32-40-13 Emergency-Parking Brake

PNEUDRAULICS, INC.
COMPONENT MAINTENANCE MANUAL

PART NUMBER 8196
HIGHLIGHTS
TO: HOLDERS OF COMPONENT MAINTENANCE MANUAL (CMM), ATA NO. 32-40-13, FOR
THE VALVE ASSEMBLY, EMERGENCY/PARKING BRAKE, PNEUDRAULICS P/N 8196-4,
DATED FEB 6/98.
REVISION 1, APR 18/05
This revision comprises a complete re-issue of CMM ATA 32-40-13. Holders of the issue of this
CMM dated Feb 6/98 should discard that issue and use this issue of the CMM dated Apr 18/05.
Highlights of the revision are given below.
PAGES DESCRIPTION OF REVISION EFFECTIVITY

ALL Incorporated new variant of the valve assembly, P/N 8196-5. ALL
Updated test data. Updated format and language of CMM to
current ATA 100 specification. Remove wire from IPL and
placed in appropriate materials lists.
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PNEUDRAULICS, INC.
PART NUMBER 4140
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PneuDraulics Publication: 06177-8196-1
PNEUDRAULICS, INC.
8575 HELMS y RANCHO CUCAMONGA, CALIFORNIA 91730
VALVE ASSEMBLY,
EMERGENCY/PARKING
BRAKE
PneuDraulics P/N
8196-4
8196-5
Component Maintenance Manual

with
Illustrated Parts List
Initial Issue Feb 6/98 T-1

32-40-13 Apr 18/05
PNEUDRAULICS, INC.
PART NUMBER 8196
Copyright, 1998, 2005

PneuDraulics, Inc.
All rights reserved.
We welcome your comments concerning this manual. Although every effort has been made to keep
it free from errors, some may occur. When reporting a specific problem, please describe if briefly
and include the manual number, the paragraph or figure number, and the page number.
Please submit comments regarding this manual to the following address:
PneuDraulics, Inc., 8575 Helms, Rancho Cucamonga, CA 91730
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PNEUDRAULICS, INC.
PART NUMBER 8196
RECORD OF REVISIONS
Keep this record in the front of this document.
When a revision is received:
A. Remove the superseded pages from this document and discard.
B. Put the revised pages into this document.
C. Record the revision number, the issue date, the insertion date, and the initials of the
person who inserted the revised pages.
REVISION REVISION DATE REVISION REVISION DATE
NUMBER DATE INSERTED BY NUMBER DATE INSERTED BY
1 Apr 18/05
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PART NUMBER 8196
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PART NUMBER 8196
RECORD OF TEMPORARY REVISIONS

When a temporary revision is received:
A. Put the temporary revision page(s) into this document.
B. Put the revised pages into this document.
C. Write the temporary revision (TR) number, the issue date, the page(s) number, the
insertion date, and the initials of the person who inserted the temporary revision
pages.
When a permanent revision is received:
A. Remove the temporary revision page(s) and put the permanent revision into this
document.
B. Write the date the temporary revision was removed and the initials of the person who
removed the temporary revision.
TEMPORARY PAGE ISSUE DATE DATE
REV NO NUMBER DATE INSERTED BY REMOVED BY
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PART NUMBER 8196
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PNEUDRAULICS, INC.
PART NUMBER 8196
SERVICE BULLETIN LIST

This list provides the service bulletin number, the service bulletin revision number, the service
bulletin incorporation date and the subject title of the service bulletin.
When a service bulletin does not affect the CMM, the words “No Effect” are shown in the service
bulletin incorporation date column.
Service Bulletin
Service Bulletin Service Bulletin Incorporation Service Bulletin
Number Revision Number Date Subject Title
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PNEUDRAULICS, INC.
PART NUMBER 8196
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PART NUMBER 8196
LIST OF EFFECTIVE PAGES
SUBJECT PAGE DATE SUBJECT PAGE DATE

Title Page T-1 Apr 18/05 Disassembly 3001 Apr 18/05
T-2 Blank 3002 Apr 18/05
3003 Apr 18/05
Record of Revisions RR-1 Apr 18/05 3004 Apr 18/05
RR-2 Blank
Cleaning 4001 Apr 18/05
Record of Temporary RTR-1 Apr 18/05 4002 Apr 18/05
Revisions RTR-2 Blank
Check 5001 Apr 18/05
Service Bulletin List SBL-1 Apr 18/05 5002 Apr 18/05
SBL-2 Blank 5003 Apr 18/05
5004 Apr 18/05
List of Effective LEP-1 Apr 18/05 5005 Apr 18/05
Pages LEP-2 Apr 18/05 5006 Blank
Table of Contents TOC-1 Apr 18/05 Repair 6001 Apr 18/05

TOC-2 Apr 18/05 6002 Apr 18/05
TOC-3 Apr 18/05 6003 Apr 18/05
TOC-4 Blank 6004 Blank
Introduction INTRO-1 Apr 18/05 Assembly 7001 Apr 18/05

INTRO-2 Apr 18/05 7002 Apr 18/05
INTRO-3 Apr 18/05 7003 Apr 18/05
INTRO-4 Apr 18/05 7004 Apr 18/05
7005 Apr 18/05
Description and 1 Apr 18/05 7006 Apr 18/05
Operation 2 Apr 18/05
3 Apr 18/05 Fits and Clearances 8001 Apr 18/05
4 Apr 18/05 8002 Apr 18/05
Testing and Fault 1001 Apr 18/05 Special Tools, 9001 Apr 18/05
Isolation 1002 Apr 18/05 Fixtures, and 9002 Apr 18/05
1003 Apr 18/05 Equipment
1004 Apr 18/05
1005 Apr 18/05 Storage 15001 Apr 18/05
1006 Apr 18/05 15002 Apr 18/05
1007 Apr 18/05
1008 Apr 18/05
1009 Apr 18/05
1010 Apr 18/05
1011 Apr 18/05
1012 Apr 18/05
1013 Apr 18/05
1014 Apr 18/05
1015 Apr 18/05
1016 Apr 18/05
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PART NUMBER 8196
LIST OF EFFECTIVE PAGES
SUBJECT PAGE DATE SUBJECT PAGE DATE

Illustrated Parts List 10001 Apr 18/05
10002 Apr 18/05
10003 Apr 18/05
10004 Blank
10005 Apr 18/05
10006 Apr 18/05
10007 Apr 18/05
10008 Apr 18/05
10009 Apr 18/05
10010 Apr 18/05
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PNEUDRAULICS, INC.
PART NUMBER 8196
TABLE OF CONTENTS
SUBJECT PAGE
Description and Operation ........................................................................................................ 1
Testing and Fault Isolation........................................................................................................ 1001
Schematics and Wiring Diagrams................................................................... 2001 (Not Applicable)
Disassembly.............................................................................................................................. 3001
Cleaning.................................................................................................................................... 4001
Inspection/Check ...................................................................................................................... 5001
Repair ....................................................................................................................................... 6001
Assembly .................................................................................................................................. 7001
Fits and Clearance.................................................................................................................... 8001
Special Tools, Fixtures, and Equipment ................................................................................... 9001
Special Procedures......................................................................................... 11001 (Not Applicable)
Removal.......................................................................................................... 12001 (Not Applicable)
Installation....................................................................................................... 13001 (Not Applicable)
Servicing ......................................................................................................... 14001 (Not Applicable)
Storage ..................................................................................................................................... 15001
Rework............................................................................................................ 16001 (Not Applicable)
Illustrated Parts List .................................................................................................................. 10001
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PNEUDRAULICS, INC.
PART NUMBER 8196
LIST OF ILLUSTRATIONS
FIGURE PAGE
1 Primary Components ........................................................................................... 2
2 Operation ............................................................................................................. 3
1001 Hydraulic Thermal Relief Valve, P/N 2623, Test Setup ....................................... 1003
1002 Emergency/Parking Brake Valve, P/N 8196, Test Setup ..................................... 1005
1003 Emergency/Parking Brake Valve Actuator Position Reference............................ 1009
IPL 1 Valve Assembly, Emergency/Parking Brake, P/N 8196, Exploded View ............. 10005
IPL 2 Valve, Hydraulic Thermal Relief, P/N 2623, Exploded View ................................ 10009
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PNEUDRAULICS, INC.
PART NUMBER 8196
LIST OF TABLES
TABLE PAGE
1 Leading Particulars ........................................................................................... 4
1001 Test Tools, Fixtures, and Equipment ................................................................ 1002
1002 Test Materials.................................................................................................... 1003
1003 Fault Isolation.................................................................................................... 1014
4001 Cleaning Materials ............................................................................................ 4002
5001 Check Tools, Fixtures, and Equipment ............................................................. 5001
5002 Visual Checks ................................................................................................... 5003
5003 Dimensional Checks ......................................................................................... 5005
6001 Repair Materials ................................................................................................ 6001
7001 Assembly Materials ........................................................................................... 7002
8001 Allowable Clearances........................................................................................ 8001
8002 Spring Test Data ............................................................................................... 8002
9001 Special Tools, Fixtures, and Equipment............................................................ 9001
9002 Materials............................................................................................................ 9002
15001 Storage Materials .............................................................................................. 15001
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PNEUDRAULICS, INC.
PART NUMBER 8196
INTRODUCTION
1. Scope
A. This Component Maintenance Manual (CMM) contains maintenance instructions and
an illustrated parts list (IPL) for the Valve Assemblies, Emergency/Parking Brake,
part numbers (P/Ns) 8196-4 and 8196-5. The valves are made by PneuDraulics,
Inc., Rancho Cucamonga, California.
2. Product Support Services
A. Product support services for the valves are available from PneuDraulics, Inc. These
services include repair and overhaul, spare parts, and technical documentation.
Please speak to us at:
PNEUDRAULICS, INC. Telephone:(909) 980-5366
8575 Helms Facsimile:(909) 945-2821
Rancho Cucamonga, California 91730
3. User’s Guide
A. Select the type of procedures or maintenance information you need from the Table
of Contents. This CMM consists of 11 sections formatted in accordance with Air
Transport Association (ATA) Specification 100.
(1) DESCRIPTION AND OPERATION contains a description of the unit and its
operation.
(2) TESTING AND FAULT ISOLATION contains bench test and fault isolation
procedures.
(3) DISASSEMBLY contains procedures to disassemble the unit.
(4) CLEANING contains procedures to clean the unit.
(5) INSPECTION/CHECK contains procedures to inspect or check the parts for
continued use.
(6) REPAIR contains allowable part repair procedures.
(7) ASSEMBLY contains procedures to assemble the unit.
(8) FITS AND CLEARANCES contains fits and clearances for wear parts,
assembly torque values, and spring test data.
(9) SPECIAL TOOLS, FIXTURES, AND EQUIPMENT contains the
recommended special tools, fixtures, and equipment and the materials
needed to do the procedures in this manual. Equivalent substitutes for the
items in the tables can be used.
(10) STORAGE contains procedures and requirements for storing the unit.
(11) ILLUSTRATED PARTS LIST contains the information necessary to order
spare parts, including part numbers, nomenclature, and sources. An
exploded view drawing is provided to help find and identify parts.
B. The recommended tools, fixtures, and equipment and the materials needed to do the
procedures are given in tables in each section. Equivalent substitutes for the items
in the tables can be used.
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PNEUDRAULICS, INC.
PART NUMBER 8196
4. Verification Dates
Procedure Date
Testing/Fault Isolation Mar 18/05
Disassembly Mar 18/05
Assembly Mar 18/05
5. Revision Service
A. Revised pages will be issued when necessary throughout the service life of the unit.
For technical data or procedures changed, the revised part of the page will be
identified by a change bar or capital R in the left margin. Major revisions (more than
25% of content) will be distributed as a re-issue of the manual and will not contain
change markings.
6. Abbreviations and Unit Symbols
A. Abbreviations and unit symbols used in this manual are listed below. All mass and
weight measurements in this manual are given in standard United States (US)
avoirdupois units followed by the International Standard (SI, metric) or Specific Unit
of Measure (metric) equivalent in parentheses. All other measurements are given
first in US standard units followed by the metric equivalent in parentheses.
Abbreviation Definition
ALT alternate
AR as required
Assy assembly
ATA Air Transport Association
CAGE Commercial and Government Entity
cc cubic centimeter
CCW counter-clockwise
cm centimeter
cm2 square centimeter
CMM component maintenance manual
CRES corrosion resistant steel
CW clockwise
DC Direct current
DIM dimension
EFF effectivity
Fig. figure
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PART NUMBER 8196
FOD foreign object damage
ft lb foot pound force (torque), same as pound force foot (torque)
g gram, force or mass
gpm gallons per minute
ID inside diameter
in lb inch pound force (torque), same as pound force inch (torque)
2
in square inch
in3 cubic inch
IPL illustrated parts list
lb pound, mass
lbf pound, force
lb ft pound force foot (torque)
lb in pound force inch (torque)
kg kilogram, mass
kPa kiloPascal
lpm liters per minute
mm millimeter
MPa MegaPascal
N Newton
Nm Newton meter
NHA next higher assembly
No. number
OD outside diameter
OPT optional
oz ounce
Para. paragraph
P/N part number
POST SB after the Service Bulletin is done on a unit
PRE SB before the Service Bulletin is done on a unit
PRFD preferred
psi pound (force) per square inch
psid pound (force) square inch–differential
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PART NUMBER 8196
psig pound (force) per square inch–gauge
Qty quantity
REF reference
REPLD BY replaced by
REPLS replaces
RF reference IPL item
SB Service Bulletin
SI International Standard (units, metric)
SUPSD BY superseded by
SUPSDS supersedes
US United States of America
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PNEUDRAULICS, INC.
PART NUMBER 8196
DESCRIPTION AND OPERATION

