actuator housing unless replacement is
necessary. Refer to REPAIR 3-2.
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Figure 305. Actuator Housing
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CLEANING
1. General
A. The materials necessary to clean the unit are specified in Table 401.
NOTE: Maintenance personnel must use the specified consumable material for the
specified task. These consumable materials are known to agree with all of the
design and qualification requirements. Only approved materials engineering
can make equivalent consumable material decisions and these materials are
used at the risk of the organization who makes the decision.
Table 401. Cleaning Materials
SOURCE OR
NAME USE
SPECIFICATION
Corrosion Preventive AMS3072 Prevents corrosion.

Compound
Crocus Cloth P-C-451 Removes corrosion from
external surfaces.
Fingerprint Corrosion AMS3065 Fingerprint neutralizer.
Preventive Compound
Material Barrier MIL-B-121, Grade A Put parts in after they are
cleaned.
Petroleum Solvent AMS3160 General agent used to clean.
WARNING: DO NOT LET PETROLEUM SOLVENT, AMS3160, TOUCH YOUR SKIN OR

EYES. DO NOT BREATHE THE FUMES. USE IT ONLY WHERE THERE IS A
GOOD FLOW OF AIR. IT CAUSES SKIN IRRITATION AND IS DANGEROUS
TO YOUR EYES.
WARNING: USE EYE PROTECTION WHEN YOU USE COMPRESSED AIR TO CLEAN.
CONTAMINATION CAN BECOME AIRBORNE AND CAUSE INJURY TO
YOUR EYES.
CAUTION: DO NOT USE METAL WOOL, METAL BRUSHES OR ABRASIVES TO CLEAN
PARTS. THESE MATERIALS CAN CAUSE SCRATCHES AND DAMAGE
PARTS. DO NOT USE PAPER TOWELS TO DRY PARTS. PAPER TOWELS
CAN LEAVE CONTAMINANTS ON PARTS.
B. Clean all metal parts with petroleum solvent, AMS3160. Loosen dirt from external
surfaces with a non-metal bristle brush. Remove blockages from ports and passages
with a piece of soft copper wire. Dry parts fully with a clean, lint-free cloth or with
compressed air (25 psig maximum nozzle pressure.)
C. Use a very fine stone, emery, or crocus cloth, P-C-451, on external cast aluminum
surfaces to remove any remaining corrosion. Put the protective surface layer back on all
areas cleaned by this procedure (See REPAIR-GENERAL).
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D. Dry all passageways with compressed air at 25 psig maximum.

E. Put corrosion preventive compound, AMS3072, on all steel parts that you will not
assemble immediately. Put these parts in material barrier, MIL-B-121, Grade A, to
prevent corrosion.
F. Clean the parts in petroleum solvent, AMS3160, before assembly. Shake the parts in
fingerprint corrosion preventive, AMS3065, to clear perspiration from fingerprints. Dry
the part with a lint-free cloth or compressed air at 25 psig maximum.
2. Specific Cleaning Procedures
A. Clean the air seat and filter (250, IPL Figure 3) as follows:
WARNING: USE EYE PROTECTION WHEN YOU USE COMPRESSED AIR TO
CLEAN. CONTAMINANTS CAN BECOME AIRBORNE AND CAUSE
INJURY TO YOUR EYES.
(1) Blow 25 psig maximum compressed air through the filter to remove contamination.
WARNING: DO NOT LET PETROLEUM SOLVENT, AMS3160, TOUCH YOUR SKIN
OR EYES. DO NOT BREATHE THE FUMES. USE IT ONLY WHERE
THERE IS A GOOD FLOW OF AIR. PETROLEUM SOLVENT, AMS3160,
CAUSES SKIN IRRITATION AND IS DANGEROUS TO YOUR EYES.
(2) Clean the air filter in a sonic bath or equivalent with petroleum solvent, AMS3160, at
ambient temperature for approximately 10 minutes.
(3) Blow 25 psig maximum compressed air through the filter to remove any remaining
contamination.
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CHECK
1. General
CAUTION: DO ALL THE SUBSEQUENT STEPS IN A VERY CLEAN AND DRY AREA.
USE A COVER ON ALL PARTS TO PREVENT DAMAGE WHEN THEY ARE
NOT IN USE. THIS WILL GIVE SERVICEABLE EQUIPMENT OPERATION
AND LIFE.
NOTE: You can use a light and a magnifying glass to help with visual inspections.
A. Do a visual check of all parts for wear, galling, metal pickup, cracks, nicks, burrs, dents
and other damage as given in Table 501 thru Table 514.
B. Examine all prepared parts for bare metal caused by damage. Carefully examine internal
holes in housings and machined surfaces for marks, wear, or damage. Reject all parts
worn or damaged more than that which is permitted or serviceable.
C. Reject parts which show a wear pattern (more than usual) or damage without other
checks. Repair less important damage to applicable parts as given in
REPAIR-GENERAL.
D. Examine all internal passages to be sure they are clean and without blockages.
E. Examine threads for rough or irregular edges. Make sure fits are satisfactory.
F. Do the special checks for the items shown in Table 501 thru Table 514 only when you
can see that there is some damage.
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Table 501. Special Checks for the Electrical Connector, Identification Plate,
and Actuator Cover and Tube
PART NAME,
TYPE OF LIMITS OR
ITEM AND PROCEDURE
EXAMINATION REMARKS
FIGURE NO.
Electrical Connector Visual Do a check for bent, broken No damage is

(10, IPL Figure 1) or burned-out pins. permitted.
Identification Plate Visual Make sure that you can All letters and numbers
(60, IPL Figure 1) read the letters and must be clear.
numbers.
Actuator Cover and Dimensional Make sure that the flange Refer to Figure 501.
Tube surface is flat.
(90, IPL Figure 1)
Figure 501. Actuator Cover and Tube
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Table 502. Special Checks for the Pull Solenoid
PART NAME,
TYPE OF LIMITS OR
ITEM AND PROCEDURE
EXAMINATION REMARKS
FIGURE NO.
Pull Solenoid Functional Apply 28 ±1 0.5VDC to pins Refer to Figure 502.

(120, IPL Figure 1) A and B of the connector
(10, IPL Figure 1). Measure
the travel of the plunger.
Visual Examine the end of the No damage is
plunger. permitted.
Examine the connector for No corrosion or
corrosion and burned or damaged pins are
bent pins. permitted.
Figure 502. Pull Solenoid
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Table 503. Special Checks for the Valve Seat
PART NAME,
TYPE OF LIMITS OR
ITEM AND PROCEDURE
EXAMINATION REMARKS
FIGURE NO.
Valve Seat Visual Do a check of the ball No nicks and burrs are
(160, IPL Figure 1) mating surface for nicks permitted on the ball
and burrs. Refer to Figure mating surface
503.
Figure 503. Valve Seat
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Table 504. Special Checks for the Valve Body
PART NAME,
TYPE OF LIMITS OR
ITEM AND PROCEDURE
EXAMINATION REMARKS
FIGURE NO.
Valve Body Visual Do a check of the ball No nicks and burrs are
(200, IPL Figure 1) mating surface for nicks permitted on the ball
and burrs. Refer to Figure mating surface
504.
Figure 504. Valve Body
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Table 505. Special Checks for the Piston Guide
PART NAME,
TYPE OF LIMITS OR
ITEM AND PROCEDURE
EXAMINATION REMARKS
FIGURE NO.
Piston Guide Dimensional Measure the groove. Refer to Figure 505

(70, IPL Figure 1)
Figure 505. Piston Guide
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Table 506. Special Checks for the Piston Ring
PART NAME,
TYPE OF LIMITS OR
ITEM AND PROCEDURE
EXAMINATION REMARKS
FIGURE NO.
Piston Ring Visual Examine the ring for helix Refer to Figure 506.
(80, IPL Figure 2) and wear.
Dimensional Measure the wear pattern Refer to Figure 507.
and the ring gap.
Figure 506. Piston Ring-Helix, Wear and Edges
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Figure 507. Piston Ring-Wear Pattern and Gap
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Table 507. Special Checks for the Link Retainer, Link Connector,
Sleeve Bushing, Air Filter, Actuator Housing,
and the Disc and Shaft
PART NAME,
TYPE OF LIMITS OR
ITEM AND PROCEDURE
EXAMINATION REMARKS
FIGURE NO.
Link Retainer Visual Make sure that the threads Damaged or loose
(90, IPL Figure 2) of the inserts (110) are not inserts are not
damaged. permitted.
Link Connector Dimensional Do a check of the inside The inside diameter
(150, IPL Figure 2) diameter of the two holes. must be 0.1265
(3.2131) maximum.
Sleeve Bushing Visual Examine it for nicks, burrs No damage is
(160, IPL Figure 3) and other damage. permitted.
Dimensional Measure the inside The inside diameter
diameter in two locations must be 0.271 (6.8834)
that are 90° from each maximum.
other.
Actuator Housing Visual Make sure that the threads Damaged or loose
(260, IPL Figure 3) of the inserts (20, 30, 40, inserts are not
50, 60, IPL Figure 5) are permitted.
not damaged and the
inserts are not loose.
Make sure that the threads Damaged or loose
of the studs (70, IPL Figure studs are not permitted.
5) are not damaged and the
studs are not loose.
Disc and Shaft Dimensional Make sure that the The diameters of the all
(70, IPL Figure 4) diameter of the pin holes in the holes must be in
the locking crank (80), the specified limit.
linkage crank (90), valve
shaft (100) and butterfly
disc (110) are less than the
limit specified in Figure 508.
NOTE:The disc and shaft (70, IPL Figure 4) has these matched parts: locking crank (80), linkage
crank (90), valve shaft (100) and butterfly disc (110). Keep the matched parts together.
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Figure 508. Disc and Shaft
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Table 508. Special Checks for the Locking Crank
PART NAME,
TYPE OF LIMITS OR
ITEM AND PROCEDURE
EXAMINATION REMARKS
FIGURE NO.
Locking Crank Dimensional Measure the diameter of The diameter must be

