21-32-20_R4

COMPONENT MAINTENANCE MANUAL 816601

TO ALL HOLDERS OF HAMILTON HAMILTON SUNDSTRAND’S COMPONENT MAINTENANCE MANUAL 21-32-20 APPLICABILITY: APPLICABILITY: EMB135, EMB145 THIS SHEET TRANSMITS REVISION NO. 4 DATE 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 wi th 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:[email protected] or fax at (860) 660-9014. The changes made to the manual during this revision are described in the table that follows: Page All Affected Affected Pages Pages

Description of Change

Change Driver References

Revised the special special tools and and consumable consumable materials notes.

Non-technical change; 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 1.A.(5).


1003

Added the definition of REFER TO SB XX.


1011

Added Service Bulletin 21-2197 reference to item 110.

IH-07726-124433 SB 21-2197

1021

Added Change Code 3.

IH-07726-124433 SB 21-2197

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HIGH-STAGE BLEED VALVE PART NUMBER: 816601-1 © 1996, 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 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.

COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST

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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 re sult 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 o n the sheet, but are intended to supplement them.

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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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RECORD OF REVISIONS BASIC ISSUE: Oct 30/96 REV. NO.

ISSUE DATE

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

REV. NO.

ISSUE DATE

DATE INSERTED

BY

HS

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RECORD OF TEMPORARY REVISIONS REV. NO.

ISSUE DATE

DATE INSERTED

BY

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DATE INCORPORATED

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SERVICE BULLETIN LIST SERVICE BULLETIN 21-2197

ISSUE DATE Jul 17/02

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LIST OF EFFECTIVE PAGES Subject

Page

Date

Subject

Title Page

T-1 T-2 SA-1 SA-2

Aug 29/07 Aug 1/03 Aug 1/03 Aug 1/03

Testing and 115 Trouble-Shooting Continued 116

Aug 1/03 Aug 1/03

Disassembly

RR-1 RR-2

Jan 15/00 Jan 15/00

Record of Temporary Revisions

RTR-1 RTR-2

Jan 15/00 Jan 15/00

Service Bulletin List

SBL-1 SBL-2

Aug 29/07 Jan 15/00

List of Effective Pages

LEP-1 LEP-2

Aug 29/07 Aug 29/07

T/C-1 T/C-2

Aug 29/07 Aug 1/03

301 302 303 304 305 306 307 308 309 310 311 312

Aug 29/07 Jan 15/00 Jan 15/00 Jan 15/00 Jan 15/00 Jan 15/00 Jan 15/00 Jan 15/00 Jan 15/00 Jan 15/00 Jan 15/00 Jan 15/00

Cleaning

List of Figures

LOF-1 LOF-2

Aug 29/07 Aug 29/07

401 402

Aug 29/07 Aug 1/03

Check

List of Tables

LOT-1 LOT-2

Aug 29/07 Aug 1/03

INTRO-1 INTRO-2

Jan 15/00 Jan 15/00

501 502 503 504 505 506 507 508 509 510 511 512 513 514 515 516 517 518

Jan 15/00 Jan 15/00 Jan 15/00 Jan 15/00 Jan 15/00 Jan 15/00 Jan 15/00 Jan 15/00 Jan 15/00 Jan 15/00 Jan 15/00 Jan 15/00 Jan 15/00 Jan 15/00 Jan 15/00 Jan 15/00 Jan 15/00 Jan 15/00

Repair-General

601 602 603 604

Aug 29/07 Aug 29/07 Aug 29/07 Jan 15/00

Repair 1-1

601 602

Aug 1/03 Aug 1/03

Repair 2-1

601 602

Jan 15/00 Jan 15/00

Safety Summary Record of Revisions

Table of Contents

Introduction Description and Operation

Testing and Trouble-Shooting

1 2 3 4 5 6

Jan 15/00 Jan 15/00 Jan 15/00 Jan 15/00 Jan 15/00 Jan 15/00

101 102 103 104 105 106 107 108 109 110 111 112 113 114

Aug 29/07 Aug 29/07 Aug 29/07 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03

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Date

Page LEP-1 Aug 29/07


Subject

Page

Date

Repair 3-1

601 602

Jan 15/00 Jan 15/00

Repair 3-2

601 602

Jan 15/00 Jan 15/00

Assembly

701 702 703 704 705 706 707 708 709 710 711 712 713 714 715 716 717 718 719 720 721 722 723 724

Aug 29/07 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03

Fits and Clearances

801 802

Jan 15/00 Jan 15/00

Special Tools, Fixtures, and Equipment

901 902

Aug 29/07 Jan 15/00

1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1016 1017 1018

Aug 29/07 Aug 29/07 Aug 29/07 Aug 29/07 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 29/07 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03 Aug 1/03

Illustrated Parts List

Subject

Page

Date

Illustrated Parts List (Continued)

1019 1020 1021 1022

Aug 1/03 Aug 1/03 Aug 29/07 Aug 1/03

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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 Figure 1. Figure 2. Figure 3. Figure 4. Figure 101. Figure 102. Figure 103. Figure 104. Figure 105. Figure 106. Figure 301. Figure 302. Figure 303. Figure 304. Figure 305. Figure 501. Figure 502. Figure 503. Figure 504. Figure 505. Figure 506. Figure 507. Figure 508. Figure 509. Figure 510. Figure 511. Figure 512. Figure 513. Figure 514. Figure 601. Figure 601. Figure 601. Figure 601. Figure 701. Figure 702. Figure 703. Figure 704. Figure 705. Figure 706. Figure 707. Figure 708.

