Maintenance Manual and Illustrated Parts Catalogue

Extra EA -400

Chapter 37
Vacuum

Page Date: 8. December 1999 37 Page 1

Maintenance Manual and Illustrated Parts Catalogue
Extra EA -400
Vacuum

Table of Contents

37-00-00 GENERAL .........................................................................................................3

Description ..........................................................................................................3
Vacuum System Surview .........................................................................................4
System Components ............................................................................................5
Troubleshooting...................................................................................................6

37-10-00 DISTRIBUTION................................................................................................8
37-10-01 Vacuum Pump ...................................................................................................8
Removal (LH / RH Side) .....................................................................................8
Installation...........................................................................................................8
37-10-02 Vacuum System Inlet Filter..............................................................................8
Filter Element Replacement ................................................................................8
37-10-03 Vacuum Regulator Valve ..................................................................................9
Removal (LH Side)..............................................................................................9
Installation (LH Side) ........................................................................................10
Removal (RH Side) ...........................................................................................10
Installation (RH Side) ........................................................................................10
Filter Element Replacement ..............................................................................11
37-10-04 Vacuum Check Valve Manifold .....................................................................11
Removal.............................................................................................................11
Installation.........................................................................................................12

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 Maintenance Manual and Illustrated Parts Catalogue
Extra EA -400
Vacuum

37-00-00 GENERAL

Description
The vacuum and pneumatic system (refer to Figure 30-01) is installed to
provide a source of vacuum for the vacuum instruments and the de- icing boots,
and also air pressure for the latter. The system consists of two engine driven
dry air pumps, vacuum and pressure regulating valves, vacuum and pressure
manifolds with internal check valves, the suction gage and the gyro
instruments. Furthermore the components of the de- icing system, such as
control and distribution valves, timer, and pressure switches are incorporated in
the system.
Each air pump operates continuously when the engine is running and pulls a
vacuum on the common vacuum manifold. The maximum amount of vacuum
pulled on the manifold by each air pump is controlled to a preset level by each
vacuum regulating valve. Should either of the pumps fail, a check valve is
provided in each end of the manifold to isolate the inoperative pump from the
system.
The exhaust air side of each attitude gyro is connected to the vacuum manifold
thus providing a smooth steady vacuum for the gyros. The vacuum pressure
being applied to the gyros is constantly present on the suction gage. This gage
also provides failure indicators for the left and right air pumps. These
indicators are small red buttons located in the lower portion of the suction gage
which are spring- loaded to the extended (failed) positio n. When normal
vacuum is applied in the manifold, the failure buttons are pulled flush with the
gage face. Should insufficient vacuum occur on either side, the respective red
button will extend. No corrective action is required by the pilot, as the system
will automatically isolate the failed vacuum source, allowing normal operation
on the remaining operative vacuum pump.
The inlet air side of the attitude gyros are connected to a common vacuum air
filter located between the LH and RH keelbeams, which cleans the air before
allowing it to enter the gyro. (With SN 03 through 14, the air inlet filter is
installed in the fuselage portion of the wing).
At the same time the air pumps pull a vacuum on the common vacuum
manifold they provide air pressure to the common pressure manifold. However,
the pressure side is active only if de- ice system is ON. The maximum amount
of air pressure in the system is controlled to a preset level by a pressure
regulating valve. Should either of the pumps fail, a check valve is provided in
each end of the manifold to isolate the inoperative pump from the system.
Controlled by the timer, the distributing valve of the de-icing system, which is
connected to the vacuum and the pressure manifold, takes either vacuum or
pressure as required for the respective cycles of the activated de- icing system
(refer also to Paragraph 7.25 in Pilot's Operating Handbook). In case air
pressure is not necessary, the de- ice control valve exhausts the air to relieve the
pressure system.
Page Date: 5.11.
July 2002 2000
August 37 Page 3
Maintenance Manual and Illustrated Parts Catalogue
Extra EA -400
Vacuum

1H5-29

5000B-52

4000B-22

Hoses not designated specified to MIL-H-5593-6

Figure 37-01
Vacuum System Surview
Legend
Vacuum line from vacuum system inlet filter to gyro installation
Vacuum line from gyro installation to vacuum manifold
Vacuum line from vac. manifold to LH vac. regulating valve / vac. pump
Vacuum line from vac. manifold to RH vac. regulating valve / vac. pump
LH / RH pressure lines from vac. pump to pressure manifold / de-ice system
Vacuum line from vac. manifold to de- ice system
LH vacuum line from vac. manifold to dual source differential vac. gage
RH vacuum line from vac. manifold to dual source differential vac. gage
Vacuum line from gyro inlet manifold to dual source differential vac. gage
Vacuum line from attitude indicator to dual source differential vac. gage

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 Maintenance Manual and Illustrated Parts Catalogue
Extra EA -400
Vacuum

System Components
Refer to Figure 37-01.