1. Description
A. The Valve Assemblies, Emergency/Parking Brake, P/Ns 8196-4 and 8196-5,
(Emergency/Parking Brake Valve) are manually operated spool valve assemblies
each with an integral thermal relief valve for control of brake pressure during parking
and emergency braking use. The valves include a position sensing microswitch to
indicate when the valve is actuated.
2. Emergency/Parking Brake Valve Primary Components
A. Refer to Figure 1.
B. The primary components of the valve are the Hydraulic Thermal Relief Valve, P/N
2623, the operating linkage, springs and spring guides, the spool and sleeve
assembly (consisting of the spool, loading piston, and sleeve), the manifold
assembly, and fittings.
C. Most of the primary components of the Emergency/Parking Brake Valve and the
Hydraulic Thermal Relief Valve are manufactured primarily from corrosion resistant
steel (CRES). The manifold assembly, gland, closure, nameplates, relief valve
housing, and relief valve inlet nut are manufactured from aluminum alloy.
3. Emergency/Parking Brake Valve Operation
A. Refer to Figures 1 and 2.
B. When the valve is in the released position, the spool is forced against the spring
guide by the force of the spool valve spring. In this position, the spool blocks inlet
pressure at the PRESS port (and directly connected ACC port) and aligns the brake
lines with the hydraulic system return removing hydraulic pressure from the brakes.
C. When the valve is operated to the park position, the manual linkage and associated
springs provide force against the spool which positions inlet pressure (from either the
PRESS or ACC port) to the brake lines and isolates the brake lines from the
hydraulic system return. The thermal relief valve ports any overpressure from brake
line operation and heating to the return port.
D. During use of the valve for emergency braking, the operating linkage springs, and
loading spool act together to provide the pilot with “feel” of the braking system while
attempting to regulate brake pressure rather than simply locking the brakes.
E. The inlet PRESS fitting is a check valve ensuring that a loss of fluid failure in the
hydraulic system will not remove hydraulic pressure from the brakes.
4. Leading Particulars
A. Leading particulars are given in table 1.
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PART NUMBER 8196
Primary Components
Figure 1
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PART NUMBER 8196
Operation
Figure 2
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PART NUMBER 8196
Leading Particulars—Table 1
PARTICULAR VALUE
Manufacturer PneuDraulics, Inc. (V06177)
Part Numbers
PneuDraulics, Inc. 8196-4 and 8196-5
Component Name Valve, Solenoid Operated, 2-Way, 2-Position,
Normally Open
Operation
Fluid Type Hydraulic Fluid per MIL-H-5606
Temperature Range -65°F to +165°F (-54°C to +74°C)

System Pressure
Operating 3000 psig (20,7 MPa)
Proof 4650 psig (32,0 MPa)
Burst 7500 psig (51,7 MPa)
Return Pressure
Operating 80 psig (0,55 MPa)
Proof 2250 psig (16,0 MPa)
Burst 3750 psig (25,8 MPa)
Leakage
Internal 6.0 cc/hr maximum in the RELEASED position at
100°F (38°C)
4.0 cc/hr maximum in the PARK position at 100°F
(38°C)
External Zero leakage from the static seals, 1 drop/25 cycles
at the dynamic seals
Physical Properties
Height 4.26 in (108,2 mm)
Length 10.06 in (255,5 mm)
Width 2.48 in (62,9 mm)
Weight 0.95 lbs (0,431 kg) maximum
Leading Particulars—Table 1
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PART NUMBER 8196
TESTING AND FAULT ISOLATION

1. General Instructions
NOTE: Use TESTING AND FAULT ISOLATION procedures to find malfunctions and to
find the cause of the fault. When you can, repair the valve without complete
disassembly.
A. This section contains test procedures for the fully assembled valve.
B. Perform test procedures before disassembly to identify damaged parts and after
assembly to test performance.
C. The tools, fixtures, and equipment, other than standard shop tools, needed to do the
test procedures of this section are given in table 1001 and in the SPECIAL TOOLS,
FIXTURES, AND EQUIPMENT section.
D. Equivalent substitutes for the items given in table 1001 may be used.
E. The materials needed to do the test procedures of this section are given in table
1002 and in the SPECIAL TOOLS, FIXTURES, AND EQUIPMENT section.
F. Equivalent substitutes for the items given in table 1002 may be used.
G. Sources given in the tools, fixtures, and equipment table and in the materials table
are listed by vendor code (V followed by the CAGE code).
H. Vendor codes used in this manual are cross-referenced to the vendor name and
address in the ILLUSTRATED PARTS LIST.
I. Fault isolation procedures are given in table 1003 at the end of this section.
J. The numbers in parentheses following a part name are that’s part figure and item
number in the ILLUSTRATED PARTS LIST.
K. For the valve, P/N 8196-4, filter the test fluid through a non-bypassing 55 micron
absolute filter during all testing.
L. For the valve, P/N 8196-5, filter the test fluid through a non-bypassing 15 micron
absolute filter during all testing.
M. Ambient temperature must be 80°F ± 20°F (27°C ± 11°C) during testing.
N. The test fluid temperature must be 100°F ± 20°F (38°C ± 11°C) during testing.
O. Before testing, all instrumentation must be calibrated and the calibration must be
documented.
P. The test setup tare differential pressure (or pressure drop), caused by the test setup
components, must be subtracted from all pressure drop readings at rated flow to
obtain the actual pressure drop. For use during testing, obtain the tare value of the
test setup pressure drop.
(1) Install straight tubing and unions equivalent to the inlet and outlet port unions
in the flow and pressure drop test setup (Figures 1001 and 1002).
(2) Make a flow rate equal to the rated flow of the unit under test.
(3) Write down inlet and outlet pressure of the tare setup at rated flow.
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PART NUMBER 8196
(4) Calculate the difference between inlet and outlet pressure. This difference is
the system tare value.
Q. External leakage at the static seals must not happen during testing. A slight wetting
that doesn’t form a drop is not considered leakage.
2. Test Tools, Fixtures, and Equipment
A. The test tools, fixtures, and equipment given in Table 1001 and in SPECIAL TOOLS,
FIXTURES, AND EQUIPMENT are needed to do the test procedures of this section.
B. Equivalent substitutes can be used for the items given in Table 1001.
Test Tools, Fixtures, and Equipment—Table 1001
NOTE: Equivalent substitutes can be used for the items given in the table.
PART OR
NOMENCLATURE SPECIFICATION NUMBER SOURCE
Filter, 5 micron absolute (non-bypassing) ––– Commercially Available

Flowmeter, Digital, 0 to 2.0 gpm (0 to 7,57 ––– Commercially Available
lpm)
Gauge, Hydraulic Pressure, 0 to 5000 psig (0 ––– Commercially Available
to 41,37 MPa) ± 2.0%, 2 needed
Hydraulic Test Stand, 0 to 6000 psig (0 to ––– Commercially Available
34,45 MPa), 0 to 15.0 gpm (0 to 56,8 lpm)
Temperature Sensor, 0 °F to 120 °F (18 °C ––– Commercially Available
to 49 °C)
Test Plug 8196 V06177
Test Manifold 2623TM V06177
Test Tools, Fixtures, and Equipment—Table 1001
3. Test Materials
A. The test materials given in Table 1002 and in SPECIAL TOOLS, FIXTURES, AND
EQUIPMENT are needed to do the test procedures of this section.
B. Equivalent substitutes can be used for the items given in Table 1002.
4. Test Procedures
A. Hydraulic Thermal Relief Valve, P/N 2623, Test
WARNING: TO STOP INJURY TO PEOPLE, HYDRAULIC TEST EQUIPMENT
MUST BE SHIELDED AT ALL TIMES WHILE PRESSURE IS
APPLIED. ALL HYDRAULIC FITTINGS AND HOSES MUST BE
SAFE FOR 10000 PSI (68,95 MPA) OPERATION.
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PART NUMBER 8196
Hydraulic Thermal Relief Valve, P/N 2623, Test Setup

Figure 1001
Test Materials—Table 1002

NOTE: Equivalent substitutes can be used for the items given in the table.
PART OR
Hydraulic Fluid MIL-H-5606 Commercially Available

Lockwire, CRES MS20995C32 Commercially Available
Test Materials—Table 1002

(1) Install the relief valve in a test setup equivalent to the one given in Figure
1001.
(2) Increase pressure at the IN port of the test manifold until flow begins from the
OUT port (flow indicates the hydraulic thermal relief valve has opened.) This
is the relief valve crack pressure.
(3) The pressure when the valve opens must be 3800 ± 50 psid (26,2 ± 0,34
MPa).
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PART NUMBER 8196
(4) Increase pressure to set flow from the test manifold OUT port to 0.1 gpm
(0,38 lpm.)
(5) Measure pressure at the IN port and at the OUT port of the test manifold.
Calculate the pressure difference. This is the gross pressure drop.
(6) Calculate the difference between the gross pressure drop and the test setup
tare pressure drop. This is the actual pressure drop.
(7) The actual relief valve pressure drop must be 3950 ± 50 psid (27,23 ± 0,34
MPa).
(8) Decrease pressure at the IN port of the test manifold until flow from the OUT
port stops (no flow indicates the hydraulic thermal relief valve has closed.)
This is the relief valve reseat pressure.
(9) The pressure when the hydraulic thermal relief valve closes must be 3300 ±
100 psid (22,75 ± 0,69 MPa).
(10) Close the isolation valve in the test manifold hydraulic return connection and
open the vent valve to atmosphere.
(11) Decrease pressure at the IN port of the test manifold to 3200 psig (22,06
MPa.)
(12) Keep the inlet pressure at 3200 psig (22,06 MPa) for 3 minutes.
(13) In the third (last) minute of the 3 minutes, measure leakage at the
atmospheric vent. The leakage at this pressure is the reseat leakage.
(14) Leakage must not be more than 1 cc/min.
(15) Decrease inlet pressure to 3000 psig (20,68 MPa.)
(16) Keep the inlet pressure at 3000 psig (20,68 MPa) for 3 minutes.
(17) In the third (last) minute of the 3 minutes, measure leakage at the
atmospheric vent. The leakage at this pressure is the internal leakage.
(18) There must be no leakage during the third minute at 3000 psig (20,68 MPa)
inlet pressure.
(19) Depressurize the IN port of the test manifold.
(20) Close the vent valve on the OUT port of the test manifold.
(21) Open the return side isolation valve.
(22) Remove the hydraulic thermal relief valve, P/N 2623, from the test setup.
B. Indicator Switch Installation and Test
(1) Measure the electrical continuity between Pin A and Pin B of the switch
assembly (1-33) while you install the switch assembly.
(2) Install the switch assembly (1-33) into the emergency/parking brake valve
manifold (1-3) until an open electrical circuit is indicated between Pin A and
Pin B of the switch.
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PART NUMBER 8196
(3) From the switch installation position when an open circuit was indicated, turn
the switch an additional 90° CW.
(4) Install the jam nut (1-30).
(5) Install lockwire, MS20995C32, between the jam nut (1-30) and the manifold
(1-3).
Emergency/Parking Brake Valve, P/N 8196, Test Setup