(80, IPL Figure 4) the hole shown in Figure in the specified limit.
509.
Figure 509. Locking Crank
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Table 509. Special Checks for the Linkage Crank
PART NAME,
TYPE OF LIMITS OR
ITEM AND PROCEDURE
EXAMINATION REMARKS
FIGURE NO.
Linkage Crank Dimensional Measure the diameter of The diameter must be

(90, IPL Figure 4) the hole shown in Figure in the specified limit.
510.
Figure 510. Linkage Crank
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Table 510. Special Checks for the Valve Shaft
PART NAME,
TYPE OF LIMITS OR
ITEM AND PROCEDURE
EXAMINATION REMARKS
FIGURE NO.
Valve Shaft Dimensional Measure the dimensions The dimensions must

(100, IPL Figure 4) specified in Figure 511. be in the specified
limits.
Figure 511. Valve Shaft
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Table 511. Special Checks for the Butterfly Disc
PART NAME,
TYPE OF LIMITS OR
ITEM AND PROCEDURE
EXAMINATION REMARKS
FIGURE NO.
Butterfly Disc Dimensional Measure the dimensions The dimensions must

(110, IPL Figure 4) specified in Figure 512. be in the specified
limits
Figure 512. Butterfly Disc
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Table 512. Special Checks for the Seal Ring
PART NAME,
TYPE OF LIMITS OR
ITEM AND PROCEDURE
EXAMINATION REMARKS
FIGURE NO.
Seal Ring Dimensional Do a check of the ring as Refer to Figure 513.

(120, IPL Figure 4) shown in Figure 513.
Do a light-tightness test The ring must not be
with the ring in a gage with less than 85%
an internal diameter of light-tight.
1.875 (47.625). Use a 40
watt lamp.
NOTE:You can use light finger pressure (3 pounds [1.36 kilograms] maximum radial load) on the
inside diameter of the seal ring while it is in the gage.
Figure 513. Seal Ring
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Table 513. Special Checks for the Valve Housing
PART NAME,
TYPE OF LIMITS OR
ITEM AND PROCEDURE
EXAMINATION REMARKS
FIGURE NO.
Valve Housing Visual Make sure the chromium Refer to Figure 514.
130, IPL Figure 4) plated surface is not
broken.
Figure 514. Valve Housing
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2. Spring Checks
A. Do checks to the springs as specified in Table 514.
Table 514. Spring Checks
ITEM AND FIGURE NO. PROCEDURE LIMITS
190, IPL Figure 1 Put a load on the spring until the 0.07 ±0.007 pound
length is 0.16 (4.06). (0.032 ±0.0032 kilogram)
is the load necessary to get
the specified length.
220, IPL Figure 1 Put a load on the spring until the 7 ±0.7 pounds
length is 0.24 (7.00). (3.18 ±0.318 kilograms)
length is 2.1 (53.34). (0.91 ±0.091 kilogram)
length is 0.934 (27.72). (7.27 ±0.727 kilograms)
Page 517
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Page 518
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REPAIR-GENERAL
1. General
A. You can do the procedures in this section to repair small damage to parts if the parts can
be repaired to the limits given in the CHECK section. First look in the list of Special
Repairs given in paragraph 4. If there is a Special Repair for the damage that you have
you can do that. If there is not, you can do the general repair as specified in paragraph
D.
B. The special tools, fixtures and equipment necessary to do the repairs to the parts of the
unit are specified in Table 601.
Locks, CT 06096-1010.
TOOL NO. NAME USE
GS22441-1 Bushing Inserter Install the plain bearing in the valve

housing.
GS23154-1 Bushing Remover Remove the split bearing from the
actuator housing.
GS23158-1 Holding Fixture Hold the actuator housing in the
necessary position.
GS23610-1 Bushing Inserter Install the split bearing in the actuator
housing.
M22520/1-01 Crimping Tool Used to crimp electrical contacts to the
wires.
M22520/1-04 Turret Head Assembly Used to get a correct position on the
electrical contacts.
M81969/14-02 Insertion/Removal Tool Used to install or remove contacts from
the electrical connector.
Repair-General
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C. The materials necessary to do the repairs to the parts of the unit are specified in Table
602.
Table 602. Materials
SOURCE OR
NAME USE
SPECIFICATION
Abrasive Cloth P-C-451 Remove damage from external
surfaces.
Chemical Film AMS2473 Prevent damage on the surface of
aluminum.
Clear Epoxy Polyamide MIL-C-22750 Paint for the identification plate.
Contact Replaces damaged connector pins.
Crocus Cloth P-C-458 Polish damaged areas.
EA9394 Adhesive and Hysol Division Bond the studs to the actuator housing.
EA9394 Hardener The Dexter Corp.
P.O. Box 312
2850 Willow Pass Rd.
Pittsburg, CA 94565
Vendor Code 04347

Epoxy Polyamide Primer MIL-P-23377 Paint for the threads of the screw thread
inserts in the actuator housing.
Isopropyl Alcohol TT-I-735, Grade A Solvent to clean the parts.
Petroleum Solvent AMS3160 Solvent to clean the parts.
Wipe-On Regular Red Lake Chemical Co. Fills the data on the identification plate.
Lacquer Stick 270 No. Whiternaw Ave.
Chicago, IL 60612
Vendor Code 08854

Zinc Chromate Primer TT-P-1757 Paint for the threads of the screw thread
inserts in the link retainer.
D. Small Repairs
(1) You can do this type of repair if:
• you do not change the dimensions
• you do not make the surface finish rougher.
Repair-General
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(2) You cannot do this type of repair if there is much damage on areas that seal air.
(3) Steel Parts
(a) Remove nicks, burrs, rough edges or other damage with a fine stone and
abrasive cloth, P-C-451.
(b) Polish nicks, burrs, or rough edges with a fine stone and crocus cloth, P-C-458,
to keep interference fits to a minimum. Do not remove more material than
necessary.
WARNING: KEEP ISOPROPYL ALCOHOL AWAY FROM HEAT AND FLAMES.
USE SKIN AND EYE PROTECTION IN AN AREA WHERE THERE IS
A GOOD FLOW OF AIR. DO NOT BREATHE THE FUMES. IT IS
FLAMMABLE AND POISONOUS.
(c) Clean parts after repair with isopropyl alcohol, TT-I-725.
(4) Aluminum Parts
(a) Remove nicks, burrs, rough edges or other damage with abrasive cloth,
P-C-451.
(b) Remove grease or rub the repaired area with isopropyl alcohol, TT-I-725.
(c) Apply chemical film, AMS2473, to repaired areas.
2. Replace the Screw Thread Inserts
A. Replace the insert(s) (110, IPL Figure 2) in the link retainer (90) as follows:
(1) Remove the worn or damaged insert.
WARNING: USE GOGGLES AND GLOVES WHEN YOU USE PETROLEUM
SOLVENT AND ZINC CHROMATE PRIMER. USE THEM IN AN AREA
WHERE THERE IS A GOOD FLOW OF AIR. THEY CAN CAUSE
IRRITATION TO YOUR EYES, SKIN, AND RESPIRATORY TRACT.
(2) Clean the hole for the insert with petroleum solvent, AMS3160.
(3) Apply a layer of zinc chromate primer, TT-P-1757, to the insert.
(4) Install the insert (refer to MS33537).
B. Replace the insert(s) (20, 30, 40, 50, IPL Figure 5) in the actuator housing as follows:
WARNING: USE GOGGLES AND GLOVES WHEN YOU USE EPOXY POLYAMIDE
PRIMER. USE IT IN AN AREA WHERE THERE IS A GOOD FLOW OF
AIR. IT CAN CAUSE IRRITATION TO YOUR EYES, SKIN, AND
RESPIRATORY TRACT.
(1) Remove the worn or damaged insert.
(2) Mix together, equal parts of the epoxy resin and polyamide components of the epoxy
polyamide primer, MIL-P-23377.
(3) Let the primer stand for 1 hour. Do not make the primer thin.
NOTE: You must use the primer mixture in 8 hours or less.
Repair-General
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21-32-20 Aug 29/07
816601
(4) Apply a layer of epoxy polyamide primer, MIL-P-23377, to the insert.