Item Manufacturer Part-Nr. Qty.

Engine Driven Vacuum Pump Airborne A/M 442CW-6 2
optional: Aero Accessories CH 442CW-6 2
Attitude Indicator King KI 256 060-0017-01 1
Pneumatic Attitude Gyro (Copilot) RC-Allen RCA22-11F 1
optional: Sigma-Tek 5000B-52 1
Pneumatic Directional Gyro (Copilot) RC-Allen RCA11A-17BF 1
optional: Sigma-Tek 4000B-22 1
Vacuum Regulator Valve Airborne 2H3-6 2
Vacuum Check Valve Manifold Airborne 1H5-29 1
Dual Source Differential Vacuum Gage Airborne 1G5-4 1
Vacuum System Inlet Filter Extra 75551.00 1
Vacuum System Inlet Filter Element Airborne D9-18-1 1
Triple Bulkhead Fitting Vacuum Line Extra 25227.80 1
Triple Bulkhead Fitting Vacuum Line -6 Extra 25227.04 1
Bulkhead Fitting Gyro Suction Line Extra 75554.10 1
Gyro Inlet Manifold Extra 75552.10 1
Gyro Outlet Manifold Extra 75553.10 1

Vacuum hose fittings protected by spring clamps VW 60184-xx

Hose Elastic Clamp
-4 VW 60184 - 15
-6 VW 60184 - 19
-8 VW 60184 - 23
-10 VW 60184 - 27

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Maintenance Manual and Illustrated Parts Catalogue
Extra EA -400
Vacuum

Troubleshooting
Complaint Possible Cause Remedy
Correct indication on vacuum Vacuum pump defective Identify and replace defective
gauge, bull’s eye pops up vacuum pump
Vacuum plumbing defective Check and replace defective
plumbing
No indication on vacuum Vacuum plumbing defective Check and replace defective
gauge, no bull’s eye popped plumbing
up
Vacuum gauge defective Replace vacuum gauge
Vacuum regulator maladjusted Identify and readjust vacuum
regulator
No indication on vacuum Both vacuum pumps defective Replace both vacuum pumps
gauge, both bull’s eyes popped
Vacuum gauge defective Replace vacuum gauge
up
Vacuum gauge indication low Vacuum regulator maladjusted Identify and readjust vacuum
regulator
Vacuum plumbing defective Check and replace defective
plumbing
Vacuum indication high Vacuum system filter dirty Replace vacuum system filter
Vacuum regulator maladjusted Identify and readjust vacuum
regulator
Erratic vacuum indication Drive pad seal leakage Replace seal
Premature vacuum pump Incorrect pump model Install correct clockwise (CW)
failure rotating pump
Pump overload due to airflow Replace defective and
restriction or system contaminated components
contamination before replacing pump
Excessive gyro precession Restricted airflow due to Check and replace defective
leaking or kinked lines or plumbing, replace vacuum
clogged filter filter
Gyro failure Replace gyro, see chapter 34
Gauge indication follows Foreign matter in regulator Remove contamination and
engine rpm seat reset regulator
Regulator defective Replace defective regulator
Frequent regulator adjustment Kinks in lines, deteriorated Check and replace defective
hoses, leaking hose plumbing, reset regulator
connections

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 Maintenance Manual and Illustrated Parts Catalogue
Extra EA -400
Vacuum

NOTE Use Airborne 343 Test Kit to troubleshoot vacuum and pressure system,
and to readjust regulating valves.

Page Date: 5.11.

July 2002 2000
August 37 Page 7
Maintenance Manual and Illustrated Parts Catalogue
Extra EA -400
Vacuum

37-10-00 DISTRIBUTION

37-10-01 Vacuum Pump

Refer to Airborne Service Letter No. 58, latest edition.