Figure 1002
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PART NUMBER 8196

(6) Install the valve in a test setup equivalent to the one given in Figure 1002.
(7) Close the PRESS port test setup isolation valve.
(8) Open the PRESS port vent valve.
(9) Set the emergency/parking brake valve handle to the RELEASED position.
(10) Pressurize the emergency/parking brake valve ACC port to 3000 psig (20,68
MPa).
(11) Measure the electrical continuity between Pin A and Pin B of the switch
assembly (1-33).
(12) Observe pressure at the BRK port of the emergency/parking brake valve.
(13) Operate the handle of the emergency/parking brake valve from the
RELEASED position to the FULL PARK position while you observe the
indication of Pin A to Pin B electrical continuity.
(14) When electrically continuity (zero resistance) is indicated between Pin A and
Pin B, measure BRK port pressure.
(15) The pressure at the BRK port must be 150 psig (1,03 MPa) or less when the
switch indicates zero resistance between Pin A and Pin B.
(16) Do this a total of 10 times.
(a) Measure electrical continuity between Pin A and Pin B and between
Pin C and Pin D of the switch assembly (1-33).
(b) Put the valve handle in the RELEASED position.
(c) An open circuit must be indicated between Pin A and Pin B and a
closed electrical circuit must be indicated between Pin C and Pin D.
(d) Put the valve handle in the FULL PARK position.
(e) A closed circuit must be indicated between Pin A and Pin B and an
open electrical circuit must be indicated between Pin C and Pin D.
(17) Remove all pressure from the test setup.
C. Proof Pressure
(1) Do not install the hydraulic thermal relief valve, P/N 2623, in the emergency/
parking brake valve assembly.
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PART NUMBER 8196
(2) Install the P/N 8196 Test Plug in the relief valve cavity of the emergency/
parking brake valve assembly.
(3) Install caps on the emergency/parking brake valve ACCUM, RTN, and BRK
ports.
(4) Install the emergency/parking brake valve in a test setup equivalent to the
one given in Figure 1002.
(5) Pressurize the PRESS port of the emergency/parking brake valve to 4650
psig (32,06 MPa.)
(6) Keep PRESS port pressure at 4650 psig (32,06 MPa) for a minimum of 2
minutes.
(7) Depressurize the PRESS port of the emergency/parking brake valve.
(8) (For the P/N 8196-4) Pressurize the PRESS port of the emergency/parking
brake valve to 4575 psig (31,54 MPa.)
(9) (For the P/N 8196-5) Pressurize the PRESS port of the emergency/parking
brake valve to 4650 psig (32,06 MPa.)
(10) Keep the applied pressure for a minimum of 2 minutes.
(11) Depressurize the PRESS port of the emergency/parking brake valve to 0 psig
(0 MPa.)
(12) Disconnect the PRESS port from the hydraulic supply.
(13) Remove the cap from the RTN port of the emergency/parking brake valve.
(14) Install a cap on the PRESS port of the emergency/parking brake valve.
(15) Connect the emergency/parking brake valve RTN port to the hydraulic test
stand supply.
(16) With the P/N 8196 Test Plug installed in the emergency/parking brake valve,
pressurize the RTN port of the valve to 2250 psig (15,51 MPa.)
(17) Keep RTN port pressure at 2250 psig (15,51 MPa) for a minimum of 2
minutes.
(18) Depressurize the RTN port of the emergency/parking brake valve to 0 psig (0
MPa.)
(19) Pressurize the RTN port of the emergency/parking brake valve to 2250 psig
(15,51 MPa.)
(20) Keep RTN port pressure at 2250 psig (15,51 MPa) for a minimum of 2
minutes.
(21) Depressurize the RTN port of the emergency/parking brake valve to 0 psig (0
MPa.)
(22) The valve must not have any external leakage. The valve must operate
correctly after test. The valve must not change size in any dimension.
(23) Remove the caps from the PRESS and ACC ports.
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PART NUMBER 8196
D. Check Valve Test

(1) Install the valve in a test setup equivalent to the one given in Figure 1002,
with the following exceptions:
(a) The BRK port must be capped.
(b) The P/N 8196 Test Plug is installed in the thermal relief valve cavity of
the emergency/parking brake valve.
(2) Set the handle of the emergency/parking brake valve to the FULL PARK
position.
(5) Pressurize the ACC port to 3000 psig (20,68 MPa.)
(6) Pressurize the RTN port to 100 psig (0,69 MPa.)
(7) Keep the applied pressures at the ACC and RTN ports for 3 minutes.
(8) In the third (last) minute of the 3 minutes, measure the leakage at the PRESS
port atmospheric vent.
(9) There must be no detectable leakage.
(10) (For the P/N 8196-5 only) Do the following:
(a) Decrease pressure at the ACC port to 2000 psig (13,79 MPa.)
(b) Pressurize the RTN port to 100 psig (0,69 MPa.)
(c) Keep the applied pressures at the ACC and RTN ports for 3 minutes.
(d) In the third (last) minute of the 3 minutes, measure the leakage at the
PRESS port atmospheric vent.
(e) There must be no detectable leakage.
(f) Keep the pressure at the RTN port at 100 psig (0,69 MPa.)
(g) Decrease pressure at the ACC port to 100 psig (0,69 MPa.)
(h) Keep the applied pressures at the ACC and RTN ports for 3 minutes.
(i) In the third (last) minute of the 3 minutes, measure the leakage at the
PRESS port atmospheric vent.
(j) Detectable leakage must be no more than a slight wetting that does
not form a drop.
(11) Remove all pressure from the emergency/parking brake valve.
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PART NUMBER 8196
E. Metering Valve Operation, Plunger Stroke Relation to Brake Pressure

(1) Remove the P/N 8196 Test Plug from the emergency/parking brake valve.
(2) Install the P/N 2623 hydraulic thermal relief valve in the emergency/parking
brake valve.
(a) Install the packing (1-102) and the GT ring (1-105) on the thermal
relief valve (1-99).
CAUTION: MAKE SURE THE PACKING (1-102) AND THE GT RING
(1-105) DO NOT CAM OUT AND ARE NOT DAMAGED
WHEN THE THERMAL RELIEF VALVE (1-99) IS INSTALLED
IN THE MANIFOLD (1-3).
(b) Use a 1/2-inch open end wrench and install the thermal relief valve
(1-99) in the manifold (1-3).
(3) Remove the cap from the emergency/parking brake valve BRK port.
(4) Install the valve in a test setup equivalent to the one given in Figure 1002.
(7) Refer to Figure 1003 for valve actuator position reference. Measurement of
plunger travel is made from the RELEASED position of the plunger which is
the zero travel position.
Emergency/Parking Brake Valve Actuator Position Reference

Figure 1003
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PNEUDRAULICS, INC.
PART NUMBER 8196
MPa).
(10) Pressure at the BRK port must be zero.
(11) Observe the BRK port pressure indication and operate the emergency/
parking brake valve handle towards the FULL PARK position.
(12) Stop and hold handle in position when BRK port pressure starts to increase.
(13) Measure the plunger position.
NOTE: If the measured plunger position is more than or less than
specified, complete this test procedure before adjusting the
emergency/parking brake valve.
(14) The plunger position must be 0.060 to 0.110 inches (1,524 to 2,794 mm.) If
the measured plunger position is more than or less than specified, complete
this test procedure.
(15) Operate the emergency/parking brake valve handle towards the FULL PARK
position until BRK port pressure indicates 1000 psig (6,89 MPa.)
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PART NUMBER 8196
(23) The plunger position must be 0.405 to 0.455 inches (10,287 to 11,557 mm.)
If the measured plunger position is more than or less than specified,
complete this test procedure.
(24) Put the emergency/parking brake valve handle in the RELEASED position.
(25) Remove all pressure from the emergency/parking brake valve.
F. Metering Valve Operation, Handle Operating Force Relation to Brake Pressure
(1) Install the valve in a test setup equivalent to the one given in Figure 1002
with the exception that a cap is installed on the PRESS port.
MPa).
(4) Measure the operating force on the emergency/parking brake valve handle
while doing the following steps of this procedure.
(5) Increase the operating force on the handle.
(6) Make a record of the operating force value when pressure at the BRK port
starts to increase.
NOTE: If the measured operating force is more than or less than
(7) The operating force on the handle must be between 4.25 and 5.75 pounds
force (18,90 to 25,58 N.) If the measured operating force is more than or less
than specified, complete this test procedure.
(8) Make a record of the operating force value when BRK port pressure is 1000
psig (6,89 MPa.)
psig (13,79 MPa.)
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PNEUDRAULICS, INC.
PART NUMBER 8196
psig (20,68 MPa.)
force (86,96 to 117,66 N.) If the measured operating force is more than or
less than specified, complete this test procedure.
(14) Return the emergency/parking brake valve handle to the RELEASED
position.
G. Metering Valve Operation, Internal Leakage
with the following exception:
(a) Install a cap on the PRESS port.
(b) Close the RTN test setup isolation valve.
(c) Open the RTN test setup vent to atmosphere.
MPa.)
(4) Keep pressure at the ACC port at 3000 psig (20,68 MPa) for 3 minutes.
(5) During the third (last) minute of the 3 minutes, measure the leakage from the
test setup RTN port atmospheric vent.
(6) Leakage must not be more than 2 drops/minute.
(7) Put the emergency/parking brake valve in the FULL PARK position.
(8) Keep pressure at the ACC port at 3000 psig (20,68 MPa) for 3 minutes.
(9) During the third (last) minute of the 3 minutes, measure the leakage from the
test setup RTN port atmospheric vent.
(10) Leakage must not be more than 1 drop/minute.
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PART NUMBER 8196
H. Metering Valve Operation, Pressure Drop At Rated Flow