Page High-Stage Bleed Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 High-Stage Bleed Valve (External View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Mechanical/Pneumatic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Electrical Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Proof Pressure Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Internal Leakage Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Leakage Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 External Leakage Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Minimum and Maximum Pressure Operation Test Setup . . . . . . . . . . . . . 115 Electrical Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303 Actuator Linkage Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305 Lock and Filter Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307 Valve Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309 Actuator Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311 Actuator Cover and Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502 Pull Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503 Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504 Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505 Piston Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506 Piston Ring-Helix, Wear and Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507 Piston Ring-Wear Pattern and Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508 Disc and Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510 Locking Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511 Linkage Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512 Valve Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513 Butterfly Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514 Seal Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515 Valve Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516 Connector Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair 1-1 601 Install the Plain Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair 2-1 601 Replace the Split Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair 3-1 602 Actuator Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair 3-2 602 Valve Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 705 Measure the Dimensions Necessary to Calculate the Thickness of the Shims That Hold the Valve Shaft in Position . . . . . . . . . . . . . . . . . . 706 Install the Valve Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711 Install the Locking Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713 Install the Air Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715 Assemble the Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 717 Install the Electrical Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721 Positions of the Insulation Sleeving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 722

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Figure Figure 901. Figure 902. IPL Figure 1. IPL Figure 2. IPL Figure 3. IPL Figure 4. IPL Figure 5.

Page Crimping Tool M22520/1-01 Turret Head AssemblyM22520/1-04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902 Insertion/Removal Tool M81969/14-02. . . . . . . . . . . . . . . . . . . . . . . . . . . . 902 High-Stage Bleed Valve (Electrical Group). . . . . . . . . . . . . . . . . . . . . . . . 1010 Actuator Linkage Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1012 Lock and Filter Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1014 Valve Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1016 Actuator Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1018

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LIST OF TABLES Table

Page

Table 101. Table 102. Table 103. Table 104. Table 301. Table 401. Table 501.

Special Tools, Fixtures, and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Test To Be Done Again . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Trouble-Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Special Tools, Fixtures, and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 301 Cleaning Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401 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 701. Special Tools, Fixtures, and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 701 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 Table 901. Special Tools, Fixtures, and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 901 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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6. All measured quantities in this manual are given in English units with metric equivalents in parentheses (). 7. Verification:

8.

Testing and Troubleshooting Disassembly Assembly

Verified by simulation Verified by simulation Verified by simulation

Abbreviations and Acronyms: °C cps °F ma ppm Pamb Pc Pfm psia psig

Degrees Centigrade Cycles per second Degrees Fahrenheit Milliamperes Pounds per minute Ambient pressure Calibrated flowmeter pressure Flowmeter pressure Pounds per square inch absolute Pounds per square inch gage

Pvi °R rms Tc Tfm vac vdc Wfm Wfmc

Valve inlet pressure Degrees Rankine Root mean square Calibrated flowmeter temperature Flowmeter temperature Alternating current voltage Direct current voltage Measured flow from the flowmeter Corrected flow

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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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Figure 1. High-Stage Bleed Valve

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

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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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Figure 3. Mechanical/Pneumatic Diagram

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Figure 4. Electrical Diagram

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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 (2 required)

Cap the valve inlet and outlet 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 box, GS22907-1, and the 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, during operational test.

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. NOTE: Equivalent tools, fixtures, and equipment can be used if they agr ee with the requirements of ARINC Report 668. Table 102. Test Equipment EQUIPMENT

PARAMETER

MINIMUM RANGE

PRECISION

Flowmeter

WFM

0.1 to 1.0 ppm at 14.7 psia and 50 to 120 °F (10 to 48.9 °C)

±2% of full scale

Flowmeter

WFM

0.01 to 0.10 ppm at 40 psig and 50 to 120 °F (10 to 48.9 °C)

±2% of full scale

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 Readout

TFM

50 to 120 °F (10 to 48.9°C)

±5 °F (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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Figure 101. Wiring Diagram

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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). (2) Increase the inlet pressure (PVI) to 385 ±5 psig. Keep this pressure for a minimum of 60 seconds. (3) Decrease the pressure to zero. (4) Examine the valve for damage or deformation. There must be no signs of damage or 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. (2) Increase the inlet pressure (PVI) to 296 ±5 psig. Keep this pressure for a minimum of 60 seconds. (3) Decrease the pressure to zero. (4) Examine the valve for damage or deformation. There must be no signs of damage or deformation.

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Figure 102. Proof Pressure Test Setup

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5. Leakage Tests A. Do an internal leakage test as follows: (1) Install the valve in the test setup shown in Figure 103. NOTE: If your flow measuring device compensates for temperature, it is not necessary to measure the flowmeter pressure (P FM), 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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Figure 104. Leakage Correction (5) The corrected leakage must not be more than 0.36 ppm. (6) Decrease the pressure to zero.

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B. Do an external external leakage leakage test as follows follows:: (1) Install Install the the valve valve in the the test test setup setup shown shown in Figure 105. 105. NOTE: If your flow measuring device compensates for temperature, it is not necessary to measure the flowmeter pressure (P FM), and the flowmeter temperature (TFM) or correct for temperature as specified in steps (3) and (3) and (4). (4). (2) Increas Increase e the inle inlett pressu pressure re (PVI) to 60 ±2 psig. (3) Measur Measure e and write write the meas measure ured d flow (WFM), flowmeter pressure (PFM), and the flowmeter temperature (TFM). (4) Calculate Calculate the correcte corrected d leakage leakage rate rate as shown shown in Figure 104. 104. (5) The correcte corrected d leakage leakage must must not be more more than 0.10 ppm. ppm. (6) Decrea Decrease se the the press pressure ure to to zero. zero.