Removal (LH / RH Side)

CAUTION Turn battery switch OFF and pull OFF circuit breaker BOOTS (left side
panel) before beginning work.
CAUTION When working on vacuum system, take care not to contaminate vacuum
hoses. Install blind plugs on hose ends. Even small residues of dirt may
damage air pumps.
Detail Steps/Work Items Key Items
1 Remove upper cowling
2 Disconnect vacuum hose from vacuum VW spring clamp at vacuum
regulator valve pump
3 Disconnect pressure hose to de- ice control VW spring clamp at vacuum
valve pump
4 Pull off plastic semi-circular cooling shroud
from top of vacuum pump
5 Unscrew 4 nuts from pump flange Vacuum installation wrench
required
6 Remove vacuum pump

Installation
Detail Steps/Work Items Key Items
Install in reverse sequence of removal
Caution Install new gasket between pump and flange

37-10-02 Vacuum System Inlet Filter

Filter Element Replacement
1 Filter assembly Extra EA-75551.00 with filter element Airborne D9-18-1
(to be used with ADI KI-256 installation or aircraft approved for known icing
operation):
The filter assembly is located in the bottom fuselage area, between the LH and
RH keelbeams.

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 Maintenance Manual and Illustrated Parts Catalogue
Extra EA -400
Vacuum

2 Filter assembly Airborne with filter element Airborne D9-18-1:

The filter assembly is located in RH wing leading edge. To gain access,
remove the wing center fairing.

Detail Steps/Work Items Key Items

Removal
1 Remove 10/32 UNF nut securing filter
assembly to fuselage resp. wing section
2 Pull threaded rod out of filter assembly
3 Remove internal distance bushing
4 Remove filter assembly from fuselage resp.
wing section
5 Replace filter element
Installation
Install in reverse sequence of removal
NOTE Use new polystop nuts

37-10-03 Vacuum Regulator Valve

Removal (LH Side)
CAUTION Turn battery switch OFF and pull OFF circuit breaker BOOTS (left side
panel) before beginning work.
CAUTION When working on vacuum system, take care not to contaminate vacuum
hoses. Install blind plugs on hose ends. Even small residues of dirt may
damage air pumps.
Detail Steps/Work Items Key Items
1 Remove upper cowling
2 Disconnect vacuum hose from regulator VW spring clamp at regulator
valve at firewall to vacuum pump valve
3 Cut off vacuum hose from vacuum check
valve manifold; remove VW spring clamp
and hose end at regulator valve
4 Remove tightening nut of regulator valve Use 1 ¼ inches crowfoot
from bracket at firewall wrench
5 Remove regulator valve to outward
direction of engine compartment

Page Date: 5. July 2002 37 Page 9

Maintenance Manual and Illustrated Parts Catalogue
Extra EA -400
Vacuum

Installation (LH Side)

Detail Steps/Work Items Key Items
1 Tighten regulator valve with nut to bracket Use 1 ¼ inches crowfoot
at firewall wrench
2 Install new vacuum hose to vacuum check Use VW spring clamps
valve manifold
3 Install vacuum hose to vacuum pump Use VW spring clamp
4 Install upper cowling

Removal (RH Side)

CAUTION Turn battery switch OFF and pull OFF circuit breaker BOOTS (left side
panel) before beginning work.
CAUTION When working on vacuum system, take care not to contaminate vacuum
hoses. Install blind plugs on hose ends. Even small residues of dirt may
damage air pumps.
Detail Steps/Work Items Key Items
1 Remove upper cowling
2 Disconnect vacuum hose from regulator VW spring clamp at regulator
valve at firewall to vacuum pump valve
3 Disconnect vacuum hose from gyro VW spring clamp at vacuum
installation check valve manifold
4 Cut off vacuum hose from vacuum check
valve manifold; remove VW spring clamps
and hose ends
5 Remove tightening nut of regulator valve Use 1 ¼ inches crowfoot
from bracket at firewall wrench
6 Remove regulator valve to outward
direction of engine compartment

Installation (RH Side)

Detail Steps/Work Items Key Items
1 Tighten regulator valve with nut to bracket Use 1 ¼ inches crowfoot
at firewall wrench
2 Install new vacuum hose to vacuum check Use VW spring clamps
valve manifold
3 Install vacuum hose from gyro installation Use VW spring clamp
4 Install vacuum hose to vacuum pump Use VW spring clamp

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 Maintenance Manual and Illustrated Parts Catalogue
Extra EA -400
Vacuum

Detail Steps/Work Items Key Items

5 Install upper cowling

Filter Element Replacement

On vacuum regulator valve an Airborne B3-5-1 foam filter element is installed.
The filter element can be replaced without removing the regulator valve. Draw
the filter element from the regulator body. Install the same way.
Refer to Airborne Service Letter No. 59, latest edition.