with the following exceptions:
(a) Install a cap on the ACC port
(b) Close the RTN test setup isolation valve.
(c) Open the RTN test setup vent to atmosphere.
(2) Put the emergency/parking brake valve handle in the FULL PARK position.
(3) Pressurize the PRESS port to make a flow rate of 0.2 gpm (0.76 lpm) from
the BRK port
(4) Measure pressure at the PRESS port and at the BRK port of the emergency/
parking brake valve. Calculate the pressure difference. This is the gross
pressure drop.
(5) Calculate the difference between the gross pressure drop (pressure
differential) and the test setup tare pressure drop. This is the actual pressure
drop.
(6) The actual pressure drop must not be more than 100 psid (0.689 MPa.)
I. Handling Following Test
(1) When before-maintenance testing is complete, write the results of all tests
completed on the maintenance record.
(a) Refer to table 1003, Fault Isolation, to determine level of disassembly
needed, then go to DISASSEMBLY.
(2) When after-maintenance testing is complete and the valve has passed all
tests, record satisfactory testing on valve’s maintenance record.
(a) Drain the valve.
(b) Flush the valve with clean MIL-H-5606 hydraulic fluid.
(c) Drain to a drip dry condition.
(d) Go to STORAGE.
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PART NUMBER 8196
Fault Isolation (Sheet 1 of 3)—Table 1003
PROBLEM PROBABLE CAUSE CORRECTIVE ACTION
Hydraulic thermal relief valve The valve requires adjustment. Adjust the valve using the inlet
crack pressure is more than nut (2-6).
specified.
The spring (2-24) is damaged. Replace the spring.
The pressure drop across the The spring (2-24) is damaged. Replace the spring.
thermal relief valve is more
than specified.
The poppet assembly is Replace the poppet assembly.
damaged (2-15).
Thermal relief valve reseat The valve requires adjustment. Adjust the valve using the inlet
pressure is less than specified. nut (2-6).
The spring (2-24) is damaged. Replace the spring.
The reseat or internal leakage The poppet assembly (2-15) is Replace the poppet assembly.
or both of the thermal relief damaged.
valve is more than specified.
The seat (2-9) is damaged. Replace the seat.
There is external leakage at The gaskets (1-78, 1-84, 1-90, Replace the damaged gasket
one or more port fittings (1-75, 1-96, 1-102) or packings or packing.
1-81, 1-87, 1-93), the closure (1-111, 1-147) are damaged.
(1-60), the thermal relief valve
The sealing surface on the Replace the damaged fitting,
(1-99) or the gland (1-144).
fitting, the closure, the thermal closure, thermal relief valve, or
relief valve, or the gland is gland
damaged.
The manifold (1-3) sealing Replace the manifold.
surface is damaged.
There is external leakage at The packing (1-153) or the Replace the packing or the
the plunger (1-156) scraper (1-150) or both are scraper or both.
damaged.
The surface of the plunger is Replace the plunger.
damaged.
The seal groove of the gland Replace the gland.
(1-144) is damaged.
There is external leakage at The packing (1-72) is Replace the packing.
the switch assembly (1-33). damaged.
The seal groove of the switch Replace the switch plunger.
plunger (1-69) is damaged.
The check valve (1-87) leaks. The check valve is damaged Replace the check valve.
Page 1014
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PNEUDRAULICS, INC.
PART NUMBER 8196
When the emergency/parking The emergency/parking brake To make large adjustments

brake valve is operated, the valve requires adjustment. (0.025 inches (0.6350 mm) or
plunger position is more than more), change the number of
or less than specified for one shims (1-177, 1-165). To
or more BRK port pressure decrease plunger travel at a
levels. (For example: at a BRK given pressure, increase the
port pressure of 1000 psig quantity of shims installed. To
(6,89 MPa), the measured increase plunger travel at a
plunger position is less than given pressure, decrease the
0.280 inches (7,112 mm) or quantity of shims installed.
more than 0.330 inches (8,382
The spring (1-162) or the Test springs to dimensional
mm).)
spring (1-174) may have a check specifications of
permanent set or deformation. INSPECTION/CHECK and
FITS AND CLEARANCES.
The spool and sleeve Replace the spool and sleeve
assembly (1-120) is damaged. assembly.
BRK port pressure at FULL The spool and sleeve Replace the spool and sleeve
PARK is less than 3000 psig assembly (1-120) is damaged. assembly.
(20,68MPa.)
When the emergency/parking The emergency/parking brake To make large adjustments
brake valve is operated, the valve requires adjustment. (0.025 inches (0.6350 mm) or
handle operating force is more more), change the number of
than or less than specified for shims (1-177, 1-165). To
one or more BRK port decrease handle operating
pressure levels. (For example: force at a given pressure,
at a BRK port pressure of 1000 increase the quantity of shims
psig (6,89 MPa), the measured installed. To increase handle
handle operating force is less operating force at a given
than 9.35 lbf (41,59 N) or more pressure, decrease the
than 12.65 lbf (56,27 N).) quantity of shims installed.
The spring (1-162) or the Test springs to dimensional
spring (1-174) may have a check specifications of
permanent set or deformation. INSPECTION/CHECK and
FITS AND CLEARANCES.
The spool and sleeve Replace the spool and sleeve
assembly (1-120) is damaged. assembly.
The actual pressure drop The spool and sleeve Replace the spool and sleeve
(pressure differential ) is more assembly (1-120) is damaged. assembly.
than 100 psid (0.689 MPa.)
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PART NUMBER 8196
Internal leakage of the The packings (1-132) or the Replace the packings and
emergency/parking brake backups (1-135) or both are backups
valve with the handle in the damaged
RELEASED position is more
The GT ring (1-105) on the Replace the GT ring.
than 2 drops/minute.
thermal relief valve is
damaged.
The seal groove on the thermal Replace the thermal relief
relief valve (1-99) is damaged. valve.
surface for the sleeve or for the
damaged.
The thermal relief valve (1-99) Test the thermal relief valve.
is leaking. Repair or replace the thermal
relief valve as needed.
Internal leakage of the The packings (1-132) or the Replace the packings and
emergency/parking brake backups (1-135) or both are backups
valve with the handle in the damaged
FULL PARK position is more
The GT ring (1-105) on the Replace the GT ring.
than 1 drop/minute.
damaged.
The seal groove on the thermal Replace the thermal relief
relief valve (1-99) is damaged. valve.
surface for the sleeve or for the
damaged.
The thermal relief valve (1-99) Test the thermal relief valve.
is leaking. Repair or replace the thermal
relief valve as needed.
The indicator switch does not The switch (1-36) is damaged. Replace the switch.
operate.
Page 1016
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PNEUDRAULICS, INC.
PART NUMBER 8196
DISASSEMBLY
NOTE: Use TESTING AND FAULT ISOLATION procedures to find malfunctions and to
find the cause of the fault. When you can, repair the unit without complete
disassembly.
A. Use these general instructions during all disassembly procedures.
B. The numbers in parentheses following a part name are that’s part figure and item
C. Before you disassemble the valve, do the procedures of TESTING AND FAULT
ISOLATION to find possibly failed parts.
D. If the failed parts can be replaced without complete disassembly, disassemble the
valve only to the level needed to replace the failed parts.
E. Use standard shop tools for disassembly.
F. Equivalent substitutes for the items given in table 3001 may be used.
G. No materials are needed to disassemble the valve.
H. Do all work in a clean, ventilated room with good lighting.
I. Put parts in clean containers in the sequence they are removed to help with
assembly.
CAUTION: SEALING SURFACES ARE EASILY DAMAGED. MAKE SURE SEALING
SURFACES HAVE PROTECTION FROM DAMAGE WHEN SEALS ARE
REMOVED.
J. Use a rounded, dull-edged nylon pick to remove gaskets, packings, backup rings,
GT rings, and other seals.
K. Make a record of the way lockwire is installed on the valve before disassembly to
use when you assemble the valve. Use side cutters and long-nosed pliers to remove
lockwire.
L. Use a vise with padded jaws to hold the valve during disassembly. Adjust the
position of valve as needed for access to parts.
2. Disassembly Tools, Fixtures, and Equipment
A. There are no special test tools, fixtures, or equipment needed to do the procedures
of this section.
3. Disassembly Materials
A. No materials are needed for disassembly of the valve.
4. Disassembly Procedure
A. Use the figures of the ILLUSTRATED PARTS LIST to identify parts.
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PNEUDRAULICS, INC.
PART NUMBER 8196
B. Disassemble the Emergency/Parking Brake Valve, P/N 8196-4 or P/N8196-5

NOTE: Make a record of the method and routing of the jam nut (1-30)
lockwire installation for use during assembly.
(1) Remove the cotter pin (1-15) and the washer (1-12) from the pin (1-9).
(2) Remove the pin (1-9) from the handle (1-6) and the manifold (1-3).
(3) Remove the handle (1-6) from the manifold (1-3).
(4) Hold the handle (1-6) in the padded jaws of a vise.
(5) Use 2 wrenches (3/8-inch open end) and remove the nut (1-21) from the bolt
(1-24).
(6) Remove the bolt (1-24), the washer (1-27), and the cam (1-18) from the
handle (1-6).
(7) Remove the handle (1-6) from the vise.
(8) Make a record of the lockwire installation on the jam nut (1-30) and manifold
(1-3) before disassembly for use during assembly.
CAUTION: YOU MUST AVOID NICKING, SCRATCHING OR CRUSHING
REMOVED PARTS; MINOR SURFACE IMPERFECTIONS OR OUT
OF ROUNDNESS CAN CAUSE LEAKAGE OR FAILURE.
(9) Cut and remove the lockwire from the manifold (1-3) and the jam nut (1-30).
(10) Use a 1 1/16-inch open end wrench and remove the jam nut (1-30) from the
switch assembly (1-33).
(11) Remove the switch assembly (1-33), the spring (1-57), and the spring guide
(1-60) from the manifold (1-3).
(12) Use a slot screwdriver and remove 2 screws (1-66).
(13) Remove the retainer (1-63) and the switch plunger (1-69) from the manifold
(1-3).
(14) Remove and discard the packing (1-72) from the switch plunger.
(15) Only as needed for parts replacement, disassemble the switch assembly
(1-33).
(a) Use a slot screwdriver and a 1/8-inch hex driver and remove 2 screws
(1-42), 2 nuts (1-45), and the leaf actuator (1-39).
(b) Desolder the switch (1-36) terminals and remove the switch.
(c) The electrical connector (1-51) and the adjusting screw (1-48) are
permanently bonded. Replace both components if one is damaged.
(16) Use an 11/16-inch open end wrench, and remove the BRK port union (1-75).
(17) Remove and discard the gasket (1-78) the BRK port union.
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PNEUDRAULICS, INC.
PART NUMBER 8196
(18) Use a 13/16-inch open end wrench and remove the ACC port reducer (1-81),
the PRESS port check valve (1-87 or 1-87A), and the RTN port union (1-93).
(19) Remove and discard 3 gaskets (1-84, 1-90, 1-96) from the ACC port reducer,
the PRESS port check valve, and the RTN port union.
(20) Use a 1/2-inch open end wrench and remove the hydraulic thermal relief
valve (1-99).
(21) Remove and discard the packing (1-102) and the GT ring (1-105).
WARNING: YOU MUST USE CARE WHEN REMOVING THE CLOSURE (1-108),
INTERNAL PARTS ARE SPRING LOADED. SPRING LOAD CAN
CAUSE PARTS TO EJECT AND INJURE PEOPLE.
(22) Use a 5/8-inch open end wrench and remove the closure (1-108) from the
manifold (1-3).
(23) Remove and discard the packing (1-111) from the closure (1-108).
(24) Remove the shim (1-114) and the disc (1-117) from the closure (1-108).
NOTE: The piston (1-123), the spool (1-126), and the sleeve (1-129) are
matched components of the spool and sleeve lap assembly
(1-120) and must be kept together during maintenance.
(25) Remove the piston (1-123) and the spring (1-138) from the manifold (1-3).
(26) Remove the spring guide (1-141), the spool (1-126), and the sleeve (1-129)
from the manifold (1-3).
(27) Remove and discard the 4 packings (1-132) and the 7 backups (1-135) from
the sleeve (1-129).
NOTE: Make a record of the method and routing of lockwire installations
prior to disassembly for use during assembly.
(28) Make a record of the lockwire installation between the spring guide (1-141)
and the spool (1-126) before disassembly for use during assembly.
(29) Cut and remove the lockwire from the spring guide (1-141) and the spool
(1-126).
(30) Remove the spring guide (1-141) from the spool (1-126).
WARNING: YOU MUST USE CARE WHEN REMOVING THE GLAND (1-144),
INTERNAL PARTS ARE SPRING LOADED. SPRING LOAD CAN
CAUSE PARTS TO EJECT AND INJURE PEOPLE.
(31) Use a pin spanner wrench and remove the gland (1-144).
NOTE: Make a record of the quantity of the shims (1-165) for use during
assembly
(32) Remove the plunger (1-156), guide (1-159), spring 1-162), shims (1-165),
guide (1-168 or 1-168A), and nut (1-171).
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PNEUDRAULICS, INC.
PART NUMBER 8196
(33) Make a record of the quantity of the shims (1-165) removed for use during
assembly.
(34) Use a 1/2-inch wide slot driver and remove the nut (1-171) from the plunger
(1-156).
(35) As needed, separate the gland (1-144), the plunger (1-156), the guide
(1-159), the spring (1-162), the shims (1-65) and the guide (1-168 or 1-168A).
(36) Remove and discard the 2 packings (1-147, 1-153) and the DC scraper
(1-150) from the gland (1-144).
assembly
(37) Remove the spring (1-174), the shims (1-177), and the spring guide (1-180),
from the manifold (1-3).
assembly.
(39) Only if the nameplate (1-147) cannot be read, remove the nameplate opening
the crimped ends and slide off of the manifold (1-3).
(40) Remove the manifold (1-3) from the vise.
C. Disassemble the Hydraulic Thermal Relief Valve, P/N 2623
(1) Hold the hex head of the thermal relief valve housing (2-3) in the padded jaws
of a vise.
(2) Use a 3/16-inch hex driver and remove the inlet nut (2-6) from the housing
(2-3).
assembly
(3) Remove the seat (2-9), the spring guide (2-21) and the ball (2-18) (which are
the poppet assembly (2-15)), the spring (2-24), and the shims (2-27) from the
housing (2-3).
assembly.
(5) Remove and discard the GT ring (2-12).
(6) Only if the nameplate (2-30) cannot be read, scrape or peel the nameplate
from the housing (2-3).
(7) Remove the housing (2-3) from the vise.
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PNEUDRAULICS, INC.
PART NUMBER 8196
CLEANING
A. Use standard shop tools for cleaning.
B. No special tools are needed for cleaning the valve.
C. Materials needed for cleaning are given in table 4001 and in the SPECIAL TOOLS,
FIXTURES, AND EQUIPMENT section.
D. Equivalent substitutes for items given in table 4001 can be used.
E. Sources given in the materials table are listed by vendor code (V followed by the
CAGE code).
F. Vendor codes used in this manual are cross-referenced to the vendor name and
G. Do all work in a clean, ventilated room with good lighting.
H. Remove all seals (packings, gaskets, backup rings, and GT rings) before cleaning
parts.
I. Make sure you clean all cavities, ports, threads, grooves, sealing surfaces, and any
other critical surfaces.
WARNING: CLEANING SOLVENTS IGNITE AND BURN EASILY. TO PREVENT FIRE,
USE SOLVENTS ONLY WHERE THERE IS GOOD AIRFLOW AND WHERE
THERE ARE NO OPEN FLAMES OR POSSIBILITY OF SPARKS.
WARNING: CLEANING SOLVENTS IRRITATE THE EYES AND THE NOSE. TO