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Figure 105. External Leakage Test Test Setup

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6. Perf Perfor orma manc nce e Test Tests s A. Position Switch Function Function Test Test (1) Install Install a protractor protractor,, GS24194-1, GS24194-1, to measure measure the angle of the va valve. lve. (2) Refer Refer to the the wirin wiring g diagra diagram m in Figure 101. 101. NOTE: You can use an ohmmeter, 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 valve closed, closed, do a check to make make sure there is continui continuity ty between between pins C and D. (4) Turn Turn the valve to the open open position. position. The continuity continuity between between pins 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 continui continuity ty between between pins C and and D does not stop stop when the the valve is between between 3 and 9, you can adjust the position as follows: (a) Loosen Loosen the nuts on the environme environment nt free (position) (position) switch switch (110, (110, IPL Figure 1). (b) Adjust Adjust the position position of the the switch switch with the positi position on of the two nuts. nuts. (c) (c) Tight ighten en the the nut nuts. s. (d) Do st step (4) again. (4) again. (6) Turn Turn the valve to the the closed position position.. The continuity continuity between 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 Adjust the environment environment free (position) (position) switch switch (110) (110) as necessary necessary to get the conditions in steps (4) and (4) and (6). (6). The test result is satisfactory when you can do steps (4) and (4) and (6) with (6) with no adjustment between the steps.

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B. Minimum Pressure Operation Test (1) Install the valve in the test setup shown in Figure 106. (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. (6) Decrease the pressure to zero. C. Maximum Pressure Operation Test (1) Install the valve in the test setup shown in Figure 106. (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. (6) Decrease the pressure to zero. 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 given in the dielectric test.

The insulation on the wires or contacts are damaged.

Examine the wires and the 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 given in the insulation resistance test.

The insulation on the wires is damaged or the wires are broken.

Replace the solenoid (120, IPL Figure 1) or environment free switch (110), as necessary.

The valve is not in the limits given in the internal leakage test.

The split ring or the butterfly disc is worn or damaged.

Replace the split ring or the butterfly disc. Refer to ASSEMBLY. Do the tests that are specified in Table 103.

The valve is not in the limits given in the external leakage test.

The split bushings in the valve housing are worn or damaged.

Replace the split bushings. Refer to REPAIR. Do the tests that are specified in Table 103.

The valve is not in the limits given in the position switch function test.

The environment free switch or the wiring is damaged.

Replace the environment free switch. Refer to ASSEMBLY. 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. 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 301. Special Tools, Fixtures, and Equipment 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 a ll of the design and qualification requirements. Only approved materials engineering can make equivalent consumable material decisions and these materials a re used at the risk of the organization who makes the decision. Table 401. Cleaning Materials NAME Corrosion Preventive Compound Crocus Cloth

SOURCE OR SPECIFICATION AMS3072

USE Prevents corrosion.

P-C-451

Removes corrosion from external surfaces.

Fingerprint Corrosion Preventive Compound

AMS3065

Fingerprint neutralizer.

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, ITEM AND FIGURE NO.

TYPE OF EXAMINATION

PROCEDURE

LIMITS OR REMARKS

Electrical Connector (10, IPL Figure 1)

Visual

Do a check for bent, broken or burned-out pins.

No damage is permitted.

Identification Plate (60, IPL Figure 1)

Visual

Make sure that you can read the letters and numbers.

All letters and numbers must be clear.

Actuator Cover and Tube (90, IPL Figure 1)

Dimensional

Make sure that the flange surface is flat.

Refer to Figure 501.

Figure 501. Actuator Cover and Tube

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Table 502. Special Checks for the Pull Solenoid PART NAME, ITEM AND FIGURE NO. Pull Solenoid (120, IPL Figure 1)

TYPE OF EXAMINATION

PROCEDURE

LIMITS OR REMARKS

Functional

Apply 28 ±1 0.5VDC to pins A and B of the connector (10, IPL Figure 1). Measure the travel of the plunger.


Visual

Examine the end of the plunger.


Examine the connector for corrosion and burned or bent pins.

No corrosion or damaged pins are permitted.

Figure 502. Pull Solenoid

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Table 503. Special Checks for the Valve Seat PART NAME, ITEM AND FIGURE NO. Valve Seat (160, IPL Figure 1)

TYPE OF EXAMINATION Visual

PROCEDURE Do a check of the ball mating surface for nicks and burrs. Refer to Figure 503.

LIMITS OR REMARKS No nicks and burrs are permitted on the ball mating surface

Figure 503. Valve Seat

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Table 504. Special Checks for the Valve Body PART NAME, ITEM AND FIGURE NO. Valve Body (200, IPL Figure 1)


PROCEDURE Do a check of the ball mating surface for nicks and burrs. Refer to Figure 504.

LIMITS OR REMARKS No nicks and burrs are permitted on the ball mating surface

Figure 504. Valve Body

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Table 505. Special Checks for the Piston Guide PART NAME, ITEM AND FIGURE NO. Piston Guide (70, IPL Figure 1)

TYPE OF EXAMINATION Dimensional

PROCEDURE Measure the groove.