37-10-04 Vacuum Check Valve Manifold

Refer to Airborne Service Letter No. 39, latest edition.

Removal
CAUTION Turn battery switch OFF and pull OFF circuit breaker BOOTS (left side
panel) before beginning work.
CAUTION When working on vacuum system, take care not to contaminate vacuum
hoses. Install blind plugs on hose ends. Even small residues of dirt may
damage air pumps.
Detail Steps/Work Items Key Items
1 Remove upper cowling
2 Disconnect pressure hose from LH vacuum VW spring clamp at de- ice
pump to de- ice control valve at firewall control valve
3 Disconnect vacuum hose from LH regulator VW spring clamp at regulator
valve to vacuum pump valve
4 Cut off pressure hose from LH de- ice
control valve to pressure check valve
manifold; remove VW spring clamps and
hose ends
5 Cut off vacuum hose from vacuum check
valve manifold to LH regulator valve;
remove VW spring clamps and hose ends
6 Disconnect pressure hose from RH vacuum VW spring clamp at de- ice
pump to de- ice control valve control valve
7 Disconnect vacuum hose from RH regulator VW spring clamp at regulator
valve to vacuum pump valve
8 Cut off pressure hose from RH de- ice
control valve to pressure check valve
manifold; remove VW spring clamps and
hose ends

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Maintenance Manual and Illustrated Parts Catalogue
Extra EA -400
Vacuum

Detail Steps/Work Items Key Items

9 Cut off vacuum hose from vacuum check
valve manifold to RH regulator valve;
remove VW spring clamps and hose ends
10 Disconnect vacuum hose from LH dual VW spring clamp
source differential vacuum gage to vacuum
check valve manifold
11 Disconnect vacuum hose from gyro VW spring clamp
installation to vacuum check valve manifold
12 Disconnect vacuum hose from RH dual VW spring clamp
source differential vacuum gage to vacuum
check valve manifold
13 Disconnect vacuum hose from de- ice system VW spring clamp
to vacuum check valve manifold
14 Disconnect pressure hose from pressure VW spring clamp
check valve manifold to de- ice system
15 Cut electrical wiring to de- ice control valves
on both sides of 2 splices
16 Remove vacuum installation holder bracket 4 bolts M6
from firewall
17 Remove vacuum check valve manifold from 2 bolts and nuts M6
holder bracket

Installation
Detail Steps/Work Items Key Items
1 Install vacuum check valve manifold to
vacuum installation holder bracket
2 Install holder bracket to firewall
3 Install pressure hose from pressure check
valve manifold to de- ice system
4 Install vacuum hose from de- ice system to Use VW spring clamp
vacuum check valve manifold
5 Install vacuum hose from RH dual source Use VW spring clamp
differential vacuum gage to vacuum check
valve manifold
6 Install vacuum hose from gyro installation Use VW spring clamp
to vacuum check valve manifold

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 Maintenance Manual and Illustrated Parts Catalogue
Extra EA -400
Vacuum

Detail Steps/Work Items Key Items

7 Install vacuum hose from LH dual source Use VW spring clamp
differential vacuum gage to vacuum check
valve manifold
8 Install new vacuum hose from vacuum Use VW spring clamps
check valve manifold to LH regulator valve
9 Install new pressure hose from LH de-ice Use VW spring clamps
control valve to pressure check valve
manifold
10 Install vacuum hose from LH regulator Use VW spring clamp
valve to vacuum pump
11 Install pressure hose from LH vacuum pump Use VW spring clamp
to de-ice control valve at firewall
12 Install new vacuum hose from vacuum Use VW spring clamps
check valve manifold to RH regulator valve
13 Install new pressure hose from RH de-ice Use VW spring clamps
control valve to pressure check valve
manifold
14 Install vacuum hose from RH regulator Use VW spring clamp
valve to vacuum pump
15 Install pressure hose from RH vacuum pump Use VW spring clamp
to de-ice control valve
16 Re-establish splices at electrical wiring to
de-ice control valves
17 Install upper cowling

Page Date: 5. July 2002 37 Page 13