PREVENT INJURY, USE SOLVENTS ONLY WHERE THERE IS GOOD
AIRFLOW. IF YOUR EYES BECOME IRRITATED, FLUSH THEM WITH
LARGE AMOUNTS OF WATER, THEN GET MEDICAL ASSISTANCE.
2. Cleaning Tools, Fixtures, and Equipment
A. No special tools, fixtures, or equipment are needed for cleaning the valve.
3. Cleaning Materials
A. The materials needed to do the cleaning procedures of this section are given in table
4001.
B. Equivalent substitutes for items given in table 4001 can be used.
4. Cleaning Procedure
A. Clean all parts using lint-free cloths and cleaning solvent.
B. If needed, use a non-metallic, stiff bristle brush to scrub the parts.
CAUTION: DO NOT USE ABRASIVES ON MICROFINISHED SURFACES.
C. If needed, use a nylon scrub pad to remove layers of surface contamination.
Page 4001
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PNEUDRAULICS, INC.
PART NUMBER 8196
Cleaning Materials—Table 4001

NOTE: Equivalent substitutes can be used for items given in the table.
PART OR
Abrasive Cloth, Aluminum Oxide P-C-451 Commercially Available

Abrasive Cloth, Crocus P-C-458 Commercially Available
Bag, Polyethylene MIL-B-117 Commercially Available
Brush, Stiff Bristle, Non-Metallic H-B-1490 Commercially Available
Cloth, Lint-Free MIL-C-85043 Commercially Available
Goggles, Safety, Fluid and Particle Resistant ––– Commercially Available
Nylon Scrub Pad ––– Commercially Available
Solvent, Cleaning P-D-680, Type III Commercially Available
Cleaning Materials—Table 4001
CAUTION: DO NOT USE CROCUS ABRASIVE CLOTH ON ALUMINUM OR

ALUMINUM ALLOY PARTS. CROCUS CLOTH CONTAINS AN IRON
OXIDE THAT MAY DAMAGE ALUMINUM.
D. If solvent does not remove corrosion, paint, or accumulations on steel parts, crocus
abrasive cloth may be used to remove the material.
E. If solvent does not remove corrosion, paint, or accumulations on aluminum or
aluminum alloy parts, aluminum oxide abrasive cloth may be used to remove the
material.
F. Make sure you clean all cavities, ports, threads, grooves, sealing surfaces, and any
other critical surfaces.
G. Dry all parts using clean, lint-free cloths or by evaporative drying under ambient
atmospheric conditions.
H. Apply a layer of hydraulic fluid to the parts after cleaning.
I. Store all parts in clean heat-sealed polyethylene bags until they are used again.
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PNEUDRAULICS, INC.
PART NUMBER 8196
INSPECTION/CHECK
A. The tools, fixtures, and equipment needed to do the procedures in this section are
given in table 5001 and in the SPECIAL TOOLS, FIXTURES, AND EQUIPMENT
section.
C. No materials are needed to the check procedures in this section.
D. Sources given in the tools, fixtures, and equipment table are listed by vendor code (V
followed by the CAGE code).
E. Vendor codes used in this manual are cross-referenced to the vendor name and
F. Inspect parts under a strong, glare-less light.
G. Use 10X magnification to inspect parts.
H. Make sure all parts are clean, are not corroded, and have not deteriorated.
I. Inspect all threads for cross-threading, stripping, and dirt.
J. Inspect all packing grooves for distortion, damage, burrs, or corrosion.
K. Inspect all parts for burrs, nicks, scratches, cracks, or structural damage.
NOTE: Burrs, nicks, and scratches are specified as material that extends above
the normal surface. These conditions if not removed or repaired would
prevent the complete and correct mating of parts and sealing surfaces.
With the exception of microfinished surfaces, repair any surface where
damage shows bare metal through a coating or protective finish. Dents
and other damage must not stop a part from functioning correctly.
L. Replace any parts that do not meet CHECK requirements.
2. Check Tools, Fixtures, and Equipment
A. The tools, fixtures, and equipment given in table 5001 are needed to do the check
procedures in this section.
Check Tools, Fixtures, and Equipment—Table 5001
PART OR
10X (minimum) Magnifier ––– Commercially Available

High Intensity Inspection Lamp ––– Commercially Available
Check Tools, Fixtures, and Equipment—Table 5001
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PNEUDRAULICS, INC.
PART NUMBER 8196
3. Check Materials
A. There are no materials needed to do the check procedures in this section.
4. Visual Checks
A. Do visual checks given in table 5002.
B. Refer to the figures of the ILLUSTRATED PARTS LIST to identify parts.
C. Refer to the definitions below as a reference for the visual checks given in table
5002.
(1) Burrs, nicks, and scratches are damage to the base material of a part that
could stop the part from assembling or sealing correctly when assembled.
(2) Burrs are projections from a surface or edge which has raised and exposed
the base material.
(3) Nicks are small surface depressions with sharp edges or corners caused by a
sharp object.
(4) Scratches are linear defects caused by a sharp object that do not cause
separations in the base material.
(5) Cracks are damage to the base material of a part that show the part is not
structurally sound.
(6) Cracks are linear defects that show separation at the surface of the base
material.
(7) Dents and gouges must not remove protective finishes or stop the part from
working correctly.
(8) Dents are depressions caused by impact of a blunt object that do not cause
separation at the surface of the base material.
(9) Gouges are smooth depressions caused by impact of a sharp object that do
not cause separation of the base material.
(10) Foreign object damage (FOD) can cause any of the defects listed above and
also applies to the presence of any foreign object that could cause future
damage.
(11) Corrosion is any change in the base material caused by chemical reaction
that was not done intentionally to form a passivated protective surface.
(12) Pits are small, irregular holes in the surface of the base material caused by
removal of base material during a chemical reaction.
(13) Too much wear is any visible damage to the part that could stop it from
operating correctly when assembled.
(14) A damaged part is any part you think is damaged, replace the part.
(15) Repairable thread damage is damage to 50 percent or less of one thread.
(16) Replacement thread damage is any thread damage more than 50 percent of
one thread or any cross threading.
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PART NUMBER 8196
Visual Checks (Sheet 1 of 2)—Table 5002
METHOD OF CORRECTIVE
COMPONENT INSPECTION INSPECT FOR ACTION
Manifold (1-3) Visual Burrs, cracks, dents, FOD, Replace the

gouges, nicks, or scratches on manifold.
the inside surfaces.
Corrosion buildup or pits in Replace the
threads or internal surfaces manifold.
Thread damage due to cross Repair the threads.
threading, stripping, or FOD.
Replace the manifold
Check valve (1-87 or Visual Burrs, cracks, dents, FOD, Replace the part.
1-87A), unions (1-75, gouges, nicks, or scratches on
1-93), and reducer sealing surfaces.
(1-81)
Replace the part.
Closure (1-108) Visual Burrs, cracks, dents, FOD, Replace the closure.
gouges, nicks, or scratches on
the inside surfaces.
Corrosion buildup or pits in the Replace the closure.
threads or internal surfaces
Replace the closure.
Spool and sleeve lap Visual Burrs, cracks, dents, gouges, Replace the spool
assembly (1-120) nicks, or scratches. and sleeve lap
assembly.
Springs (1-57, 1-138, Visual Deformation or permanent set. Replace the spring.
1-162, 1-174, 2-24)
Gland (1-144) Visual Burrs, cracks, dents, FOD, Replace the gland.
the inside or outside seal
surfaces.
Corrosion buildup or pits in Replace the gland.
threads or internal surfaces
Replace the gland.
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PART NUMBER 8196
Housing (2-3) Visual Burrs, cracks, dents, FOD, Replace the housing.
the inside surfaces or on the
seal grooves.
Corrosion buildup or pits in Replace the housing.
threads or on internal surfaces
Replace the housing.
Inlet nut (2-6) Visual Thread damage due to cross Repair the threads.
Replace the inlet nut.
Seat (2-9) Visual Burrs, cracks, dents, FOD, Replace the seat
the seating surface or on the
seal groove.
Poppet assembly Visual Burrs, cracks, dents, FOD, Replace the poppet
(2-21) gouges, nicks, or scratches on assembly.
the seating surface or the
sliding surfaces.