LIMITS OR REMARKS Refer to Figure 505

Figure 505. Piston Guide

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Table 506. Special Checks for the Piston Ring PART NAME, ITEM AND FIGURE NO. Piston Ring (80, IPL Figure 2)

TYPE OF EXAMINATION

PROCEDURE

LIMITS OR REMARKS

Visual

Examine the ring for helix and wear.


Dimensional

Measure the wear pattern 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, ITEM AND FIGURE NO.

TYPE OF EXAMINATION

PROCEDURE

LIMITS OR REMARKS

Link Retainer (90, IPL Figure 2)

Visual

Make sure that the threads of the inserts (110) are not damaged.

Damaged or loose inserts are not permitted.

Link Connector (150, IPL Figure 2)

Dimensional

Do a check of the inside diameter of the two holes.

The inside diameter must be 0.1265 (3.2131) maximum.

Sleeve Bushing (160, IPL Figure 3)

Visual

Examine it for nicks, burrs and other damage.


Dimensional

Measure the inside diameter in two locations that are 90° from each other.

The inside diameter must be 0.271 (6.8834) maximum.

Visual

Make sure that the threads of the inserts (20, 30, 40, 50, 60, IPL Figure 5) are not damaged and the inserts are not loose.

Damaged or loose inserts are not permitted.

Make sure that the threads of the studs (70, IPL Figure 5) are not damaged and the studs are not loose.

Damaged or loose studs are not permitted.

Make sure that the diameter of the pin holes in the locking crank (80), linkage crank (90), valve shaft (100) and butterfly disc (110) are less than the limit specified in Figure 508.

The diameters of the all the holes must be in the specified limit.

Actuator Housing (260, IPL Figure 3)

Disc and Shaft (70, IPL Figure 4)

Dimensional

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, ITEM AND FIGURE NO. Locking Crank (80, IPL Figure 4)


PROCEDURE Measure the diameter of the hole shown in Figure 509.

LIMITS OR REMARKS The diameter must be in the specified limit.

Figure 509. Locking Crank

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Table 509. Special Checks for the Linkage Crank PART NAME, ITEM AND FIGURE NO. Linkage Crank (90, IPL Figure 4)


PROCEDURE Measure the diameter of the hole shown in Figure 510.

LIMITS OR REMARKS The diameter must be in the specified limit.

Figure 510. Linkage Crank

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Table 510. Special Checks for the Valve Shaft PART NAME, ITEM AND FIGURE NO. Valve Shaft (100, IPL Figure 4)


PROCEDURE Measure the dimensions specified in Figure 511.

LIMITS OR REMARKS The dimensions must be in the specified limits.

Figure 511. Valve Shaft

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Table 511. Special Checks for the Butterfly Disc PART NAME, ITEM AND FIGURE NO. Butterfly Disc (110, IPL Figure 4)


PROCEDURE Measure the dimensions specified in Figure 512.

LIMITS OR REMARKS The dimensions must be in the specified limits

Figure 512. Butterfly Disc

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Table 512. Special Checks for the Seal Ring PART NAME, ITEM AND FIGURE NO. Seal Ring (120, IPL Figure 4)


PROCEDURE

LIMITS OR REMARKS

Do a check of the ring as shown in Figure 513.


Do a light-tightness test with the ring in a gage with an internal diameter of 1.875 (47.625). Use a 40 watt lamp.

The ring must not be less than 85% light-tight.

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, ITEM AND FIGURE NO. Valve Housing 130, IPL Figure 4)


PROCEDURE Make sure the chromium plated surface is not broken.

LIMITS OR REMARKS Refer to Figure 514.

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 length is 0.16 (4.06).

0.07 ±0.007 pound (0.032 ±0.0032 kilogram) is the load necessary to get the specified length.

220, IPL Figure 1


7 ±0.7 pounds (3.18 ±0.318 kilograms) is the load necessary to get the specified length.

130, IPL Figure 2


2 ±0.2 pounds (0.91 ±0.091 kilogram) is the load necessary to get the specified length.

240, IPL Figure 3


16 ±1.6 pounds (7.27 ±0.727 kilograms) is the load necessary to get the specified length.

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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. 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 601. Special Tools, Fixtures, and Equipment 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



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C. The materials necessary to do the repairs to the parts of the unit are specified in Table 602. 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 602. Materials NAME

SOURCE OR SPECIFICATION

USE

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 EA9394 Hardener

Hysol Division The Dexter Corp. P.O. Box 312 2850 Willow Pass Rd. Pittsburg, CA 94565

Bond the studs to the actuator housing.

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 Lacquer Stick

Lake Chemical Co. 270 No. Whiternaw Ave. Chicago, IL 60612

Fills the data on the identification plate.

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.

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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.

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(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

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Repair-General Page 604 Jan 15/00


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

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Repair 1-1 Page 601 Aug 1/03



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Repair 1-1 Page 602 Aug 1/03


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. 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. 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

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Repair 2-1 Page 601 Jan 15/00



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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. 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 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.

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Figure 601. Replace the Split Bushing

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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).

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Figure 601. Actuator Studs

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ASSEMBLY 1. General A. The special tools, fixtures and equipment necessary to assemble the unit are specified in Table 701. 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 701. Special Tools, Fixtures, and Equipment TOOL NO.

