New Dry Air Pump Owners Manual
Contents
1. Attach the pump s cooling shroud if removed i Enable the ignition system j Attach and secure cowling k Perform a post maintenace run up check to verify that the vacuum pressure system as well as any other system your work may have affected is working properly m A PNEUMATIC SYSTEM MAINTENANCE A C Oil Leaks Inspect engine and engine compartment for oil leaks that could contaminate the dry air pump or reach the inlet filter on pressure systems or the vacuum regulator if located in the engine compartment Oil Seal Inspect drive pad seal it should be dry If any oil is found replace the oil seal Refer to engine manufacturer s parts manual for correct seal part number and installation instructions RECOMENDATION fanew pump is being installed on a midtime engine replace the oil seal even if area is dry The oil seal could start leaking before engine TBO is reached Filters Clean filters are essential for a pneumatic system to operate properly Dirty filters reduce air flow to pump causing the pump to operate at higher temperatures and increasing pump wear Dirty filters affect operation of pneumatic instruments and regulator s and can cause low vacuum or low or excessive pressure NOTE REFER TO AIRCRAFT MAINTENACE SERVICE MANUAL FOR FILTER REPLACEMENT SCHEDULE 14 An D Pump Fittings 1 Inspect for damage and cleanliness 2 Bent or kinked fittings Fig 1 can r2. as engine compression check NEVER move the propeller on a hot engine ENSURE Magnetos set to BOTH OFF Fuel Mixture Closed Fuel to OFF ALWAYS remain clear of the propeller s arc and ensure that other personnel do so i 3 Vane length measurement NOTE in most cases measuring the vanes can be done with the pump mounted on the aircraft However if the inspection port hole can not be accessed with the pump mounted remove it from the engine turn the pump s shaft by hand and follow the same general instructions with respect to measuring the vanes Reinstall the pump in accordance with instructions in the aircraft s maintenance manual a Safe The Engine remove the pump cooling shroud if necessary b Insure the area around the inspection port plug is clean so that when the plug is removed nothing can fall into the pump c Remove the Inspection Port Plug AND Star Washer refer to Fig 4 Failure to remove the star washer will cause a false indication d While looking into the indicator port have an assistant slowly move the propeller by hand in the normal direction of rotation until a vane slot is aligned precisely in the center of the port refer to Fig 5 If you go too far just keep turning to the next slot 11 AA e Insert the Vane Wear Indicator Tool Fig 6 into the inspection port as illustrated in Fig 7 Hold the barrel securely and squarely against the pump body With you
3. Installation Operators Manual Manual 1240 Springwood Avenue Gibsonville NC 27249 USA FAA PMA Approved 390 O TAKING AVIATION BY STORM 2 Tornado AA3215CC AA3215CC 9 and the AA3216CW Series Dry Air Pumps as well as our AA240 and AA400 Series Dry Air Pumps are truely revolutionary They incorporate proven technology designed to provide long service life and reduce premature failures 2 An Aero Accessories Inc Tempest AA3200 Series AA240 Series amp AA400 Series Dry Air pumps incorporate our patented channel cut in the mounting flange face which when utilized with our patented LRT Diverter is designed to channel oil away from mechanical workings of the pump if the drive pad s oil seal begins to leak The Closed Front End is designed to elimate oil and or solvent residues from entering the pump s drive mechanism er ae ened ar E r Kri a oa k it i Most dry air pumps are installed with the inlet and outlet ports in the 12 00 3 00 6 00 or 9 00 positions Tornado pumps have four 4 exit channels in the mounting flange face When a pump is installed on an aircraft the three 3 upper most channels MUST be plugged by the LRT diverter The bottom channel is left open to allow oil to drain away from the pump s mechanical workings In other words the open unplugged channel should be pointing towards the ground The photographs below and on the next pa
4. LRT pointing UP regardless of the pump inlet amp outlet port orientation being vertical or horizontal and that the LRT be flush with the flange mounting surface before installing the mounting gasket As shown below Refer to pages 4 amp 5 for further amplification of LRT usage 82 50130 B LRT Shown air Mounting Gasket Shown FAA PMA 82 50130 B The 82 50130 gasket incorporates 8 small holes for accessories that require engine oil lubrication The oil passage holes have been eliminated in the 82 50130 B mounting gasket The LRT diverter is required on the Aero Accessories Dry Air Pumps that have channels milled into their mounting flange faces Either the 82 50130 or 82 50130 B gaskets can be used with the LRT diverter however the B gasket is preferred due to its increased sealing capability Refer to pages 4 amp 5 for further amplification on LRT usage Oil Passage Holes Not required in Dry Air Pump Installations Standard 82 50130 Gasket LRT Diverter Used with either Gasket dependent upon pump flange being milled to accept LRT 82 5013 B Gasket 7 REAR WEAR INDICATOR PORT 3200 SERIES MODELS AA3215CC AA3215CC 9 amp AA3216CW Models Aero Accessories Inc s AA3215CC AA3215CC 9 and AA3216CW dry air pumps feature our patented rear cover wear indicator port Removal of the port plug allows visual observation to determine vane length The end of the vane closest t