5. Dimensional Checks
A. Do dimensional checks given in table 5003.
B. Refer to IPL Figure 1 to identify parts.
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PNEUDRAULICS, INC.
PART NUMBER 8196
Dimensional Checks—Table 5003
Spool and sleeve lap Dimensional Allowable clearance. Refer to Replace lap
assembly (1-120) table 8001, Allowable assembly.
Clearances, in FITS AND
CLEARANCES
Spring (1-57) Dimensional Refer to table 8003, Spring Replace the spring
Test Data, in FITS AND
CLEARANCES.
CLEARANCES.
Spring (1-162) Dimensional Refer to table 8003, Spring Replace the spring.
CLEARANCES.
CLEARANCES.
Spring (2-24) Dimensional Refer to table 8003, Spring Replace the spring.
CLEARANCES.
Dimensional Checks—Table 5003
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PART NUMBER 8196
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Page 5006
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PNEUDRAULICS, INC.
PART NUMBER 8196
REPAIR
A. Parts that fail during procedures of TESTING AND FAULT ISOLATION or do not
meet the requirements for continued use of INSPECTION/CHECK must be replaced.
B. Use standard shop tools for repair.
C. No special tools, fixtures, or equipment are needed in the procedures of this section.
D. The materials needed in the procedures of this section are given in table 6001 and in
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT.
CAGE code).
2. Repair Tools, Fixtures, and Equipment
A. No special tools, fixtures, or equipment are needed in the procedures of this section.
3. Repair Materials
A. The materials given in table 6001 are necessary to do the repair procedures in this
section.
Repair Materials—Table 6001
NOTE: Vendor names and addresses given in ILLUSTRATED PARTS LIST.
PART OR

Alodine, Brush No. 1200 V84063
Repair Materials—Table 6001

4. Repair Procedures
A. Thread Damage Repair
(1) Replace part if damage is more than 50 percent of one thread.
(2) Chase the threads with the die or tap for threads being repaired.
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PART NUMBER 8196
B. Surface Damage Repair

(1) Replace part if the damage is on any functional surface.
(2) Replace part if the repair will change any function of the part.
(3) Replace part if the repair will change the future repair or use of the part.
(4) Replace part if the repair could decrease the ability of the part to handle any
type of load.
(5) Replace part if the damage is on or next to a packing groove.
(6) Replace part if the damage is on a sealing surface.
(7) Replace the part if damaged area is more than 25 percent of the surface area
of the part.
(8) Repair nicks, burrs, or scratches only on surfaces of the part which do not
perform an operating or sealing function.
CAUTION: DO NOT USE CROCUS ABRASIVE CLOTH ON ALUMINUM OR
ALUMINUM ALLOY PARTS. CROCUS CLOTH CONTAINS AN
IRON OXIDE THAT MAY DAMAGE ALUMINUM.
CAUTION: DO NOT POLISH MICROFINISHED SURFACES.

(9) Polish out minor nicks, scratches, and corrosion on steel parts with crocus
abrasive cloth.
(10) Polish aluminum or aluminum alloy parts with aluminum oxide abrasive cloth.
(11) Clean all the reworked parts, CLEANING.
C. Repair Alodine or Anodize Finish
CAUTION: DO NOT REPAIR ALODINE OR ANODIZE FINISH ON
MICROFINISHED SURFACES.
(1) Polish area of finish damage with aluminum oxide abrasive cloth.
WARNING: ALODINE, NO. 1200, IS TOXIC TO SKIN, EYES, AND
RESPIRATORY TRACT. WEAR SKIN AND EYE PROTECTION.
USE IN WELL VENTILATED AREA AND DO NOT BREATH FUMES
OR VAPORS. REMOVE ANY ALODINE WHICH CONTACTS SKIN
IMMEDIATELY. WASH EXPOSED SKIN WITH HOT SOAP AND
WATER IMMEDIATELY AFTER USE OF ALODINE.
(2) Apply alodine with cotton swab to polished area of damage.
NOTE: The color of the surface will change when the alodine is applied.
CAUTION: DAMAGE TO PARTS WILL OCCUR IF HEAVY PRESSURE IS

APPLIED TO THE WET ALODINE CHEMICAL FILM.
(3) Flush treated area with water and remove alodine film.
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PART NUMBER 8196
(4) If needed, use a cotton swab or lint-free rag to remove excess alodine film.
(5) Dry part at ambient atmospheric conditions or oven dry at a maximum
temperature of 130°F (54.4°C).
(6) Keep the original surface finish and critical dimensions of the part.
Page 6003
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PART NUMBER 8196
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PNEUDRAULICS, INC.
PART NUMBER 8196
ASSEMBLY
A. The numbers in parentheses following a part name are that’s part figure and item
B. Use standard shop tools for assembly.
C. The materials needed by the assembly procedures of this section are given in table
7001 and in SPECIAL TOOLS, FIXTURES, AND EQUIPMENT.
D. Equivalent substitutes can be used for items given in table 7001.
CAGE code).
G. Do all work in a clean, ventilated room with good lighting.
H. Make sure all parts are clean while the valve is being assembled.
I. Lubricate parts before assembly with the hydraulic fluid listed in table 7002.
J. During assembly, protect sealing and dynamic surfaces from damage.
CAUTION: MAKE SURE SEALING SURFACES ARE PROTECTED WHEN SEALS
(PACKINGS AND BACKUP RINGS) ARE INSTALLED.
K. Replace any seal (packings and backup rings) if it is exposed after initial assembly.
L. Make sure dated seals are not past the assigned shelf life date.
M. Prior to use, inspect all new seals for cuts, nicks, mold-line flashing, or other
damage. Do not use damaged seals; get new seals.
N. Use the correct type and size of installation bullet or other assembly aid when
installing seals.
O. Take care during assembly to avoid pinching or cutting seals.
P. After a seal is installed, make sure the seal is fully seated in the packing groove and
is not damaged or twisted.
Q. Use the correct sizing tools to fully install each seal.
R. Use the double-twist method with lockwire, MS20995C32, to safety parts needing
lockwire. Refer to MS33540. Lockwire parts after valve has passed all tests of
TESTING AND FAULT ISOLATION.
S. Take care with threaded parts to prevent cross-threading or stripping the threads.
T. Use a vise with padded jaws to hold the manifold (1-3) or housing (2-3) during
assembly.
U. Storage instructions are given in STORAGE.
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PART NUMBER 8196
2. Assembly Tools, Fixtures, and Equipment

A. There are no special tools, fixtures, or equipment needed for the assembly
procedures of this section.
3. Assembly Materials
A. The materials needed to do the assembly procedures of this section are given in
table 7001 and in SPECIAL TOOLS, FIXTURES, AND EQUIPMENT.
B. Equivalent substitutes can be used for items given in table 7001.
Assembly Materials—Table 7001
PART OR
Adhesive (Scotchweld) #2214 V60200

Potting Compound 3118 RTV V5DO26
Solder, 60/40 Rosin Core ––– Commercially Available
Wire, Teflon coated #26 AWG, MIL-W-16878 Commercially Available
Assembly Materials—Table 7001

4. Assembly Procedure
A. Refer to the figures of the ILLUSTRATED PARTS LIST to identify parts and to see
how the parts are oriented.
B. Assemble the Hydraulic Thermal Relief Valve
PARTS; MINOR SURFACE IMPERFECTIONS OR OUT OF
ROUNDNESS CAN CAUSE LEAKAGE OR OPERATING FAILURE.
CAUTION: IF ANY RESISTANCE IS NOTED DURING ASSEMBLY, SEPARATE

AND INSPECT COMPONENTS FOR BINDING OR GALLING OR
BOTH. BEFORE YOU CONTINUE ASSEMBLY, MAKE SURE PARTS
FIT CORRECTLY.
(1) Refer to the record of the quantity of shims (2-27) removed during
disassembly and install the same quantity of shims into the housing (2-3).
(2) Install the spring (2-24) and the poppet assembly (2-15) in the housing (2-3).
(3) Install the GT ring (2-12) in the seal groove of the seat (2-9).
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PART NUMBER 8196
CAUTION: MAKE SURE THE GT RING (2-12) DOES NOT CAM OUT AND IS
NOT DAMAGED WHEN THE SEAT (2-9) IS INSTALLED.
(4) Install the seat (2-9) in the housing (2-3).
(5) Use a 3/16-inch hex driver and install the inlet nut (2-6) in the housing (2-3).
(6) If the nameplate is replaced or the housing is replaced, copy the nameplate
data from the maintenance record or existing nameplate to the new
nameplate (2-30).
(7) Use the adhesive given in table 7001 and bond the nameplate (2-30) in the
recess in the hex head of the housing (2-3).
C. Assemble the Switch Assembly
(1) Cut and solder prep 3 3-inch lengths of #26 AWG wire.
(2) Solder a 3-inch length of wire to each of the 3 connector (1-51) sockets.
(3) Put the free ends of the 3 wires through the hole in the adjusting screw
(1-48).
(4) Mark each wire with the connector pin it is soldered to.
(5) Put the connector (1-51) in the adjusting screw (1-48) and solder in place.
(6) Fill the cavity of the adjusting screw (1-48) with 3118 RTV or equivalent.
(7) Position the switch (1-36) and the leaf actuator (1-39) on the adjusting screw
(1-48).
(8) Use a slot screwdriver and a 1/8-inch hex driver and install 2 screws (1-42)
and 2 nuts (1-45).
(9) Refer to Figure 1 of DESCRIPTION for electrical schematic of the switch
assembly.
(10) One at a time, cut each wire to length and solder to switch (1-36) post that is
to connect to the electrical connector pin the wire is connected to.
(11) Install the electrical connector per the procedure in TESTING AND FAULT
ISOLATION.
D. Assemble the Emergency/Parking Brake Valve
PARTS; MINOR SURFACE IMPERFECTIONS OR OUT OF
ROUNDNESS CAN CAUSE LEAKAGE OR OPERATING FAILURE.
CAUTION: IF ANY RESISTANCE IS NOTED DURING ASSEMBLY, SEPARATE