NAME

USE

GS24180-1

Power Arm Fixture


GS24181-1

Closure Kit

Cap all open ports during shipment and storage to prevent contamination.

M81969/14-02



B. The materials necessary to assemble the unit are specified in Table 702. NOTE: Maintenance personnel must use the specified consumable material for the specified task. These consumable materials are known to agree with a ll of the design and qualification requirements. Only approved materials engineering can make equivalent consumable material decisions and these materials a re used at the risk of the organization who makes the decision. Table 702. Materials NAME Dow Corning 44, Light Lubricant (DC44)

SOURCE OR SPECIFICATION Dow Corning 3901 S. Saginaw Rd. Midland, MI 48640

USE Lubricate the preformed packings.

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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Page 701 Aug 29/07


Table 702. Materials (Continued) NAME Mo-Lith No. 2 Thread Lubricant

SOURCE OR SPECIFICATION Fiske Brothers Refining Co. Lubriplate Div. 129 Lockwood St. Newark, NJ 07105

USE Used to lubricate the threads of fasteners.

Vendor Code 73219 Insulated Sleeving

M23053/13-001-0, M23053/13-002-0, M23053/13-003-0,

Insulate the wires between the connector and the push 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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Page 702 Aug 1/03



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Page 703 Aug 1/03


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) throug h 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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Page 704 Aug 1/03


Figure 701. Valve Group

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Page 705 Aug 1/03


Figure 702. Measure the Dimensions Necessary to Calculate the Thickness of the Shims That Hold the Valve Shaft in Position

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Page 706 Aug 1/03


(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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Page 707 Aug 1/03


(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, ITEM NUMBER

PART NUMBER

THICKNESS

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.

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Page 708 Aug 1/03


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.

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Page 709 Aug 1/03


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 unde r 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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Page 710 Aug 1/03


Figure 703. Install the Valve Group

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Page 711 Aug 1/03


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). 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. 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 pound-inches (0.4 to 3.4 Newton-meters).

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Page 712 Aug 1/03


Figure 704. Install the Locking Screw

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Page 713 Aug 1/03


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). 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. 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.

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Page 714 Aug 1/03


Figure 705. Install the Air Filter

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Page 715 Aug 1/03


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). 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. 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).

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Page 716 Aug 1/03


Figure 706. Assemble the Actuator

21-32-20

Page 717 Aug 1/03


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 (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 (40) to the specified torque again. Tighten to the specified torque again when the assembly is at ambient temperature.

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Page 718 Aug 1/03



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Page 719 Aug 1/03


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 (2.3 to 2.8 Newton-meters). 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. 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. 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 (0.06 to 0.34 Newton-meters). 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 (2) Lubricate the preformed packing (210) with lubricating oil, MIL-L.-15719. Install the 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. (4) Lubricate the preformed packing (170) with lubricating oil, MIL-L.-15719. Install the 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.

21-32-20

Page 720 Aug 1/03


Figure 707. Install the Electrical Group

21-32-20

Page 721 Aug 1/03


(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 pound-inches (0.17 to 1.02 Newton-meters). 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. (2) Cut 1 piece of electrical insulation sleeving, M23053/13-002-0, in the applicable 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

21-32-20

Page 722 Aug 1/03


(3) Cut 1 piece of electrical insulation sleeving, M23053/13-003-0, in the applicable 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.

21-32-20

Page 723 Aug 1/03



21-32-20

Page 724 Aug 1/03


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 NAME AND FIGURE-ITEM NUMBER Butterfly Disc (110, IPL Figure 4) Valve Housing (130)

FIT OR CLEARANCE AND LIMIT The butterfly disc must be in the center of the valve housing bore ± 0.005 (0.127).

ASSEMBLY PARAGRAPH AND PAGE REFERENCES Paragraph 3.B. page 704

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 NAME AND (IPL FIGURE-ITEM NUMBER)

SPECIFIED TORQUE POUND-INCHES (NEWTON-METERS)

RUNNING TORQUE POUND-INCHES (NEWTON-METERS)

ASSEMBLY PARAGRAPH AND PAGE (REFERENCE)

Screw * (20, IPL Figure 1)

3 to 5 (0.34 to 0.57)

0.5 to 3 (0.06 to 0.34)

Paragraph 8.C. page 720


20 to 25 (2.3 to 2.8)

1.5 to 9 (0.17 to 1.02)

Paragraph 7.Q. Page 718

Environment Free Switch (110, IPL Figure 1)

20 to 25 (2.3 to 2.8)

-

Paragraph 8. A. Page 720


20 to 25 (2.3 to 2.8)

1.5 to 9 (0.17 to 1.02)

Paragraph 8.D.(8) page 722


20 to 25 (2.3 to 2.8)

1.5 to 9 (0.17 to 1.02)

Paragraph 8.D.(8) page 722


20 to 25 (2.3 to 2.8)

1.5 to 9 (0.17 to 1.0)

Paragraph 7.L. page 718

Nut * (60, IPL Figure 3)

30 to 35 (3.4 to 4.0)

2 to 13 (0.22 to 1.47)

Paragraph 4.B.(5) page 710


30 to 35 (3.4 to 4.0)

2 to 13 (0.22 to 1.47)


21-32-20

Page 801 Jan 15/00


Table 802. Assembly Torques (Continued) NAME AND (IPL FIGURE-ITEM NUMBER)