(5) Install the insert (refer to MS33537).
3. Replace the Identification Plate (60, IPL Figure 1)
WARNING: KEEP ISOPROPYL ALCOHOL AWAY FROM HEAT AND FLAMES. USE SKIN
AND EYE PROTECTION IN AN AREA WHERE THERE IS A GOOD FLOW OF
AIR. DO NOT BREATHE THE FUMES. IT IS FLAMMABLE AND POISONOUS.
A. Remove the damaged identification plate with a plastic scraper and isopropyl alcohol,
TT-I-725.
B. Make a copy of the necessary data on the replacement plate with a typewriter without
ribbon. Fill in the data with red pigment, Wipe-On regular red lacquer stick.
C. Fully clean the surface that the plate bonds to with isopropyl alcohol, TT-I-725. Let the
surface dry.
D. Remove the back from the identification plate and push the plate on the surface.
E. Push the identification plate in position with a hard rubber roller (or equivalent) until all
areas bond. Make sure the corners and edges are flat.
WARNING: USE SKIN AND EYE PROTECTION WHEN YOU USE CLEAR EPOXY
POLYAMIDE, MIL-C-22750. USE IN AN AREA WHERE THERE IS A GOOD
FLOW OF AIR. DO NOT BREATHE THE FUMES. CLEAR EPOXY
POLYAMIDE, MIL-C-22750, IS POISONOUS AND CAN CAUSE INJURY.
F. Seal the full identification plate plus a 0.125 inch (3.175 millimeters) overlap with clear
epoxy polyamide, MIL-C-22750. Refer to MIL-C-22751.
G. Apply two layers, minimum, of the epoxy. Let it dry for 30 minutes, minimum, between
layers.
H. Let the identification plate dry for 12 hours, minimum, before you touch it.
4. Special Repairs
REPAIR 1-1: Connector - Replace the Contacts

REPAIR 2-1: Valve Housing - Replace the Plain Bearings
REPAIR 3-1: Actuator Housing - Replace the Split Bushing
REPAIR 3-2: Actuator Housing - Replace the Studs
Repair-General
Page 604
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816601
CONNECTOR - REPAIR 1-1

1. Replace the Contacts
A. Remove the damaged contacts from electrical connector (10, IPL Figure 1) with removal
tool, M81969/14-02.
B. Remove the insulation to get 0.1870 to 0.2340 inch (4.7498 to 5.9436 millimeters) of
bare wire.
C. Install a new contact on the wire and crimp in position. Use crimping tool, M22520/1-01,
with a turret head assembly, M22520/1-04. Use positioner A with the selector control set
for 3 for the 20-gage wires for the environment-free switch (110) and set for 2 for the
22-gage wires for the push solenoid (120).
D. Install the contacts with wires into the connector (10, IPL Figure 1). Use insertion tool,
M81969/14-02. Refer to Figure 601 for the location of the applicable pin holes in the
connector.
Figure 601. Connector Pins
Repair 1-1
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816601
Repair 1-1
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VALVE HOUSING-REPAIR 2-1

1. Replace the Plain Bearings
A. Drill out two plain bearings (140 and 150, IPL Figure 4) from the valve housing (240) with
a 3/8 inch (9.525 mm) diameter drill. Remove the remaining material of the plain
bearings from the holes in the valve housing.
B. Clean the holes in the valve housing with isopropyl alcohol, TT-I-725. Let the area dry.
C. Push two new plain bearings to the bottom of the holes in the valve housing with bushing
inserter, GS22441-1. Refer to Figure 601.
Figure 601. Install the Plain Bearings
Repair 2-1
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816601
Repair 2-1
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ACTUATOR HOUSING-REPAIR 3-1

1. Replace the Split Bushing (10, IPL Figure 5)
A. Install the actuator housing in holding fixture, GS23158-1.
B. Remove the damaged (or worn) split bushing (10, IPL Figure 5) with bushing remover,
GS23154-1.
NOTE: The split bushing has an outer layer made of tin plated steel, a middle layer of
bronze and Teflon, and an inner layer of Teflon and lead.
C. Clean the hole in the actuator housing with isopropyl alcohol, TT-I-725. Let the area dry.
D. Use bushing inserter, GS23610-1, to push the new split bushing into the housing to the
dimension shown in Figure 601.
Repair 3-1
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816601
Figure 601. Replace the Split Bushing
Repair 3-1
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ACTUATOR HOUSING-REPAIR 3-2

1. Replace the Studs (Refer to Figure 601)
WARNING: USE GLOVES WITH INSULATION WHEN YOU TOUCH HOT ITEMS. THEY
CAN CAUSE DAMAGE TO YOUR SKIN.
A. Increase the temperature of the actuator housing to 290 to 310 °F (143.3 to 154.4 °C).
Remove the damaged stud(s). Let the housing become cool.
B. Remove the remaining adhesive from the hole(s) with a strong bristle brush.
C. Prepare the surfaces of the new stud(s) (70, IPL Figure 5) and the holes in the actuator
housing (80) as follows:
WARNING: KEEP ISOPROPYL ALCOHOL, TT-M-735, ADHESIVE, EA9394, AND
HARDENER, EA9394, AWAY FROM SPARKS AND FLAMES. USE
GOGGLES AND RUBBER GLOVES WHEN YOU USE THEM. USE THEM
IN AN AREA WITH A GOOD FLOW OF AIR. THEY ARE FLAMMABLE
AND CAN CAUSE IRRITATION TO YOUR EYES, SKIN AND
RESPIRATORY TRACT.
(1) Clean the surfaces with isopropyl alcohol, TT–I–735.
(2) Let the surfaces dry.
D. Prepare the adhesive and bond the stud(s) in the actuator housing as follows:
(1) Mix 100 parts by weight of adhesive, EA9394, with 20 parts by weight of hardener,
EA9394.
(2) Apply an equal layer of the adhesive mixture to the threads and bottom of the
stud(s), and to the threads in the hole in the actuator housing.
(3) Install the stud into the hole until the shoulder of the stud is 0.005 to 0.019 inch
(0.127 to 0.483 millimeter) below the surface of the housing.
(4) Put the actuator housing in an oven for 2 hours minimum at 240 to 260 °F (115.5 to
126.6 °C).
Repair 3-2
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Figure 601. Actuator Studs
Repair 3-2
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ASSEMBLY
1. General
A. The special tools, fixtures and equipment necessary to assemble the unit are specified
in Table 701.
Locks, CT 06096-1010.
TOOL NO. NAME USE

necessary position.
GS24181-1 Closure Kit Cap all open ports during
shipment and storage to
prevent contamination.
contacts from the electrical
connector.
B. The materials necessary to assemble the unit are specified in Table 702.
Table 702. Materials
SOURCE OR
NAME USE
SPECIFICATION
Dow Corning 44, Dow Corning Lubricate the preformed

Light Lubricant (DC44) 3901 S. Saginaw Rd. packings.
Midland, MI 48640
Vendor Code 5D028

Lockwire MS20995C20 Safety the plugs and the
environment free switch.
Lubricating Oil MIL-L-15719 Lubricate the preformed
packings.
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Table 702. Materials (Continued)
SOURCE OR
NAME USE
SPECIFICATION
Mo-Lith No. 2 Fiske Brothers Refining Co. Used to lubricate the threads
Thread Lubricant Lubriplate Div. of fasteners.
129 Lockwood St.
Newark, NJ 07105
Vendor Code 73219

Insulated Sleeving M23053/13-001-0, Insulate the wires between the
M23053/13-002-0, connector and the push
M23053/13-003-0, solenoid and environment free
switch.
C. Tighten all screws, bolts, and nuts to the correct torque in increments of 5 to 6
pound-inches (0.56 to 0.68 Newton-meters). Do not tighten each nut to the full torque at
one time. This can cause equipment not to be aligned.
D. Running torque is the level of torque that is necessary to turn the fastener before the
flange surfaces touch. Add the measured running torque to the specified (clamping)
torque for the total torque.
2. Actuator Housing
A. If the split bushing (10, IPL Figure 5), inserts (20, 30, 40, 50, 60), or studs (70) are worn
or damaged, refer to REPAIR-GENERAL, REPAIR 3-1 or REPAIR 3-2, as applicable.
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21-32-20 Aug 1/03
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816601
3. Assemble the Valve Group (Refer to Figure 701).

A. If the plain bearings (140 and 150) were removed from the housing (160), refer to
REPAIR 2-1 to install the new plain bearings.
B. Calculate the thickness of the plain solid discs (30) necessary to put the butterfly disc
(110) in the correct position in the valve housing (130) as follows:
NOTE: The procedure that follows calculates the thickness of the plain solid disc(s)
necessary to put the outside diameter of the disc in the center of the internal
diameter of the housing in ±0.005 inch (±0.127 millimeter) with the valve shaft
against the discs.
(1) Put the butterfly disc (110) in position in the valve housing (130). Install valve shaft
(100) through the housing and disc. Align the valve shaft as shown in Figure 702.
Put the headed straight pin (60) through butterfly disc and valve shaft. Do not install
the cotter pin (50) in the headed straight pin at this time.
(2) Put a load on the valve shaft (100) in the direction F, measure and write dimension
A, the distance from the top of the valve housing to the valve shaft, with a depth
micrometer, as shown in Figure 702.
(3) Put a load on the valve shaft (100, IPL Figure 4) in the direction G, measure and
write dimension B, the distance from the top of the valve housing to the valve shaft,
with a depth micrometer, as shown in Figure 702.
(4) Calculate dimension C, which is half the clearance between the butterfly disc (110,
IPL Figure 4) and valve housing (130), as follows (Refer to Figure 702):
C = (A - B) ÷ 2
Example:
A = 0.350 (8.890)
B = 0.330 (8.382)
C= [0.350 (8.890) - 0.330 (8.382)] ÷ 2
= 0.020 (0.508) ÷ 2
= 0.010 (0.254)
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Figure 701. Valve Group
Page 705
21-32-20 Aug 1/03
816601
Figure 702. Measure the Dimensions Necessary to Calculate the Thickness