AND INSPECT COMPONENTS FOR BINDING OR GALLING OR
BOTH. BEFORE YOU CONTINUE ASSEMBLY, MAKE SURE PARTS
FIT CORRECTLY.
(1) Hold the manifold (1-3) in the padded jaws of a vise. Adjust the position of
the manifold to access the different parts of the emergency/parking brake
valve.
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PNEUDRAULICS, INC.
PART NUMBER 8196
(2) Refer to the record made during disassembly and put the same quantity of
shims (1-177) into the spring guide (1-180) as were removed.
(3) Put the spring guide (1-180), the shims (1-177), and the spring (1-174) in the
manifold (1-3).
(4) Install the packing (1-153), the DC scraper (1-150), and the packing (1-147)
on the gland (1-144).
CAUTION: MAKE SURE THE PACKING (1-153) AND THE DC SCRAPER
(1-150) ARE NOT DAMAGED WHEN THE PLUNGER (1-156) IS PUT
IN THE GLAND (1-144).
(5) Put the plunger (1-156) in the gland (1-144).
(6) Refer to the record made during disassembly and, during assembly, install
the same quantity of shims (1-165) as were removed.
(7) Install the guide (1-159), the spring (1-162), the shims (1-165), and the guide
(1-168) on the plunger and gland.
(8) Use a 1/2-inch wide slot driver and install the nut (1-171) on the plunger
(1-156).
CAUTION: MAKE SURE THE PACKING (1-147) DOES NOT CAM OUT AND IS
NOT DAMAGED WHEN THE GLAND (1-144) IS INSTALLED IN THE
MANIFOLD (1-3).
(9) Use a pin spanner wrench and install the gland (1-144) with attached parts in
the manifold (1-3).
(10) Refer to the record made during disassembly and install the spring guide
(1-141) on the spool (1-126).
(11) Install 4 packings (1-132) and 7 backups (1-135) on the sleeve (1-129).
(12) Put the piston (1-123) in the spool (1-126).
(13) Put the spool (1-126) in the sleeve (1-129).
CAUTION: MAKE SURE THE PACKINGS (1-132) AND THE BACKUPS (1-135)
DO NOT CAM OUT AND ARE NOT DAMAGED WHEN THE SLEEVE
(1-129) IS INSTALLED IN THE MANIFOLD (1-3).
(14) Install the sleeve (1-129), the spool (1-126), the piston (1-123), and the
spring guide (1-141) in the manifold (1-3).
(15) Put the spring (1-138) in the manifold (1-3).
(16) Install packing (1-111) on the closure (1-108).
(17) Refer to the record made during disassembly and put the same quantity of
shims (1-114) in the closure (1-108) as were removed.
(18) Put the disc (1-117) in the closure (1-108).
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PART NUMBER 8196
CAUTION: MAKE SURE THE PACKING (1-111) DOES NOT CAM OUT AND IS
NOT DAMAGED WHEN THE CLOSURE (1-108) IS INSTALLED IN
THE MANIFOLD (1-3).
(19) Use a 5/8-inch open end wrench and install the closure (1-108) in the
manifold (1-3).
(20) Install the gasket (1-96) on the RTN port union (1-93).
(21) Use a 13/16-inch open end wrench and install the union (1-93) in the RTN
port of the manifold (1-3).
(22) Install the gasket (1-96) on the RTN port union (1-93).
CAUTION: MAKE SURE THE GASKET (1-96) DOES NOT CAM OUT AND IS
NOT DAMAGED WHEN THE UNION (1-93) IS INSTALLED IN THE
MANIFOLD (1-3).
(23) Use a 13/16-inch open end wrench and install the union (1-93) in the RTN
(24) Install the gasket (1-84) on the ACC port reducer (1-81).
NOT DAMAGED WHEN THE REDUCER (1-81) IS INSTALLED IN
THE MANIFOLD (1-3).
(25) Use a 13/16-inch open end wrench and install the reducer (1-81) in the ACC
(26) Install the gasket (1-90) on the PRESS port check valve (1-87 or 1-87A).
NOT DAMAGED WHEN THE CHECK VALVE (1-87 OR 1-87A) IS
INSTALLED IN THE MANIFOLD (1-3).
(27) Use a 13/16-inch open end wrench and install the check valve (1-87 or
1-87A) in the PRESS port of the manifold (1-3).
(28) Install the gasket (1-78) on the BRK port union (1-75).
NOT DAMAGED WHEN THE UNION (1-75) IS INSTALLED IN THE
MANIFOLD (1-3).
(29) Use an 11/16-inch open end wrench and install the union (1-75) in the BRK
(30) Hold the handle (1-6) in the padded jaws of a vise.
(31) Put the cam (1-18) into position on the handle (1-6) and put the bolt (1-24)
through the handle and cam.
(32) Install the washer (1-27) on the bolt (1-24).
(33) Use 2 wrenches (3/8-inch open end) and install the nut (1-21) on the bolt
(1-24).
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PART NUMBER 8196
(34) Remove the handle (1-6) from the vise and position the handle on the
manifold (1-3).
(35) Install the pin (1-9), the washer (1-12), and the cotter pin (1-15) on the handle
(1-6) and the manifold (1-3).
(36) Install the packing (1-72) on the switch plunger (1-69).
(37) Install the switch plunger (1-69) in the manifold (1-3).
(38) Install the retainer (1-63) with the 2 screws (1-66) in the manifold.
(39) Install the spring guide (1-60) and the spring (1-57) in the manifold.
(40) If needed, prepare nameplate by marking data from the maintenance record.
(41) Install nameplate (1-183) around manifold (1-3) switch assembly boss and
crimp the ends of the nameplate together and fold crimp flat.
(42) If the emergency/parking brake valve is not tested immediately, install
hydraulic thermal relief valve and switch assembly prior to storage.
(a) Install the packing (1-102) and the GT ring (1-105) on the thermal
relief valve (1-99).
CAUTION: MAKE SURE THE PACKING (1-102) AND THE GT RING
(1-105) DO NOT CAM OUT AND ARE NOT DAMAGED
WHEN THE THERMAL RELIEF VALVE (1-99) IS INSTALLED
IN THE MANIFOLD (1-3).
(b) Use a 1/2-inch open end wrench and install the thermal relief valve
(1-99) in the manifold (1-3).
(c) For storage, install the switch assembly (1-33) in the manifold (1-3) for
only 5 or 6 turns of the adjusting screw.
(d) Place jam nut (1-30) on the adjusting screw but do not tighten.
(43) Go to STORAGE or TESTING AND FAULT ISOLATION.
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PART NUMBER 8196
FITS AND CLEARANCES

1. General Information
A. This section contains data on allowable clearances, assembly torque limits and
spring test data for the valve.
B. Parts in this section are identified by figure-item number to the figures of the
ILLUSTRATED PARTS LIST.
2. Fits and Clearances
A. Allowable clearances of parts are given in table 8001.
B. Allowances are made for wear when possible.
Allowable Clearances—Table 8001
DIMENSIONS-INCHES (MILLIMETERS)
IPL DIAMETRAL
FIG-ITEM ITEM NAME DIM. MIN. MAX. CLEARANCE
1-129 Sleeve ID Honed Honed 0.000070 - 0.000090
1-126 Spool OD Lapped Lapped (0.001778 - 0.002286)
1-126 Spool ID Honed Honed 0.000070 - 0.000090
1-123 Piston OD Lapped Lapped (0.001778 - 0.002286)
Allowable Clearances—Table 8001

3. Assembly Torque Limits
A. There are no allowable assembly torque limits applicable to this valve.
4. Spring Test Data
A. Spring test data is given in table 8002.
Page 8001
32-40-13 Apr 18/05
PNEUDRAULICS, INC.
PART NUMBER 8196
Spring Test Data—Table 8002
IPL LENGTH UNDER LOAD TEST LOAD

FIG-ITEM INCHES (MILLIMETERS) POUNDS FORCE (NEWTONS)
1-57 2.620 (66,548) Free Length

0.665 (16,891) 4.9 ± 0.5 (21,796 ± 2,224)
0.620 (15,748) 5.0 ± 0.5 (22,241 ± 2,244)
1-138 1.108 (28,143) Free Length
0.665 (16,891) 13.3 ± 1.3 (59,2 ± 5,8)
0.585 (14,859) 15.7 ± 1.6 (69,8 ± 7,1)
1-162 1.016 (25,806) Free Length
0.966 (24,536) 31.0 ± 4.0 (137,9 ± 17,8)
1-174 1.113 (28,27) Free Length
0.953 (24,206) 16.0 ± 1.6 (71,171 ± 7,117)
0.608 (15,443) 50.0 ± 5.0 (222,41 ± 22,24)
2-24 0.75 (19,05) Free Length
0.501 (12,73) 5,36 (23,84)
Spring Test Data—Table 8002
Page 8002
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PNEUDRAULICS, INC.
PART NUMBER 8196
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT

1. General Information
A. The special tools, fixtures, and equipment and the materials given in this section are
needed for repair, overhaul, and testing of the valve.
B. Sources given in the tools, fixtures, and equipment table and in the materials table
are listed by vendor code (V followed by the CAGE code).
2. Special Tools, Fixtures, and Equipment
A. The special tools, fixtures, and equipment used for maintenance of the valve are
given in table 9001.
Special Tools, Fixtures, and Equipment—Table 9001
PART OR
10X (minimum) Magnifier ––– Commercially Available

Flowmeter, Digital, 0 to 2.0 gpm (0 to 7,57 ––– Commercially Available
lpm)
Gauge, Hydraulic Pressure, 0 to 5000 psig (0 ––– Commercially Available
to 41,37 MPa) ± 2.0%, 2 needed
High Intensity Inspection Lamp ––– Commercially Available
Hydraulic Test Stand, 0 to 6000 psig (0 to ––– Commercially Available
34,45 MPa), 0 to 15.0 gpm (0 to 56,8 lpm)
Temperature Sensor, 0 °F to 120 °F (18 °C to ––– Commercially Available
49 °C)
Test Plug 8196 V06177
Test Manifold 2623TM V06177
Special Tools, Fixtures, and Equipment—Table 9001
3. Materials
A. The materials used during maintenance of the valve are given in table 9002.
Page 9001
32-40-13 Apr 18/05
PNEUDRAULICS, INC.
PART NUMBER 8196
Materials—Table 9002
PART OR

Adhesive (Scotchweld) #2214 V60200
Alodine, Brush No. 1200 V84063
Bag, Polyethylene, 25 mil MIL-B-117 Commercially Available
Box, Corrugated Cardboard --- Commercially Available
Brush, Stiff Bristle, Non-Metallic H-B-1490 Commercially Available
Cloth, Lint-Free MIL-C-85043 Commercially Available
Desiccant MIL-D-3464 Commercially Available
Goggles, Safety, Fluid and Particle Resistant ––– Commercially Available
Nylon Scrub Pad ––– Commercially Available
Packing, Bubble Wrap --- Commercially Available
Potting Compound 3118 RTV V5DO26
Solder, 60/40 Rosin Core ––– Commercially Available
Solvent, Cleaning P-D-680, Type III Commercially Available
Tag, Identification --- Commercially Available
Wire, Teflon coated #26 AWG, MIL-W-16878 Commercially Available
Materials—Table 9002
Page 9002
32-40-13 Apr 18/05
PNEUDRAULICS, INC.
PART NUMBER 8196
STORAGE
A. Standard shop tools and equipment are used to do the storage procedures.
B. The recommended storage materials are given in table 15001.
C. Sources given in the materials table are listed by vendor code (V followed by the
CAGE code).
D. Vendor codes used in this manual are cross-referenced to the vendor name and
2. Storage Tools, Fixtures, and Equipment
A. No special tools, fixtures, or equipment are needed to do the storage procedures.
3. Storage Materials
A. The material given in table 15001 is needed for storage of the valve.
Storage Materials—Table 15001
PART OR
Bag, Polyethylene, 25 mil MIL-B-117 Commercially Available

Box, Corrugated Cardboard --- Commercially Available
Desiccant MIL-D-3464 Commercially Available
Packing, Bubble Wrap --- Commercially Available
Tag, Identification --- Commercially Available
Storage Materials—Table 15001

4. Storage Instructions
A. Drain hydraulic fluid from the unit and install protective caps on all ports.
B. Write the unit nomenclature, part number, and maintenance date on the identification
tag and on the cardboard box.
C. Moisten the entire unit with hydraulic fluid.
D. Wrap unit in bubble wrap or equivalent padded packing material.
E. Put the wrapped unit in a 25-mil or heavier polyethylene bag.
F. Put desiccant in the polyethylene bag.
G. Put the tag in the plastic bag arranged so it can be read.
H. Heat seal the bag.
Page 15001
32-40-13 Apr 18/05
PNEUDRAULICS, INC.
PART NUMBER 8196
I. Put bag with unit in the cardboard box and fill voids with bubble wrap or equivalent
padded packing material.
J. Seal the box.
K. Store box in a well-ventilated, weather tight, area. Storage area must have low
humidity and dust and be protected from high temperatures.
Page 15002
32-40-13 Apr 18/05
PNEUDRAULICS, INC.
PART NUMBER 8196
ILLUSTRATED PARTS LIST