SPECIFIED TORQUE POUND-INCHES (NEWTON-METERS)

RUNNING TORQUE POUND-INCHES (NEWTON-METERS)

ASSEMBLY PARAGRAPH AND PAGE (REFERENCE)


30 to 35 (3.4 to 4.0)

2 to 13 (0.22 to 1.47)


Locking Screw * (180, IPL Figure 3)

20 to 25 (2.3 to 2.8)

3.5 to 30 (0.4 to 3.4)

Paragraph 5.C. page 712

Plug and Bleeder * (220, IPL Figure 3)

35 to 40 (4.0 to 4.5)

-

Paragraph 6.D. page 714

Plug and Bleeder * (10, IPL Figure 4)

30 to 35 (3.4 to 4.0)

-

Paragraph 3.G. page 709

* Lubricate the threads with Mo-Lith No. 2.

21-32-20

Page 802 Jan 15/00


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. 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 901. Special Tools, Fixtures, and Equipment TOOL NO.

NAME

USE

GS15200-2

Filter Test Fixture

Check filter for pressure drop.

GS20985-1

Pressure Test Cap (2 required)

Cap the valve inlet and outlet 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.

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 Installer

Install the retaining clip and cable on the hex screw.

GS24180-1

Power Arm Fixture


GS24181-1

Closure Kit

Cap all open ports during shipment and storage to prevent contamination.

21-32-20

Page 901 Aug 29/07


Table 901. Special Tools, Fixtures, and Equipment (Continued) TOOL NO.

NAME

USE

GS24192-1

Timing Test Cable

Adapt between the timing test box, GS22907-1, and the valve electrical connector during operational test.

GS24193-1

Timing Test Adapter

Adapt between the timing test cable, GS24192-1, and the timing test box GS22907-1, during operational test.

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 Head Assembly (Figure 901)

Used to get a correct position for and to crimp electrical contacts to the wires.

M81969/14-02

Insertion/Removal Tool (Figure 902)


Figure 901. Crimping Tool M22520/1-01 Turret Head AssemblyM22520/1-04

Figure 902. Insertion/Removal Tool M81969/14-02

21-32-20

Page 902 Jan 15/00


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).

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Page 1001 Aug 29/07


(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.

21-32-20

Page 1002 Aug 29/07


(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 OPTIONAL SUPSD BY ITEM N SUPSDS ITEM N PRE SB XXXX POST SB XXXX REFER TO SB XX

Definition This part is an optional alternative to other parts in the same item number variant group. The part with item number N replaces (supersedes) this part This part replaces (supersedes) the part with item number N. Use this part if Service Bulletin XXXX was not done. Use this part if Service Bulletin XXXX was done. 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).”

21-32-20

Page 1003 Aug 29/07


(5) “PARTI “PARTIAL AL BREAKDOWN BREAKDOWN FOLLOWS” FOLLOWS” - These words, in the NOMENCLA NOMENCLATURE TURE column, tell that two or more detail parts of the subassembly are not listed. (6) “SERVICE “SERVICE USE” USE” - These words, in the NOMENCLA NOMENCLATURE TURE column, column, tell that the part was not used in the original o riginal equipment but can be used in for in-service units. (7) “SERVICE EV EVALUATION ALUATION PART” PART” - These words, in the NOMENCLA NOMENCLATURE TURE column, tell that the part is being used on a limited population of units u nits and is not being supplied for the general population of o f units. (8) Items Not Not Shown - Some parts parts are not not shown in the illustrat illustrations. ions. These These parts parts have a dash (-) in front of their item numbers in the FIG&ITEM column. (9) (9) Chan Change ge Code Codes s (a) Numbers Numbers in the CHG CODE CODE column column show the the sequence sequence in which which changes changes were made. The Configuration Change Summary, at the end of the IPL, tells about each change code number used. (b) If an asterisk asterisk follows follows a change code, code, all of the parts parts that have that that change code code must be replaced at the same time. (c) The Configuratio Configuration n Change Summary Summary tells about the change change codes. codes. It identifies identifies each change by its change code number, and tells you: • Which Which asse assembl mblies ies change changed d • Abou Aboutt the the chan change ge • Which engineerin engineering g change caused caused the change, change, and which Service Service Bulleti Bulletin n has the change procedures. (10) Effectivity Effectivity Codes - If If there is more 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 a ssembly 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 Assembly - The UPA UPA column tells you the total number of each part that is installed in the next higher assembly. assembly. (12) All solid solid shim thickness thicknesses es are given in inches. inches. An example example is (0.010 (0.010 THK) which 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.

21-32-20

Page 1004 Aug 29/07 29/07


C. Vendors 04426

ITW Sw Switches Division of Illinois Tool Works, Inc. 6615 W. Irving Park Rd. Chicago, IL 60634-2410

7095 70958 8

Phone (773) 282-4040 Fax (773) 545-4450 2612 26124 4

Garl Garloc ock k Bea Beari ring ngs s Inc Inc.. Sub of Coltec Industries Inc. 700 Mid Atlantic Pky Thorofare, NJ 08086 Phone (609)848-3200 Fax (609)848-5115

Berge Bergen n Cabl Cable e Techn echnol olog ogies ies,, Inc Inc.. 170 Gregg St. P.O. Box 1300 Lodi, NJ 07644-9982 Phone (201) 487-3521 Fax (201) 368-0532