of the Shims That Hold the Valve Shaft in Position
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(5) Calculate dimension E as follows:
E=B+C
Example:
B = 0.330 (8.382)
C = 0.010 (0.254)
E = 0.330 (8.382) + 0.010 (0.254)
= 0.340 (8.636)
(6) Measure and write dimension D, the length of plug (10), as shown in Figure 702,
View 2, with a depth micrometer.
(7) Calculate dimension T, the thickness of plain solid discs (30, IPL Figure 4)
necessary to put the butterfly disc (110) in the center of the valve housing (130), as
shown in Figure 702, View F, as follows:
T=E-D
Example:
E = 0.340 (8.636)
D = 0.300 (7.620)
T = 0.340 (8.636) - 0.300 (7.620)
T = 0.040 (1.016)
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816601
(8) Use the plain solid discs (30, IPL Figure 4) equal to dimension T. Refer to Table 703
for plain solid disc alternatives.
Example:
T = 0.040 (1.016)
Use two plain solid discs:
(35), 0.030 (0.762)
(30), 0.010 (0.254)
0.030 (0.762) + 0.010 (0.254)
= 0.040 (1.016)
Table 703. Thicknesses Of The Plain Solid Disks That Set The Butterfly Disc
In The Center Of The Valve Housing
IPL Figure 4,
PART NUMBER THICKNESS
ITEM NUMBER
30 732158--2 0.010 (0.254)

31 732158-3 0.012 (0.305)
32 732158-4 0.014 (0.356)
33 732158-5 0.016 (0.406)
34 732158-6 0.018 (0.457)
35 732158-7 0.030 (0.762)
(9) Remove headed straight pin (60). Remove valve shaft (100) from the valve housing
(130). Remove butterfly disc (110) from the valve housing.
C. Install seal ring (120) on butterfly disc (110). Hold butterfly disc with seal ring in position
in the valve housing (130). Put valve shaft (100) into the valve housing.
NOTE: The valve shaft (100), butterfly disc (110), linkage crank (90), and locking crank
(80) are matched parts. You must keep these parts together.
D. Install the headed straight pin (60) through the butterfly disc (110) and the valve shaft
(100). Attach the headed straight pin with the cotter pin (50). Refer to AS567.
Page 708
21-32-20 Aug 1/03
816601
WARNING: USE SILCON GREASE (DOW CORNING 44 LIGHT) CORRECTLY. IT IS

FLAMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE GREASE, GET THE MATERIAL SAFETY
DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING,
W0222SE, IN THE WARNING REGIISTRY 341-006. BEFORE YOU USE THE
GREASE, PUT ON THE CHEMICAL-SPLASH GOGGLES AND THE
NEOPRENE OR RUBBER GLOVES.
E. Lubricate preformed packing (20) with grease, DC44. Put the preformed packing on plug
(10).
WARNING: USE MO-LITH GREASE CORRECTLY. IT IS A FLAMMABLE MATERIAL. IT
CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE GREASE, GET THE MATERIAL SAFETY DATA SHEET FROM THE
MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0111SE, IN THE
WARNING REGIISTRY 341-006. BEFORE YOU USE THE GREASE, PUT ON
THE CHEMICAL-SPLASH GOGGLES AND OIL-RESISTANT GLOVES. MAKE
SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE GREASE
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
F. Lubricate the threads of the plug (10) with thread lubricant, Mo-Lith No. 2.
G. Put the plain solid discs (30) into the valve housing (130) followed by the plug (10), as
shown in Figure 702, View J. Torque 30 to 35 pound-inches (3.4 to 4.0 Newton-meters).
Safety the plug with lockwire, MS20995C20. Refer to AS567.
NOTE: The linkage crank (90, IPL Figure 4) and locking crank (80) are installed on
valve shaft (100) when the valve group is installed on the actuator housing.
Page 709
21-32-20 Aug 1/03
816601
4. Install the Valve Group (Refer to Figure 703).

A. Attach the link connector (150, IPL Figure 2) to the linkage crank (90, IPL Figure 4) with
the headed straight pin (180, IPL Figure 2), washer (170), and cotter pin (160). Refer to
AS567.
B. Install valve group (50, IPLFigure 3) on the actuator housing (260) as follows:
WARNING: USE GOGGLES AND GLOVES WHEN YOU USE LUBRICATING OIL.
USE IT IN AN AREA WITH A GOOD FLOW OF AIR. IT CAN CAUSE
IRRITATION TO YOUR EYES, SKIN AND RESPIRATORY TRACT
(1) Lubricate preformed packing (170) with lubricating oil, MIL-L.-15719. Install the
sleeve bushing (160) and preformed packing (170) on the valve shaft (100, IPL
Figure 4).
(2) Put the five solid shims (150, IPL Figure 3) on the studs (70, IPL Figure 5) of the
actuator housing (260, IPL Figure 3). This is done to keep these parts aligned for
easier assembly when you install the valve on the actuator housing.
(3) Install the valve group (50) on the actuator housing (260). At the same time, install
the linkage crank (90, IPL Figure 4) and link connector (150, IPL Figure 2) on the
valve shaft (100, IPL Figure 4) in the actuator housing.
WARNING: USE MO-LITH GREASE CORRECTLY. IT IS A FLAMMABLE MATERIAL.
IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE
YOU USE THE GREASE, GET THE MATERIAL SAFETY DATA SHEET
FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND
READ IT CAREFULLY. READ THE DETAILED WARNING, W0111SE, IN
THE WARNING REGIISTRY 341-006. BEFORE YOU USE THE GREASE,
PUT ON THE CHEMICAL-SPLASH GOGGLES AND OIL-RESISTANT
GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO
KEEP THE GREASE FUMES BELOW THE MATERIAL SAFETY DATA
SHEET LIMIT.
(4) Lubricate the threads of the nuts (60, 100, 120, IPL Figure 3) with thread lubricant,
Mo-Lith No. 2.
(5) Put two screws (80) and washers (90) through the flange of the actuator housing
(260). Attach the valve group (50) to the flange with the nuts (60, 100, 120) and
washers (70, 110). Install the retaining cable and terminal under the nut (120).
Torque 30 to 35 pound-inches (3.4 to 4.0 Newton-meters) more than running torque.
NOTE: The specified running torque for the nuts (60, 100, 120) is 2 to 13
pound-inches (0.22 to 1.47 Newton-meters).
(6) Lubricate the preformed packing (140) with lubricating oil, MIL-L.-15719. Install the
preformed packing in the actuator housing (260) around valve shaft (100, IPL Figure
4). Install the retainer (130, IPL Figure 3) on the preformed packing (140).
(7) Install the locking crank (80, IPL Figure 4) on the valve shaft. Put the headed straight
pin (20, IPL Figure 3) through the locking crank and valve shaft. Install the cotter pin
(10) through the headed straight pin (20). Refer to AS567.
(8) Attach the linkage crank (90, IPL Figure 4) to valve shaft (100) with headed straight
pin (40, IPL Figure 3). Install the with cotter pin (30). Refer to AS567.
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21-32-20 Aug 1/03
816601
Figure 703. Install the Valve Group
Page 711
21-32-20 Aug 1/03
816601
5. Install the Locking Screw (Refer to Figure 704).

A. Attach the chain retainer (210, IPL Figure 3) between the retaining cable and terminal
(200) and the locking screw (180) with retaining clip and cable installer, GS23984-1.
B. Install the packing (190) on the locking screw (180).
C. Lubricate the locking screw (180) with thread lubricant, Mo-Lith No. 2.
D. Install the locking screw (180) in the actuator housing (260, IPL Figure 3). Torque 20 to
25 pound-inches (2.3 to 2.8 Newton-meters) more than running torque.
NOTE: The specified running torque for the locking screw (180) is 3.5 to 30
Page 712
21-32-20 Aug 1/03
816601
Figure 704. Install the Locking Screw
Page 713
21-32-20 Aug 1/03
816601
6. Install the Air Filter (Refer to Figure 705).

A. Put the air filter (250, (IPL Figure 3) and helical compression spring (240) in the hole in
the actuator housing (260).
WARNING: USE SILCON GREASE (DOW CORNING 44 LIGHT) CORRECTLY. IT IS
FLAMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE GREASE, GET THE MATERIAL SAFETY
DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING,
W0222SE, IN THE WARNING REGIISTRY 341-006. BEFORE YOU USE THE
GREASE, PUT ON THE CHEMICAL-SPLASH GOGGLES AND THE
NEOPRENE OR RUBBER GLOVES.
B. Lubricate the preformed packing (230) with grease, DC44. Put the preformed packing on
plug and bleeder (220).
C. Lubricate the threads of the plug and bleeder (220) with thread lubricant, Mo-Lith No. 2.
D. Install the plug and bleeder (220) in the hole in the actuator housing (260). Torque 35 to
40 pound-inches (4.0 to 4.5 Newton-meters). Safety the plug with lockwire,
MS20995C20. Refer to AS567.
Page 714
21-32-20 Aug 1/03
816601
Figure 705. Install the Air Filter
Page 715
21-32-20 Aug 1/03
816601
7. Assemble the Actuator (Refer to Figure 706).