1. Introduction
A. Purpose
The IPL illustrates and lists authorized replacement parts with attaching hardware for
the Valve, Solenoid Operated, 2-Way, 2-Position, Normally Open, P/N 8196.
B. Guide to Use of IPL
(1) If the part number is not known:
(a) Locate the part in the illustration for IPL figure.
(b) Note the item number assigned to the part.
(c) Refer to the parts list and locate the item number in the FIG. ITEM
column.
(2) If the part number is known:
(a) Refer to the parts list and locate the part in the PART NUMBER
column.
(b) Note the figure number and item number assigned to the part.
(c) Refer to the illustration to identify attaching hardware and related
assembly parts.
2. Explanation of Detail Parts List Entries
The Detail Parts List is arranged in the general sequence of disassembly. The parts are
illustrated in an exploded-view illustration and listed in the related parts list.
A. FIG. ITEM Column
(1) The first number at the top of each FIG. ITEM column is the figure number of
the corresponding illustration. The number listed opposite each part number
is the item number assigned to the part in the illustration.
(2) A dash (–) in front of an item number means that the part is not illustrated.
(3) Alpha-variants A through Z (except I and O) are assigned to item numbers
when necessary to identify added parts, alternate parts, and service bulletin
modified parts.
B. PART NUMBER Column
This column contains the manufacturer’s part number for each part, as modified to
meet the requirements of ATA 200 and ATA 2000. These modifications may include:
(1) Removal of blank spaces and special characters, with the possible exception
of dashes. Dashes are permitted only between numeric characters.
(2) Insertion of a reference part number compatible with ATA 200/2000 if the
manufacturer’s part number exceeds 15 characters. In these cases, the
manufacturer’s part number is listed in the NOMENCLATURE column.
Page 10001
32-40-13 Apr 18/05
PNEUDRAULICS, INC.
PART NUMBER 8196
C. NOMENCLATURE Column
(1) This column contains descriptive nomenclature for each part, and may also
list the manufacturer’s CAGE code (if the part was not manufactured by
PneuDraulics, Inc.), part number (if longer than 15 digits or modified by ATA
200/2000), service bulletins affecting the part, and obsolete part numbers.
(2) The indenture system used in the NOMENCLATURE column indicates the
relationship of one part to another, as follows:
123
End Item or Major Assembly
ATTACHING PARTS
Attaching Parts for End Item or Major Assembly
***
. Detail Parts for End Item or Major Assembly Subassemblies
ATTACHING PARTS
. Attaching Parts for Subassemblies
***
. . Detail Parts for Subassemblies
ATTACHING PARTS
. . Attaching Parts for Detail Parts
***
(3) Assemblies, subassemblies, and detail parts subject to modification, deletion,
addition, or replacement by an issued service bulletin are annotated to
indicate both pre-service bulletin and post-service bulletin configurations.
The term (PRE SB XXXX) in the NOMENCLATURE column designates the
original configuration, and the term (POST SB XXXX) identifies assemblies
and parts after the modification has been completed.
(4) The terms listed below are used when applicable to indicate the
interchangeability of parts.
Term Abbreviation Definition
Alternate ALT The part fully meets functional and structural
specifications, but is different in external
dimensions, connection installation, and
mounting provisions or in any combination
thereof. Rework or possible modifications can
be necessary.
Optional OPT The listed part is an option to other parts within
the same item number variant group or to other
item numbers if noted.
Preferred PRFD The part is preferred over other alternate or
optional parts given.
Replaced By REPLD BY The part is replaced by and is interchangeable
with the item number given in the note.
Page 10002
32-40-13 Apr 18/05
PNEUDRAULICS, INC.
PART NUMBER 8196
Term Abbreviation Definition

Replaces REPLS The part replaces and is interchangeable with
the item number given in the note.
Superseded By SUPSD BY The part is replaced by, but is not
interchangeable with, the item number given in
the note.
Supersedes SUPSDS The part replaces and is not interchangeable
with the item number given in the note.
D. EFF CODE Column
This column contains effectivity codes (A, B, etc.) to indicate the alternate models or
configurations of the end item to which the listed parts apply. This column is left
blank when the listed parts apply to all models or configurations included in the parts
list.
E. UNITS PER ASSY Column
The quantity given in this column represents the units needed for one next higher
assembly (NHA) or, when referring to attaching parts, the quantity to attach one such
item. The abbreviation RF (referenced item) indicates that the IPL figure shows the
parts breakdown for that item. The abbreviation AR used in this column indicates
that procedures in this manual may or may not require the use of the listed part.
3. Manufacturer Names and Addresses
A list of all manufacturers (vendors) of items in this CMM is given below. The list is in CAGE
(Commercial And Government Entity) code sequence. The absence of a code in the
NOMENCLATURE column of the Detail Parts List indicates that the part was manufactured
or modified by PneuDraulics, Inc.
CODE NAME AND ADDRESS
V06177 PneuDraulics, Inc, 8575 Helms, Rancho Cucamonga, CA 91730
V09257 Shamban WS and Co, PO Box 176, Fort Wayne, IN 46801
V5DO26 Dow Corning Corp, 250 McCormick Ave, Costa Mesa, CA 92627
V5F573 Greene Tweed and Co Inc, Detwiler Rd, Box 305, Kulpsville, PA 19443-0305
V60200 3M Company, 6023 S Garfield Ave, Los Angeles, CA 90040-3608
V77535 Associated Spring, Barnes Group Inc., 226 S Center Street, Corry, PA
16407-1992
V84063 Amchem Products, Inc, 300 Brookside Ave, Ambler, PA 19002-3436
V86928 Seastrom Mfg. Co., Inc., 701 Sonora Ave, Glendale, CA 91201
V99240 Crissair, Inc., 38905 10th St E, Palmdale, CA 93550
Page 10003
32-40-13 Apr 18/05
PNEUDRAULICS, INC.
PART NUMBER 8196
This page is empty.
Page 10004
32-40-13 Apr 18/05
PNEUDRAULICS, INC.
PART NUMBER 8196
Valve Assembly, Emergency/Parking Brake, P/N 8196, Exploded View

IPL Figure 1
Page 10005
32-40-13 Apr 18/05
PNEUDRAULICS, INC.
PART NUMBER 8196
IPL AIRLINE UNITS

FIG 1— STOCK EFF PER
ITEM PART NUMBER NUMBER 1 2 3 4 5 6 7 NOMENCLATURE CODE ASSY
-1 8196-4 Valve Assembly, Emergency/ A RF
Parking Brake
-1A 8196-5 Valve Assembly, Emergency/ B RF
Parking Brake
3 80440 . Manifold Assembly 1
6 80459-1 . Handle 1
ATTACHING PARTS
9 MS20392-2C31 . Pin 1
12 5710-289-16P . Washer (V86928) 1
15 MS24665-132 . Pin, Cotter 1
***
18 80468 . Cam 1
ATTACHING PARTS
21 MS21083N3 . Nut, Self-Locking 1
24 NAS1103-8 . Bolt 1
27 AN960C10L . Washer 1
***
30 80465 . Nut, Jam 1
-33 80463-1 . Switch Assembly 1
36 1SX1-T . . Switch 1
39 80531 . . Leaf Actuator 1
42 MS35275-207 . . Screw 2
45 MS21042-02 . . Nut, Self-Locking 2
48 80464-1 . . Adjusting Screw (Permanently 1
bonded to item 51, replace as a set.)
51 MS3443H8C98PN . . Connector (Permanently bonded 1
to item 48, replace parts as a set.)
-54 Deleted
57 80530 . Spring 1
60 80529 . Spring Guide 1
63 80462-1 . Retainer 1
- Indicates item not shown
Page 10006
32-40-13 Apr 18/05
PNEUDRAULICS, INC.
PART NUMBER 8196
IPL AIRLINE UNITS

66 MS35275-203 . Screw 2
69 80461 . Plunger, Switch 1
72 M83461/1-004 .Packing 1
75 MS21902K4 . Union 1
78 MS28778-4 . Gasket 1
81 MS21916K6-4 . Reducer 1
84 MS28778-4 . Gasket 1
87 2C4360 . Check Valve (V99240) A 1
-87A 1C4124 . Check Valve (V99240) B
90 MS28778-6 . Gasket 1
93 MS21902K6 . Union 1
96 MS28778-6 . Gasket 1
99 2623 . Hydraulic Thermal Relief Valve 1
(V06177) (Refer to IPL Figure 2
for Breakdown)
102 M83461/1-111 . Packing 1
105 7012MR160T . GT Ring (V5F573) 1
108 80441 . Closure 1
111 M83461/1-116 . Packing 1
114 5710-9-10P . Shim (V86928) AR
117 80517 . Disk 1
-120 80508-1 . Spool And Sleeve Lap Assembly 1
123 80510 . . Piston (Matched Part, Order NHA) 1
126 80509-1 . . Spool (Matched Part, Order NHA) 1
129 80445 . . Sleeve (Matched Part, Order 1
NHA)
132 M83461/1-013 . Packing 4
135 M8791/1-013 . Backup 7
138 80519 . Spring 1
144 80469 . Gland 1
Page 10007
32-40-13 Apr 18/05
PNEUDRAULICS, INC.
PART NUMBER 8196
IPL AIRLINE UNITS

147 M83461/1-120 . Packing 1
150 S34382-1/4-99 . Scraper DC (V09257) 1
153 M83461/1-010 . Packing 1
156 80513 . Plunger 1
159 80498 . Guide 1
162 80500 . Spring 1
165 80505 . Shim AR
168 80495 . Guide A 1
-168A 80532 . Guide B
171 80494 . Nut 1
174 80512 . Spring 1
177 80504 . Shim AR
-183 80460 . Nameplate 1
Page 10008
32-40-13 Apr 18/05
PNEUDRAULICS, INC.
PART NUMBER 8196
Valve, Hydraulic Thermal Relief, P/N 2623, Exploded View

IPL Figure 1
Page 10009
32-40-13 Apr 18/05
PNEUDRAULICS, INC.
PART NUMBER 8196
IPL AIRLINE UNITS

-1 2623 Valve, Hydraulic Thermal Relief RF
(Refer to IPL Figure 1 for NHA)
3 16726 . Housing 1
6 16727 . Inlet Nut 1
9 16728 . Seat 1
12 7007MR160T . GT Ring (V5F573) 1
15 16729 . Poppet Assembly 1
18 MS19060-1004 . . Ball 1
21 16730 . . Spring Guide 1
24 C0180-029-0750S . Spring (V77535) 1
27 16731 . Shim AR
30 16732-1 . Nameplate 1
Page 10010
32-40-13 Apr 18/05

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PNEUDRAULICS, INC.

COMPONENT MAINTENANCE MANUAL

REVISION 1, APR 18/05

PAGES DESCRIPTION OF REVISION EFFECTIVITY

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Component Maintenance Manual

Initial Issue Feb 6/98 T-1

Copyright, 1998, 2005

This page is empty.

RECORD OF TEMPORARY REVISIONS

This page is empty.

SERVICE BULLETIN LIST

This page is empty.

LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

Table of Contents TOC-1 Apr 18/05 Repair 6001 Apr 18/05

Introduction INTRO-1 Apr 18/05 Assembly 7001 Apr 18/05

LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

This page is empty.

DESCRIPTION AND OPERATION

Manufacturer PneuDraulics, Inc. (V06177)

Temperature Range -65°F to +165°F (-54°C to +74°C)

TESTING AND FAULT ISOLATION

Filter, 5 micron absolute (non-bypassing) ––– Commercially Available

Hydraulic Thermal Relief Valve, P/N 2623, Test Setup

Test Materials—Table 1002

Hydraulic Fluid MIL-H-5606 Commercially Available

Test Materials—Table 1002

Emergency/Parking Brake Valve, P/N 8196, Test Setup

WARNING: TO STOP INJURY TO PEOPLE, HYDRAULIC TEST EQUIPMENT

D. Check Valve Test

E. Metering Valve Operation, Plunger Stroke Relation to Brake Pressure

Emergency/Parking Brake Valve Actuator Position Reference

H. Metering Valve Operation, Pressure Drop At Rated Flow

Fault Isolation (Sheet 1 of 3)—Table 1003

PROBLEM PROBABLE CAUSE CORRECTIVE ACTION

Fault Isolation (Sheet 1 of 3)—Table 1003

Fault Isolation (Sheet 2 of 3)—Table 1003

PROBLEM PROBABLE CAUSE CORRECTIVE ACTION

When the emergency/parking The emergency/parking brake To make large adjustments

Fault Isolation (Sheet 2 of 3)—Table 1003

Fault Isolation (Sheet 3 of 3)—Table 1003

PROBLEM PROBABLE CAUSE CORRECTIVE ACTION

Fault Isolation (Sheet 3 of 3)—Table 1003

B. Disassemble the Emergency/Parking Brake Valve, P/N 8196-4 or P/N8196-5

WARNING: CLEANING SOLVENTS IRRITATE THE EYES AND THE NOSE. TO

Cleaning Materials—Table 4001

Abrasive Cloth, Aluminum Oxide P-C-451 Commercially Available

Cleaning Materials—Table 4001

CAUTION: DO NOT USE CROCUS ABRASIVE CLOTH ON ALUMINUM OR

10X (minimum) Magnifier ––– Commercially Available

Check Tools, Fixtures, and Equipment—Table 5001

Visual Checks (Sheet 1 of 2)—Table 5002

Manifold (1-3) Visual Burrs, cracks, dents, FOD, Replace the

Visual Checks (Sheet 1 of 2)—Table 5002

Visual Checks (Sheet 2 of 2)—Table 5002

Dimensional Checks—Table 5003