5. eaned and filters replaced Particles from the previous failed pump can contaminate new pump and cause FOD damage leading to failure Teflon tape or other thread compound on threaded fittings or port threads may be ingested into the pump These substances will bind up lubrication dust and cause FOD damage leading to failure NOTE More than 95 of dry air pump failures are the result of one or more of the above points 24 fh New Dry Air Pump Warranty Dry Air Pumps manufactured by Aero Accessories Inc are warranted against defects in materials and or workmanship for the time periods listed below by model series number Aero Accessories Inc obligation under this warranty is limited to the repair or replacement at Aero Accessories Inc sole descretion any pump that upon inspection by Aero Accessories Inc is found to be defective in materials or workmanship AA3215CC AA3216CW 3 Years or 1300 Hours from Time of Installation AA241CC AA242CW 1 Year or 500 Hours from Time of Installation AA441CC AA442CW 1 Year or 500 Hours from Time of Installation Contact your local distributor for our new FAA PMA Vacuum Regulators Filters and Fittings 4s Aero Accessories Inc 1240 Springwood Avenue Gibsonville NC 27249 USA Tel 336 449 5054 800 822 3200 Fax 336 449 5461 Website www aeroaccessories com Tempest Dry Air Pumps are manufactured by Aero Accessories Inc in the USA FAA PMA Approved
6. educe air flow 3 Check threads for damage replace if necessary 4 Clean fittings inside and out to remove any loose debris 5 Install fittings as described in Section 2 Dry Air Pump Installation E Hoses Remove and inspect hoses for the following conditions 1 Hard Cracked Brittle or Oil Contaminated 2 Determine if liner separation has occurred inside of hose Liner separation can restrict air flow Replace hose if any one of these conditions is found 3 If replacing a prviously failed pump throughly clean inside of hoses making sure all loose debris have been removed before attaching hoses NOTE PUMPS INTERNAL CLEARANCES WILL NOT ALLOW FOREIGN PARTICLES TO PASS THOUGH WITHOUT CAUSING DAMAGE OR FAILURE MAKE SURE HOSES ARE CLEAN 15 i F Vacuum Regulator Regulator must be clean oil free and in airworthy condition for proper operation Replace filter after installing new pump or every 100 hours or annually Run engine and check for proper operation of regulator Refer to Aircraft Service Maintenance Manual adjust a necessary for correct vacuum setting for your aircraft Tempesttm Regulators should require no field adjustment contact Aero Accessories Inc ifa Tempesttm regulator give an indication of improper operation Regulator Valves and Deice Valves Before installing new pump particularly if old pump has failed prematurely the following guidelines must be accomplished 1 Determine i
7. f pnuematic system problem was cause of failure This can be accomplished using a commercially available test kit Contact Aero Accessories Inc for test kit information 2 Test aircraft s pneumatic system according to outlined instructions supplied with test kit and the Aircraft Service Maintenance Manual 3 Any regulator valve or deice valve found to be defective must be replaced in accordance with the Aircraft Service Maintenance Manual to prevent possible premature failure of new pump after installation on aircraft 16 H Manifolds Check Valves Manifolds and check valves have internal rubber components that can deteriorate from age becoming hard and brittle and lose their sealing capacity Refer to Aircraft Service Maintenance Manual for manifolds check valves inspection intervals and procedures CAUTION AIRCRAFT WITH DUAL DRY AIR PUMPS MAY LOSE REDUNDANCY FEATURE IF THE MANIFOLD CHECK VALVE IS NOT FUNCTIONING PROPERLY DRY AIR PUMP INSTALLATION 1 Before installing pump confirm it is the correct model for the application 2 Perform maintenace check of fittings hoses regulator s and filters NOTE If previous pump has failed prematurely perform maintenance system check to insure all components of the pneumatic system are functional and working correctly 17 3 With new pump gripped by the mounting flange in vise Fig 2 install fittings into ports finger tight Tighten