A. Turn the actuator housing (260, IPL Figure 3) so that the internal diameter of the
actuator is up. Hold the link connector (150, IPL Figure 2) parallel to the hole. Put spring
retainer (140) in the bottom of the hole. Put helical compression spring (130) on the
spring retainer.
B. If the inserts (120) are worn or damaged, refer to REPAIR-GENERAL.
C. Install the link retainer (90) on the link connector (150) and spring (130). Attach the link
retainer to the link connector with headless straight pin (100).
D. Push the retainer (90) two or three times and make sure the butterfly disc (110, IPL
Figure 4) moves easily.
E. Put a wood wedge between the hole in the housing and the disc. This will hold the
butterfly disc open in the valve.
NOTE: Do not remove the wood wedge until the actuator cover is attached or the
piston guide (270, IPL Figure 1) will move quickly from the hole in the actuator.
F. Assemble the piston ring (80) and its ring expander. Put the slot in the two parts 180×
apart. Install the piston ring on the piston guide (70).
G. Put the piston guide, piston (60), and diaphragm (50) on the link retainer (90). Make sure
that the holes in the diaphragm are aligned with the holes in the actuator housing (260,
IPL Figure 3).
H. Make sure the fabric side of the diaphragm (50) is against the piston (60).
I. Install the rider ring (10) on the rider plate (20).
J. Lubricate the threads of two screws (30) with thread lubricant, Mo-Lith No. 2.
K. Install the screws and washers (40) through the rider plate (20), diaphragm (50), piston
(60), and piston guide (70) and in the link retainer (90).
Page 716
21-32-20 Aug 1/03
816601
Figure 706. Assemble the Actuator
Page 717
21-32-20 Aug 1/03
816601
L. Torque the screws (30) as follows:

(1) Torque of 20 to 25 pound-inches (2.3 to 2.8 Newton-meters) more than running
torque.
NOTE: The specified running torque for the screws (30) is1.5 to 9 pound-inches
(0.17 to 1.0 Newton-meters).
WARNING: USE GLOVES WITH INSULATION WHEN YOU TOUCH HOT ITEMS.
THEY CAN CAUSE DAMAGE TO YOUR SKIN.
(2) Put the assembly in an oven for 1 hour at 250 ±10°F (121.1 ±5.6°C). While the
assembly is hot, tighten the screws (30) to the specified torque again. Tighten to the
specified torque again when the assembly is at ambient temperature.
M. Install preformed packing (100, IPL Figure 1) in the actuator housing (260, IPL Figure 3).
N. Put the actuator cover and tube (90, IPL Figure 1) on the assembly.
O. Lubricate the threads of the screws (140, IPL Figure 1) with thread lubricant, Mo-Lith No.
2.
P. Install the mounting plate (80) on the actuator cover and tube (90). Install the screws
(40) and the clamp (50).
Q. Torque the screws (40) as follows:
(1) Torque of 20 to 25 pound-inches (2.3 to 2.8 Newton-meters) more than running
torque.
NOTE: The specified running torque for the screws (40) is1.5 to 9 pound-inches
WARNING: USE GLOVES WITH INSULATION WHEN YOU TOUCH HOT ITEMS.
THEY CAN CAUSE DAMAGE TO YOUR SKIN.
(2) Put the assembly in an oven for 1 hour at 250 ±10 °F (121.1 ±5.6 °C). While the
assembly is hot, tighten the screws (40) to the specified torque again. Tighten to the
specified torque again when the assembly is at ambient temperature.
Page 718
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816601
Page 719
21-32-20 Aug 1/03
816601
8. Install the Electrical Group (Refer to Figure 707).

A. Install the environment-free switch (110, IPL Figure 1) on the actuator housing (260, IPL
Figure 3). Tighten the environment-free switch nuts to a torque of 20 to 25 pound-inches
NOTE: Make sure the tab of the lock washer of the environment-free switch (110, IPL
Figure 1) is installed in the hole in the actuator housing.
B. Lubricate the threads of four screws (30) with thread lubricant, Mo-Lith No. 2.
C. Install the electrical connector (10) on the actuator housing (260, IPL Figure 3) with four
screws (20A, IPL Figure 1) and washers (30). Tighten the screws to 3 to 5 pound-inches
(0.34 to 0.57 Newton-meters) more than running torque.
NOTE: The specified running torque for the screws (20A) is 0.5 to 3 pound-inches
D. Install the Ball Valve and Push Solenoid
(1) Install the helical compression spring (220, IPL Figure 1) in the bottom of the hole in
the actuator housing for the push solenoid (120).
WARNING: USE GOGGLES AND GLOVES WHEN YOU USE LUBRICATING OIL.
USE IT IN AN AREA WITH A GOOD FLOW OF AIR. IT CAN CAUSE
IRRITATION TO YOUR EYES, SKIN AND RESPIRATORY TRACT
preformed packing on the valve body (200).
(3) Put the helical compression spring (190) on the valve body (200) and install the
valve body in the hole in the actuator housing.
preformed packing on the valve seat (160).
(5) Install the ball (180) on the spring (190).
(6) Install valve seat (160) in the actuator housing (260, IPL Figure 3).
(7) Lubricate the threads of screw (130, 140, IPL Figure 1) with thread lubricant, Mo-Lith
No. 2.
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21-32-20 Aug 1/03
816601
Figure 707. Install the Electrical Group
Page 721
21-32-20 Aug 1/03
816601
(8) Remove the masking tape from the push solenoid (120). Install the push solenoid on
the actuator housing (260, IPL Figure 3). Attach the solenoid with the screws (130,
140, IPL Figure 1). Torque 20 to 25 pound-inches (2.3 to 2.8 Newton-meters) more
than running torque.
NOTE: The specified running torque for the screws (130, 140) is 1.5 to 9
E. If necessary, install sleeving on the wires between the connector (10) and the push
solenoid (120) and environment free switch (110) as follows (Refer to Figure 708):
(1) Cut 1 piece of electrical insulation sleeving, M23053/13-001-0, in the applicable
length for the wires from the push solenoid (120). Install the sleeving on the wires as
shown.
length for the wires from the environment free switch (110). Install the sleeving on
the wires as shown.
Figure 708. Positions of the Insulation Sleeving
Page 722
21-32-20 Aug 1/03
816601

length for the wires from the connector (10). Install the sleeving on the wires as
shown.
(4) Use the insertion tool, M81969/14-02, to put the contacts of the switch and solenoid
into the electrical connector (10). Push on the ends of the contacts to make sure that
they are correctly installed and do not push through the electrical connector.
F. Remove the wood wedge from the valve housing.
G. Safety the plug and bleeder (220, IPL Figure 3) with lockwire, MS20995C20. Refer to
AS567.
9. Calibration and Test
A. Calibrate and do a test of the valve. Refer to TESTING AND TROUBLE-SHOOTING.
B. After calibration and test, continue at paragraph 10. to complete the assembly.
10. Completion of Assembly After Calibration and Test
A. After all last adjustments, safety the nuts on the environment-free switch (110, IPL
Figure 1) with lockwire, MS20995C20.
11. Installation of the Identification Plate
A. See REPAIR-GENERAL.
12. Storage
A. Seal the valve with closure kit, GS24181-1. Put the valve in a clean plastic bag.
Page 723
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816601
Page 724
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816601
FITS AND CLEARANCES

1. Fits and Clearances
A. Refer to Table 801 for the specified fits and clearances for the unit.
Table 801. Fits And Clearances
ASSEMBLY
NAME AND FIT OR CLEARANCE AND
PARAGRAPH AND PAGE
FIGURE-ITEM NUMBER LIMIT
REFERENCES
Butterfly Disc The butterfly disc must be in Paragraph 3.B.

(110, IPL Figure 4) the center of the valve housing page 704
Valve Housing (130) bore ± 0.005 (0.127).
2. Assembly Torques
A. Refer to Table 802 for the specified assembly torques for the unit.
NOTE: Running torque is the level of torque that is necessary to turn the fastener
before the flange surfaces touch.
Table 802. Assembly Torques
ASSEMBLY
NAME AND SPECIFIED TORQUE RUNNING TORQUE
PARAGRAPH
(IPL FIGURE-ITEM POUND-INCHES POUND-INCHES
AND PAGE
NUMBER) (NEWTON-METERS) (NEWTON-METERS)
(REFERENCE)
Screw * 3 to 5 0.5 to 3 Paragraph 8.C.