81983

Lisk G. W. Co 2 South St. Clifton Springs, NY 14432-1118 14432-1118 Phone (315) 4 62-2611 62-2611 Fax (315) 462-7 611 611

21-32-20

Page 1005 Aug 1/03



21-32-20

Page 1006 Aug 1/03


2. Nume Numeri rica call Inde Index x _______________________________________________________________________________ Airline Total Airline Total Part Number Part Number Fig - Item Req. Part Number Part Number Fig - Item Req. _______________________________________________________________________________ 04DU04 65-430196 69253B4 69291C6-3-14 69291C6-3-18 69291C6-3-20 69494J10 69494J12 69494J13 69494J8 69494J904 69494J910 69522-8F32 69725-4K14 727511-3 727604-5 732158-2 732158-3 732158-4 732158-5 732158-6 732158-7 740285-6 740369-13 747771-2 751570-3-1 753642-1 753649-1 753656-2 753658-2 753659-2 753660-1 753660-10 753661-1 753662-1 753663-1 753664-1 753665-1 764448-2 764900-5 767093-1 788085-1 788086-9 790343-1

5 1 1 3 3 4 3 3 1 1 1 4 3 2 2 3 3 4 4 4 4 4 4 2 2 4 3 1 2 2 1 4 2 2 2 2 2 2 2 4 4 4 3 1 1 1

-

10 10 110 60 40 20 60 140 170 210 170 100 20 230 100 180 210 250 30 31 32 33 34 35 10 80 120 240 220 50 130 90 90 90 120 140 70 60 20 150 140 150 110 160 160 200 80

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 AR AR AR AR AR AR 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

792898-1 793489-1 810361-2 815278-1 815278-11 815287-1 815308-1 815857-1 815858-1 815890-1 815890-11 815890-12 815890-2 816601-1 AN814-10DL BWR990-02-631 D38999-20FB98PN L6646 MS19060-4810 MS21043-3

MS21209C0415 MS21209C0815

MS21209F4-10 MS21919WCH4 MS21919WCH5 MS24665-1002 MS24665-18 MS24665-82 MS28774-010 MS9385-02 MS9902-04 NAS1352N04-6 NAS1352N08-10 NAS1352N08-8 NAS1352N08H8

21-32-20

3 1 1 4 4 4 4 3 4 3 5 5 5 3 5 1 3 3 1 1 1 3 3 3 5 2 5 5 5 5 1 1 3 3 4 2 3 3 4 1 1 1 2 1 1 1

-

150 190 70 130 160 100 70 180 80 260 1 80 80 A 260 A 1A 1 220 200 10 120 18 1 80 60 100 120 20 110 30 40 50 60 50 50 A 30 10 50 16 160 13 130 190 10 20 20 A 40 30 130 14 140 A 140

5 1 1 1 1 1 1 1 1 1 RF 1 1 1 RF RF 1 1 1 1 1 2 1 1 4 2 8 2 1 1 1 1 1 1 1 1 1 1 1 4 4 8 2 1 1 1

Page 1007 Aug 1/03


_______________________________________________________________________________ Airline Total Airline Total Part Number Part Number Fig - Item Req. Part Number Part Number Fig - Item Req. _______________________________________________________________________________ NAS1802-3-16 NAS1860CA9 NAS620C10L

NAS620C4L NAS620C5L NAS620C8L

3 5 3 3 3 1 2 1

- 90 - 70 - 70 - 80 - 110 - 30 - 170 - 150

2 2 2 2 1 4 1 2

NAS620C8L RFN6041 RFN6042 RFN6043

21-32-20

2 1 2 2 3 3 4

- 40 - 230 1 - 190 1 - 50 1

2 1 RF 1 RF 1 RF

Page 1008 Aug 1/03


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.

21-32-20

Page 1009 Aug 1/03


IPL Figure 1. High-Stage Bleed Valve (Electrical Group)

21-32-20

Page 1010 Aug 1/03


Airline Fig& 1

Item -

-

-

1

Part Number

Eff

Part Number 1234567Nomenclature

Code UPA

816601-1

VALVE - HIGH STAGE BLEED,PART1 (ELECTRICAL GROUP)

10

D38999-20FB98PN

.CONNECTOR IDENT AS D38999/20FB98PN ATTACHING PARTS

1

20

NAS1352N04-6

DELETED

4

20A NAS1352N04-6

.SCREW

4

30

NAS620C4L

.WASHER ------*------

4

40

NAS1352N08-10

.SCREW

8

50

MS21919WCH4

.CLAMP SUPSD BY ITEM 50A

1

50A MS21919WCH5

.CLAMP SUPSDS ITEM 50 CHANGE CODE 2

1

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 V04426, HS740215-18 REFER TO SB 21-2197 CHANGE CODE 3