(20, IPL Figure 1) (0.34 to 0.57) (0.06 to 0.34) page 720
Screw * 20 to 25 1.5 to 9 Paragraph 7.Q.
(40, IPL Figure 11) (2.3 to 2.8) (0.17 to 1.02) Page 718
Environment Free 20 to 25 - Paragraph 8. A.
Switch (2.3 to 2.8) Page 720
(110, IPL Figure 1)
Screw * 20 to 25 1.5 to 9 Paragraph 8.D.(8)
Screw * 20 to 25 1.5 to 9 Paragraph 8.D.(8)
Screw * 20 to 25 1.5 to 9 Paragraph 7.L.
Nut * 30 to 35 2 to 13 Paragraph 4.B.(5)
Page 801
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816601
Table 802. Assembly Torques (Continued)
ASSEMBLY
NAME AND SPECIFIED TORQUE RUNNING TORQUE
PARAGRAPH
(IPL FIGURE-ITEM POUND-INCHES POUND-INCHES
AND PAGE
NUMBER) (NEWTON-METERS) (NEWTON-METERS)
(REFERENCE)

Locking Screw * 20 to 25 3.5 to 30 Paragraph 5.C.
Plug and Bleeder * 35 to 40 - Paragraph 6.D.
(220, IPL Figure 3) (4.0 to 4.5) page 714
Plug and Bleeder * 30 to 35 - Paragraph 3.G.
(10, IPL Figure 4) (3.4 to 4.0) page 709
* Lubricate the threads with Mo-Lith No. 2.
Page 802
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816601
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT

1. Special Tools, Fixtures, and Equipment
A. The special tools, fixtures, and equipment necessary to do the maintenance are
specified in Table 901.
Locks, CT 06096-1010.
TOOL NO. NAME USE
GS15200-2 Filter Test Fixture Check filter for pressure drop.

GS20985-1 Pressure Test Cap Cap the valve inlet and outlet
(2 required) flanges during proof pressure
and leakage testing.
GS21162-2 Microswitch Cable Assembly Adapt between the timing test
timing test adapter
GS24193-1, during operational
test.
GS22441-1 Bushing Inserter Install the plain bearing in the
valve housing.
GS22907-1 Timing Test Box Measures and records the
valve actuation time.
GS23154-1 Bushing Remover Remove the split bearing from
the actuator housing.
GS23158-1 Holding Fixture Hold the actuator housing in
the necessary position.
GS23610-1 Bushing Inserter Install the split bearing in the
actuator housing.
GS23984-1 Retaining Clip and Cable Install the retaining clip and
Installer cable on the hex screw.
necessary position.
GS24181-1 Closure Kit Cap all open ports during
shipment and storage to
prevent contamination.
Page 901
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816601
Table 901. Special Tools, Fixtures, and Equipment (Continued)
TOOL NO. NAME USE
GS24192-1 Timing Test Cable Adapt between the timing test

valve electrical connector
GS24193-1 Timing Test Adapter Adapt between the timing test
cable, GS24192-1, and the
timing test box GS22907-1,
GS24194-1 Protractor Measure the valve angle
during testing.
GS24195-1 Position Switch Test Box Do a functional test on the
position switch.
M22520/1-01 and M22520/1-04 Crimping Tool and Turret Used to get a correct position
Head Assembly for and to crimp electrical
(Figure 901) contacts to the wires.
(Figure 902) contacts from the electrical
connector.
Figure 901. Crimping Tool M22520/1-01

Turret Head AssemblyM22520/1-04
Figure 902. Insertion/Removal Tool M81969/14-02
Page 902
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816601
ILLUSTRATED PARTS LIST

1. Introduction
A. General
(1) Purpose - The Illustrated Parts List (IPL) shows the detail parts for each item on the
Title Page. The IPL includes all of the parts that can be disassembled, repaired or
replaced, and assembled again.
(2) Organization - The IPL is divided into:
(a) The Introduction, which tells how to use the IPL and includes the Vendor
Decoding Table.
(b) The Equipment Designator Index (if necessary), which shows all of the electrical
components in the sequence of their reference designators.
(c) The Numerical Index, which shows all of the parts in the sequence of their part
numbers.
(d) The Detailed Parts List, which shows all of the parts in their approximate
disassembly sequence with illustrations.
(e) The Configuration Change Summary, which shows the sequence and causes for
the changes in the IPL.
(3) Abbreviations and Acronyms - These abbreviations are used in Hamilton
Sundstrand’s parts lists.
AR - As Required (necessary)
Be - Beryllium
CAGE - Commercial And Government Entity
ESDS - Electrostatic Discharge Sensitive
HS - Hamilton Sundstrand Specification/Source Control Drawing
NHA - Next Higher Assembly
NP - Non-Procurable
RF - Reference
(4) The part numbers identified in this Illustrated Parts List have been shown to comply
with the applicable Federal Aviation Regulations and, when purchased from
Hamilton Sundstrand, are FAA-approved under a Hamilton Sundstrand FAA
Production Certificate (PC), Technical Standard Order (TSO), or Parts Manufacture
Approval (PMA) for use in the component listed.
(5) This IPL does not constitute a grant of direct-ship authority, or otherwise confer
FAA-approval under FAR 21.303 for parts and assemblies purchased directly from a
listed vendor. Installation eligibility of all parts and assemblies purchased directly
from a listed vendor must be supported by the vendor’s Parts Manufacture Approval
(PMA).
Page 1001
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816601
(6) Warnings and Cautions

(a) Electrostatic Discharge Sensitive (ESDS) Parts - ESDS parts and assemblies
have the letters “ESDS” in the NOMENCLATURE column. They are identified in
figures by the ESDS symbol. If an assembly is ESDS, all of its parts are ESDS.
CAUTION: ALL CIRCUIT CARD ASSEMBLIES ARE ESDS. DO NOT REMOVE

THEM FROM THEIR CONTAINERS UNTIL IMMEDIATELY BEFORE
THEY ARE INSTALLED. OBEY THE ESDS PROCEDURES IN THE
MAINTENANCE INSTRUCTIONS. DO NOT KEEP ESDS PARTS
NEAR ELECTROSTATIC, ELECTROMAGNETIC, MAGNETIC, OR
RADIOACTIVE FIELDS. ESDS PARTS CAN BE DAMAGED IF NOT
PROTECTED.
(b) Some parts contain beryllium or beryllium oxide. These parts have the letters
“Be” in the NOMENCLATURE column of the Detailed Parts List.
WARNING: USE GOGGLES, RUBBER GLOVES, AND A PARTICLE MASK WHEN
YOU CUT, DRILL, SAW, FILE, OR MACHINE ANY COMPONENTS
THAT CONTAIN BERYLLIUM OR BERYLLIUM OXIDE. WORK IN AN
AREA WITH A GOOD FLOW OF AIR. BERYLLIUM OXIDE IS
POISONOUS TO THE SKIN, EYES, AND RESPIRATORY TRACT.
B. How to Use the IPL
(1) Assembly Sequence Indentation - The names of the parts in the
“NOMENCLATURE” column of the IPL are indented to show which parts are
installed in other parts. The level of indentation is shown by the number of dots at the
left edge of the NOMENCLATURE column. For example, the top assembly for a
parts list figure is at the left margin. The names of its parts and subassemblies are
indented by one dot. Subsequent subassemblies and parts are indented with more
dots.
Top Assembly
.Detail Parts of the Top Assembly
.Subassembly of the Top Assembly
.Attaching Parts for the Subassembly
..Detail Parts of the Subassembly
..Subassemblies of the Subassembly
(2) Part Numbers - Five types of numbers are used in the PART NUMBER column of
the Detailed Parts List. They are:
(a) Hamilton Sundstrand Part Numbers - If a part is only available from Hamilton
Sundstrand, the Hamilton Sundstrand Part number is shown in the PART
NUMBER column.
Page 1002
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816601
(b) Vendor Part Numbers - If a part is not changed by Hamilton Sundstrand, the
vendor’s part number is shown in the PART NUMBER column. The vendor’s
code is shown in the NOMENCLATURE column after the letter “V”. The
equivalent Hamilton Sundstrand part number is shown in the NOMENCLATURE
column after the letters “HS”.
(c) Industrial Standard and Military Numbers - If a part has an industrial standard
number or military standard number, that number is shown in the PART
NUMBER column.
(d) RFN Numbers - “RFN” numbers refer to groups of parts which are thought of as
an assembly. This is done to make the parts list easier to use. You cannot
procure parts by their “RFN” numbers.
(e) RFL Numbers - Some vendor parts have “RFL” numbers in the PART NUMBER
column. “RFL” numbers are used when the correct vendor part number is too
long to fit in the PART NUMBER column. The correct vendor part number is in
the NOMENCLATURE column after the words “IDENT. AS”. You cannot procure
parts by their “RFL” numbers.
(3) Item Numbers and Variant Letters
(a) Each part has an item number in the FIG&ITEM column. Item numbers are in the
approximate sequence of disassembly.
(b) A variant letter is a letter after the item number for a part number. Letters A
through Z, but not I and O, are used. Variant letters are used for:
• Optional parts
• Added parts for different configurations
• Vendor changes
• Editorial changes.
(4) Parts Replacement Data - These words, in the NOMENCLATURE column, tell if one
part replaces another.
Words Definition
OPTIONAL This part is an optional alternative to other parts
in the same item number variant group.
SUPSD BY ITEM N The part with item number N replaces
(supersedes) this part
SUPSDS ITEM N This part replaces (supersedes) the part with
item number N.
PRE SB XXXX Use this part if Service Bulletin XXXX was not
done.
POST SB XXXX Use this part if Service Bulletin XXXX was done.
REFER TO SB XX If an existing part is checked, inspected and/or
modified by a Service Bulletin, without resulting
in a change to the part number, a note will appear
in the nomenclature of that part to “(REFER TO
SB XX).”
Page 1003
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816601
(5) “PARTIAL BREAKDOWN FOLLOWS” - These words, in the NOMENCLATURE

column, tell that two or more detail parts of the subassembly are not listed.
(6) “SERVICE USE” - These words, in the NOMENCLATURE column, tell that the part
was not used in the original equipment but can be used in for in-service units.
(7) “SERVICE EVALUATION PART” - These words, in the NOMENCLATURE column,
tell that the part is being used on a limited population of units and is not being
supplied for the general population of units.
(8) Items Not Shown - Some parts are not shown in the illustrations. These parts have a
dash (-) in front of their item numbers in the FIG&ITEM column.
(9) Change Codes
(a) Numbers in the CHG CODE column show the sequence in which changes were
made. The Configuration Change Summary, at the end of the IPL, tells about
each change code number used.
(b) If an asterisk follows a change code, all of the parts that have that change code
must be replaced at the same time.
(c) The Configuration Change Summary tells about the change codes. It identifies
each change by its change code number, and tells you:
• Which assemblies changed
• About the change
• Which engineering change caused the change, and which Service Bulletin
has the change procedures.
(10) Effectivity Codes - If there is more than one top assembly in a parts list figure, each
top assembly can have an effectivity code in the EFF CODE column. Effectivity
codes are letters A through Z, but not I and O. A part shown with an effectivity code
is only used in the top assembly that has the same effectivity code. Parts which do
not have effectivity codes are used in all of the top assemblies in the parts list figure.
Note that each parts list figure can have a set of effectivity codes.
(11) Units per Assembly - The UPA column tells you the total number of each part that is
installed in the next higher assembly.
(12) All solid shim thicknesses are given in inches. An example is (0.010 THK) which
represents a 0.010 inch thick solid shim. Metric equivalents are also given in
millimeters (mm). Metric equivalents are given in [ ] through out the IPL.
Page 1004
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816601
C. Vendors
04426 ITW Switches 70958 Bergen Cable Technologies, Inc.
Division of Illinois Tool Works, Inc. 170 Gregg St.
6615 W. Irving Park Rd. P.O. Box 1300
Chicago, IL 60634-2410 Lodi, NJ 07644-9982
Phone (773) 282-4040 Phone (201) 487-3521

Fax (773) 545-4450 Fax (201) 368-0532
26124 Garlock Bearings Inc. 81983 Lisk G. W. Co
Sub of Coltec Industries Inc. 2 South St.
700 Mid Atlantic Pky Clifton Springs, NY 14432-1118
Thorofare, NJ 08086
Phone (315) 462-2611
Phone (609)848-3200 Fax (315) 462-7611
Fax (609)848-5115
Page 1005
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816601
Page 1006
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816601
2. Numerical Index
_______________________________________________________________________________
Airline Total Airline Total
Part Number Part Number Fig - Item Req. Part Number Part Number Fig - Item Req.
_______________________________________________________________________________
04DU04 5 - 10 1 792898-1 3 - 150 5
65-430196 1 - 110 1 793489-1 1 - 190 1
69253B4 1 - 60 1 810361-2 1 - 70 1
69291C6-3-14 3 - 40 1 815278-1 4 - 130 1
69291C6-3-18 3 - 20 1 815278-11 4 - 160 1
69291C6-3-20 4 - 60 1 815287-1 4 - 100 1
69494J10 3 - 140 1 815308-1 4 - 70 1
3 - 170 1 815857-1 3 - 180 1
69494J12 1 - 210 1 815858-1 4 - 80 1
69494J13 1 - 170 1 815890-1 3 - 260 1
69494J8 1 - 100 1 5 - 1 RF
69494J904 4 - 20 1 815890-11 5 - 80 1
69494J910 3 - 230 1 815890-12 5 - 80A 1
69522-8F32 2 - 100 1 815890-2 3 - 260A 1
69725-4K14 2 - 180 1 5 - 1A RF
727511-3 3 - 210 1 816601-1 1 - 1 RF
727604-5 3 - 250 1 AN814-10DL 3 - 220 1
732158-2 4 - 30 AR BWR990-02-631 3 - 200 1
732158-3 4 - 31 AR D38999-20FB98PN 1 - 10 1
732158-4 4 - 32 AR L6646 1 - 120 1
732158-5 4 - 33 AR MS19060-4810 1 - 180 1
732158-6 4 - 34 AR MS21043-3 3 - 60 2
732158-7 4 - 35 AR 3 - 100 1
740285-6 2 - 10 1 3 - 120 1
740369-13 2 - 80 1 MS21209C0415 5 - 20 4
747771-2 4 - 120 1 MS21209C0815 2 - 110 2
751570-3-1 3 - 240 1 5 - 30 8
753642-1 1 - 220 1 5 - 40 2
753649-1 2 - 50 1 MS21209F4-10 5 - 50 1
753656-2 2 - 130 1 5 - 60 1
753658-2 1 - 90 1 MS21919WCH4 1 - 50 1
753659-2 4 - 90 1 MS21919WCH5 1 - 50A 1
753660-1 2 - 90 1 MS24665-1002 3 - 30 1
753660-10 2 - 120 1 MS24665-18 3 - 10 1
753661-1 2 - 140 1 4 - 50 1
753662-1 2 - 70 1 MS24665-82 2 - 160 1
753663-1 2 - 60 1 MS28774-010 3 - 130 1
753664-1 2 - 20 1 MS9385-02 3 - 190 1
753665-1 2 - 150 1 MS9902-04 4 - 10 1
764448-2 4 - 140 1 NAS1352N04-6 1 - 20 4
4 - 150 1 1 - 20A 4
764900-5 4 - 110 1 NAS1352N08-10 1 - 40 8
767093-1 3 - 160 1 2 - 30 2
788085-1 1 - 160 1 NAS1352N08-8 1 - 130 1
788086-9 1 - 200 1 1 - 140A 1
790343-1 1 - 80 1 NAS1352N08H8 1 - 140 1
Page 1007
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816601
_______________________________________________________________________________
Airline Total Airline Total
Part Number Part Number Fig - Item Req. Part Number Part Number Fig - Item Req.
_______________________________________________________________________________
NAS1802-3-16 3 - 90 2 NAS620C8L 2 - 40 2
NAS1860CA9 5 - 70 2 RFN6041 1 - 230 1
NAS620C10L 3 - 70 2 2 - 1 RF
3 - 80 2 RFN6042 2 - 190 1
3 - 110 1 3 - 1 RF
NAS620C4L 1 - 30 4 RFN6043 3 - 50 1
NAS620C5L 2 - 170 1 4 - 1 RF
NAS620C8L 1 - 150 2
Page 1008
21-32-20 Aug 1/03
816601
3. Detailed Parts List

NOTE: The items in this list are made or supplied by the Hamilton Sundstrand Division of
United Technologies Corporation, or by the suppliers shown in this list. Hamilton
Sundstrand does not give approval for items that you get from suppliers who are not
shown in this list. Approval from Hamilton Sundstrand is not necessary for
government and industry standard parts.
Page 1009
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816601
IPL Figure 1. High-Stage Bleed Valve (Electrical Group)
Page 1010
21-32-20 Aug 1/03
816601
Airline Eff
Fig& Item Part Number Part Number 1234567Nomenclature Code UPA
1 - 1 816601-1 VALVE - HIGH STAGE BLEED,PART1 RF
(ELECTRICAL GROUP)
10 D38999-20FB98PN .CONNECTOR 1
IDENT AS D38999/20FB98PN
ATTACHING PARTS
- 20 NAS1352N04-6 DELETED 4
20A NAS1352N04-6 .SCREW 4
30 NAS620C4L .WASHER 4
------*------
40 NAS1352N08-10 .SCREW 8
50 MS21919WCH4 .CLAMP 1
SUPSD BY ITEM 50A
- 50A MS21919WCH5 .CLAMP 1
SUPSDS ITEM 50
CHANGE CODE 2
60 69253B4 .PLATE - IDENTIFICATION, FOIL 1
70 810361-2 .PLATE - INSTRUCTION 1
80 790343-1 .PLATE - MOUNTING 1
90 753658-2 .ACTUATOR - COVER AND TUBE 1
100 69494J8 .PACKING - PREFORMED 1
110 65-430196 .SWITCH - ENVIRONMENT FREE 1
V04426, HS740215-18
REFER TO SB 21-2197
CHANGE CODE 3
120 L6646 .SOLENOID - PULL 1
V81983, HS747767-6
ATTACHING PARTS
130 NAS1352N08-8 .SCREW 1
140 NAS1352N08H8 .SCREW 1
SUPSD BY ITEM 140A
- 140A NAS1352N08-8 .SCREW 1
SUPSDS ITEM 140
CHANGE CODE 1
------*------
160 788085-1 .SEAT - VALVE 1
180 MS19060-4810 .BALL 1
190 793489-1 .SPRING - HELICAL COMPRESSION 1
200 788086-9 .BODY - VALVE 1
220 753642-1 .SPRING - HELICAL COMPRESSION 1
230 RFN6041 .VALVE - HIGH STAGE BLEED, 1
PART 2
(ACTUATOR LINKAGE GROUP)
FOR DETAILS SEE FIG. 2
Page 1011
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816601
IPL Figure 2. Actuator Linkage Group
Page 1012
21-32-20 Aug 1/03
816601
Airline Chg Eff