1

120

L6646

.SOLENOID - PULL V81983, HS747767-6 ATTACHING PARTS

1

130

NAS1352N08-8

.SCREW

1

140

NAS1352N08H8

.SCREW SUPSD BY ITEM 140A

1

.SCREW SUPSDS ITEM 140 CHANGE CODE 1

1

- 140A NAS1352N08-8

RF

150

NAS620C8L

.WASHER ------*------

2

160

788085-1

.SEAT - VALVE

1

170

69494J13


1

180

MS19060-4810

.BALL

1

190

793489-1

.SPRING - HELICAL COMPRESSION

1

200

788086-9

.BODY - VALVE

1

210

69494J12


1

220

753642-1

.SPRING - HELICAL COMPRESSION

1

230

RFN6041

.VALVE - HIGH STAGE BLEED, PART 2 (ACTUATOR LINKAGE GROUP) FOR DETAILS SEE FIG. 2

1

21-32-20

Page 1011 Aug 29/07


IPL Figure 2. Actuator Linkage Group

21-32-20

Page 1012 Aug 1/03


Airline Fig & Item 2

-

Part Number

Chg

Eff


Code Code UPA

1

RFN6041

VALVE,HIGH STAGE BLEED,PART 2 (ACTUATOR LINKAGE GROUP) SEE FIG. 1 FOR NHA

10

740285-6

.RING,RIDER

1

20

753664-1

.PLATE,RIDER ATTACHING PARTS

1

30

NAS1352N08-10

.SCREW

2

40

NAS620C8L

.WASHER -------*-------

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 ATTACHING PARTS

1

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 ATTACHING PARTS

1

160

MS24665-82

.PIN

1

170

NAS620C5L

.WASHER

1

180

69725-4K14

.PIN,STRAIGHT,HEADED -------*-------

1

190

RFN6042

.VALVE,HIGH STAGE BLEED, PART 3 (NP) (LOCK AND FILTER GROUP) SEE FIG. 3 FOR DETAILS

1

21-32-20

RF

Page 1013 Aug 1/03


IPL Figure 3. Lock and Filter Group

21-32-20

Page 1014 Aug 1/03



-

1

Part Number

Chg

Eff


Code Code UPA

RFN6042

VALVE,HIGH STAGE BLEED,PART 3 (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

40

69291C6-3-14


1

50

RFN6043

.VALVE,HIGH STAGE BLEED PART 4 (NP) (VALVE GROUP) SEE FIG. 4 FOR DETAILS ATTACHING PARTS

1

60

MS21043-3

.NUT

2

70

NAS620C10L

.WASHER

2

80

NAS620C10L

.WASHER

2

90

NAS1802-3-16

.SCREW

2

100

MS21043-3

.NUT

1

110

NAS620C10L

.WASHER

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

170

69494J10

.PACKING,PREFORMED

1

180

815857-1

.SCREW,LOCKING

1

190

MS9385-02

.PACKING

1

200

BWR990-02-631

.CABLE AND TERMINAL,RETAINING V70958, HS774558-4

1

210

727511-3

.RETAINER,CHAIN

1

220

AN814-10DL

.PLUG AND BLEEDER

1

230

69494J910

.PACKING,PREFORMED

1

240

751570-3-1

.SPRING,COMPRESSION

1

250

727604-5

.FILTER,AIR

1

260

815890-1

.HOUSING,ACTUATOR SEE FIG. 5 FOR DETAILS SUPSD BY ITEM 260A

1

- 260A 815890-2

.HOUSING,ACTUATOR SEE FIG. 5 FOR DETAILS SUPSDS ITEM 260

21-32-20

RF

1

1

Page 1015 Aug 1/03


IPL Figure 4. Valve Group

21-32-20

Page 1016 Aug 1/03



-

1

Part Number

Chg


Eff

Code Code UPA

RFN6043

VALVE,HIGH STAGE BLEED,PART 4 (VALVE GROUP) SEE FIG. 3 FOR NHA

10

MS9902-04

.PLUG

1

20

69494J904

.PACKING,PREFORMED

1

30

732158-2

.DISC,SOLID,PLAIN (0.010 [0.254] THK) SELECT FROM THIS AND THE FOLLOWING

AR

-

31

732158-3

.DISC,SOLID,PLAIN (0.012 [0.305] THK)

AR

-

32

732158-4


AR

-

33

732158-5


AR

-

34

732158-6


AR

-

35

732158-7


AR

50

MS24665-18

.PIN

1

60

69291C6-3-20


1

70

815308-1

.DISC AND SHAFT CONTAINS MATCHED PARTS

1

80

815858-1

..CRANK,LOCKING MATCHED PART

1

90

753659-2

..CRANK,LINKAGE MATCHED PART

1

100

815287-1

..SHAFT,VALVE MATCHED PART

1

110

764900-5

..DISC,BUTTERFLY MATCHED PART

1

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

21-32-20

RF

Page 1017 Aug 1/03


IPL Figure 5. Actuator Housing

21-32-20

Page 1018 Aug 1/03



Part Number

-

1

-

1A 815890-2

-

815890-1

Chg

Eff


Code Code UPA

HOUSING,ACTUATOR SEE FIG. 3 FOR NHA SUPSD BY ITEM 1A HOUSING,ACTUATOR SEE FIG. 3 FOR NHA SUPSDS ITEM 1 PARTIAL BREAKDOWN FOLLOWS

1

A

RF

B

RF

10

04DU04

.BUSHING,SPLIT V26124, HS799753-10

1

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) SUPSD BY ITEM 80A

80A 815890-12

.HOUSING (NP) SUPSDS ITEM 80

21-32-20

1

A

1

B

1

Page 1019 Aug 1/03



21-32-20

Page 1020 Aug 1/03


4. Configuration Change Summary IPL Table 1. Configuration Change Summary Chg Code -

Item Configuration

HS Internal Reference

Description

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.

21-2197

271973

Replaces the environment free switch with one having improved construction for high temperature operation.

3

816601-1

Service Bulletin

-

21-32-20

Page 1021 Aug 29/07

21-32-20_R4

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