Fig & Item Part Number Part Number 1234567Nomenclature Code Code UPA
2 - 1 RFN6041 VALVE,HIGH STAGE BLEED,PART 2 RF
(ACTUATOR LINKAGE GROUP)
SEE FIG. 1 FOR NHA
10 740285-6 .RING,RIDER 1
20 753664-1 .PLATE,RIDER 1
ATTACHING PARTS
30 NAS1352N08-10 .SCREW 2
-------*-------
50 753649-1 .DIAPHRAGM 1
60 753663-1 .PISTON 1
70 753662-1 .GUIDE,PISTON 1
80 740369-13 .RING,PISTON 1
90 753660-1 .RETAINER,LINK 1
ATTACHING PARTS
100 69522-8F32 .PIN,STRAIGHT,HEADLESS 1
-------*-------
110 MS21209C0815 ..INSERT 2
120 753660-10 ..RETAINER (NP) 1
130 753656-2 .SPRING,HELICAL COMPRESSION 1
140 753661-1 .RETAINER,SPRING 1
150 753665-1 .CONNECTOR,LINK 1
ATTACHING PARTS
160 MS24665-82 .PIN 1
180 69725-4K14 .PIN,STRAIGHT,HEADED 1
-------*-------
190 RFN6042 .VALVE,HIGH STAGE BLEED, 1
PART 3 (NP)
(LOCK AND FILTER GROUP)
SEE FIG. 3 FOR DETAILS
Page 1013
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816601
IPL Figure 3. Lock and Filter Group
Page 1014
21-32-20 Aug 1/03
816601
Airline Chg Eff

(LOCK AND FILTER GROUP)
SEE FIG. 2 FOR NHA
10 MS24665-18 .PIN 1
20 69291C6-3-18 .PIN,STRAIGHT,HEADED 1
30 MS24665-1002 .PIN 1
50 RFN6043 .VALVE,HIGH STAGE BLEED 1
PART 4 (NP)
(VALVE GROUP)
ATTACHING PARTS
60 MS21043-3 .NUT 2
90 NAS1802-3-16 .SCREW 2
100 MS21043-3 .NUT 1
120 MS21043-3 .NUT 1
-------*-------
130 MS28774-010 .RETAINER,PACKING BACKUP 1
140 69494J10 .PACKING,PREFORMED 1
150 792898-1 .SHIM,SOLID 5
160 767093-1 .BUSHING,SLEEVE 1
180 815857-1 .SCREW,LOCKING 1
190 MS9385-02 .PACKING 1
200 BWR990-02-631 .CABLE AND TERMINAL,RETAINING 1
V70958, HS774558-4
210 727511-3 .RETAINER,CHAIN 1
220 AN814-10DL .PLUG AND BLEEDER 1
240 751570-3-1 .SPRING,COMPRESSION 1
250 727604-5 .FILTER,AIR 1
260 815890-1 .HOUSING,ACTUATOR 1
SUPSD BY ITEM 260A
- 260A 815890-2 .HOUSING,ACTUATOR 1 1
SUPSDS ITEM 260
Page 1015
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816601
IPL Figure 4. Valve Group
Page 1016
21-32-20 Aug 1/03
816601
Airline Chg Eff

(VALVE GROUP)
SEE FIG. 3 FOR NHA
10 MS9902-04 .PLUG 1
30 732158-2 .DISC,SOLID,PLAIN AR
(0.010 [0.254] THK)
SELECT FROM THIS AND
THE FOLLOWING
- 31 732158-3 .DISC,SOLID,PLAIN AR
(0.012 [0.305] THK)
(0.014 [0.356] THK)
(0.016 [0.406] THK)
(0.018 [0.457] THK)
(0.030 [0.762] THK)
50 MS24665-18 .PIN 1
70 815308-1 .DISC AND SHAFT 1
CONTAINS MATCHED PARTS
80 815858-1 ..CRANK,LOCKING 1
MATCHED PART
90 753659-2 ..CRANK,LINKAGE 1
MATCHED PART
100 815287-1 ..SHAFT,VALVE 1
MATCHED PART
110 764900-5 ..DISC,BUTTERFLY 1
MATCHED PART
120 747771-2 .RING,SEAL 1
130 815278-1 .HOUSING,VALVE 1
140 764448-2 ..BEARING,PLAIN 1
150 764448-2 ..BEARING,PLAIN 1
160 815278-11 ..HOUSING (NP) 1
Page 1017
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816601
IPL Figure 5. Actuator Housing
Page 1018
21-32-20 Aug 1/03
816601
Airline Chg Eff

5 - 1 815890-1 HOUSING,ACTUATOR A RF
SEE FIG. 3 FOR NHA
SUPSD BY ITEM 1A
- 1A 815890-2 HOUSING,ACTUATOR 1 B RF
SEE FIG. 3 FOR NHA
SUPSDS ITEM 1
PARTIAL BREAKDOWN FOLLOWS
10 04DU04 .BUSHING,SPLIT 1
V26124, HS799753-10
20 MS21209C0415 .INSERT 4
30 MS21209C0815 .INSERT 8
40 MS21209C0815 .INSERT 2
50 MS21209F4-10 .INSERT 1
60 MS21209F4-10 .INSERT 1
70 NAS1860CA9 .STUD 2
80 815890-11 .HOUSING (NP) A 1
SUPSD BY ITEM 80A
- 80A 815890-12 .HOUSING (NP) 1 B 1
SUPSDS ITEM 80
Page 1019
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816601
Page 1020
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816601
4. Configuration Change Summary
IPL Table 1. Configuration Change Summary
Chg HS Internal
Code Item Configuration Service Bulletin Reference Description
- 816601-1 L1 Not Required - Basic coverage

1 - Not Required 235034 Added a lockwire tab on
the actuator housing for
the air filter. Replaced the
one screw for the solenoid
that had lockwire holes to
one that does not have
holes.
2 - Not Required 278324 Added a larger clamp to fit
the wires and viton tubing.
3 - 21-2197 271973 Replaces the environment
free switch with one
having improved
construction for high
temperature operation.
Page 1021
21-32-20 Aug 29/07
816601
Page 1022
21-32-20 Aug 1/03

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To All Holders of Hamilton Sundstrand'S Component Maintenance Manual 21-32-20 Applicability: Emb135, Emb145 This Sheet Transmits Revision No. 4 Date Aug 29/07 Highlights

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COMPONENT MAINTENANCE MANUAL

TO ALL HOLDERS OF HAMILTON SUNDSTRAND’S

THIS IS A BLANK PAGE

© 1996, 1997, 2000, 2003, 2007 Hamilton Sundstrand Corporation

Information Subject to Export Control Laws

COMPONENT MAINTENANCE MANUAL

THIS IS A BLANK PAGE

THE USER OF THIS PUBLICATION SHOULD OBTAIN THE MATERIAL

D. Cautions are provided in the maintenance publication or service bulletin to alert

REV. ISSUE DATE REV. ISSUE DATE

4 Aug 29/07 Aug 30/07 HS

THIS IS A BLANK PAGE

RECORD OF TEMPORARY REVISIONS

REV. ISSUE DATE DATE

THIS IS A BLANK PAGE

SERVICE BULLETIN LIST

21-2197 Jul 17/02 Aug 29/07

THIS IS A BLANK PAGE

LIST OF EFFECTIVE PAGES

Subject Page Date Subject Page Date

Subject Page Date Subject Page Date

THIS IS A BLANK PAGE

DESCRIPTION AND OPERATION

Figure 1. High-Stage Bleed Valve

Figure 2. High-Stage Bleed Valve (External View)

2. Operation (Refer to Figure 3 and Figure 4.)

Figure 3. Mechanical/Pneumatic Diagram

Figure 4. Electrical Diagram

TESTING AND TROUBLE-SHOOTING

Table 101. Special Tools, Fixtures, and Equipment

TOOL NO. NAME USE

Table 101. Special Tools, Fixtures, and Equipment (Continued)

TOOL NO. NAME USE

GS24193-1 Timing Test Adapter Adapt between the timing test

Table 102. Test Equipment

EQUIPMENT PARAMETER MINIMUM RANGE PRECISION

Flowmeter WFM 0.1 to 1.0 ppm at ±2% of full scale

Pressure Gage PVI 0 to 11 psig ±0.5 psig

Pressure Gage PVI 0 to 62 psig ±1 psig

Pressure Gage PVI 0 to 250 psig ±5 psig

Pressure Gage PVI 0 to 456 psig ±2.5 psig

Quadrant and Pointer - 0 to 90° ±1°

Table 102. Test Equipment (Continued)

EQUIPMENT PARAMETER MINIMUM RANGE PRECISION

Voltmeter - 0 to 550 vac ±20 vac

Figure 101. Wiring Diagram

4. Proof Pressure Test

Figure 102. Proof Pressure Test Setup

Figure 103. Internal Leakage Test Setup

Figure 104. Leakage Correction

B. Do an external leakage test as follows:

Figure 105. External Leakage Test Setup

THIS IS A BLANK PAGE

B. Minimum Pressure Operation Test

Table 103. Test To Be Done Again

DISASSEMBLY TEST TO BE DONE AGAIN

Removal of Solenoid Dielectric Test

Figure 106. Minimum and Maximum Pressure Operation Test Setup

Table 104. Trouble-Shooting

TROUBLE POSSIBLE CAUSE WHAT TO DO

Table 301. Special Tools, Fixtures, and Equipment

TOOL NO. NAME USE

GS24180-1 Power Arm Fixture Hold the valve in the