8. ge illustrate proper installation positions of the LRT diverter when the pump ports are at different positions Ports at 12 00 Position Ports at ue Position LRT on TOP LRT Diverter Hg es oo Installed Channel Pointing towards bottom ground Leave Open Oo The photographs below show the inlet and outlet ports at the 6 00 and 3 00 positions Notice that in both pictures the bottom channel is open and pointing towards the ground The LRT diverter MUST be installed so that the lower drain channel of the mounting flange remains open and pointing towards the ground NOTE On Cessna 150 Continental O 200 and some other engines the pump mounts with the drive shaft vertical Pumps designed for vertical installation such as the AA3215CC 9 AA215CC 9 or AA211CC 9 are normally required When installing an AA3215CC 9 the open channel should face aft towards the firewall and away from sources of oil contami nation On Cessna 172 s having 2 pumps on the engine the lower pump mounts with the ports slightly rotated at about 20 degrees The channel pointing closest to the ground should be left open Ports at 6 00 Position LRT on TOP Ports at 3 00 Position from pilots view LRT on TOP LRT Diverter Installed Leave Channel pointing towards the ground Open It is important that the LRT diverter is firmly inserted into the upper three 3 channels in the mounting flange face with the middle leg of the
9. o the center of the pump is observed through the small indicator hole in the port When less than an eighth of the indicator hole is covered by the vane it is time to replace the pump Aero Accessories Inc recommends that the first observation be accomplished at 600 hours time in service Subsequent checks should be made each 100 hours of operation or as deemed neccessary based upon wear rate of vane CG Minimal Wear Refer to AIA Service Letter No SL 004 Excessive Wear Quality Dry Air panpe mee dna aA SIDE WEAR INDICATOR PORT AA240 amp AA400 SERIES PUMPS AA241CC AA242CW amp AA441CC AA442CW Series Models Aero Accessories Inc s New AA240 amp AA400 Series Pumps feature our patented side Wear Indicator Port Removal of the wear indicator port plug allows insertion of a Vane Wear Indicator Tool The indication revealed by the tool gives a wear status of the vane Wear Indicator Ports make it possible to identify and remove pumps from service with vanes worn beyond their service life Removing such pumps BEFORE THEY FAIL reduces the risk of in flight failure and improves safety In addition to using the wear indicator port always inspect the pump in accordance with the aircraft manufacturer s recommendations as well as for any other defects orconditions such as overheating crinkled or burned decals oil contamination physical damage looseness of parts and or hardware etc that might render the pump
10. r fingertip gently push the plunger into the pump s inspection port When the plunger touches the vane slight vane movement may be felt if the vane is not at the bottom of its slot NOTE If the plunger does not slip easily into the slot DO NOT force it Remove the indicator tool and check for correct alignment of the rotor slot to the port Refer to Figure 5 DO NOT rotate propeller or pump s shaft when the indicator tool probe is inserted in the inspection port Doing so may break or chip the rotor If the pump is turned with the probe in the pump replace the pump even if you don t think it is damaged A cracked of chipped rotor may operated normally for a while then fail without warning f Observe the plunger s indicating bead land position If the indicating bead s land is touching the barrel end the vane is worn to the service limit REPLACE the pump if any vane is at it s service limit Refer to Figures 8 1 8 2 8 3 12 AA g Ifthe vanes are within service limit and the pump is otherwise serviceable clean port plug threads install a NEW starwasher and torque to 45 50 inch pounds DO NOT substitute a different screw of bolt for the plug Use only the proper starwasher The use of substitute parts can damage the pump Contact Aero Accessories Inc to obtain additional plugs and starwashers WIP Plug 82 50122 2A1 Starwasher 82 50122 2A2 or alternate AN936B 416 MS35355 32 or MS35355 61 h
11. rt Hole Plunger Indicating Bead Land Figure 6 Wear Indicating Tool installed in Pump Inspection Port Hole 22 Figure 8 3 Indicating Bead Land TOUCHING Barrel Vane at Service Limit REPLACE PUMP Figure 8 1 Figure 8 2 Vane still Good Land not touching top of barrel New Vane Indication REPLACE PUMP IF ANY VANE IS AT IT S SERVICE LIMIT AA Pump sectional views for reference only IMPORTANT POINTS ABOUT DRY AIR PUMPS Dry air pumps are just that INTERNALLY DRY Dry air pumps use the graphite dust produced by the gradual wear of the internals vanes as lubrication Any oil leak however slight that permits oil to reach the drive end of the pump may cause internal oil contamination This contamination combines with the lubricating dust and forms a gummy mixture that binds upthe internal components of the pump leading to failure When cleaning an engine with solvent or water and soap use a waterproof material to cover the entire pump s the pneumatic air filter and regulator s Contamination from solvent or water saturation of these areas may be ingested into pump causing failure in much the same way as oil contamination When a pump fails vacuum that is present in the inlet hose may suck small particles of carbon up into the hose even up to the regulator Pressure systems the inlet filter will become contaminated Hoses and regulator s should be removed and throughly cl
12. unsuitable for continued service If any condition is discovered or suspected that would render the pump unsuitable for continuation in service replace the pump regardless of vane wear status Aero Accessories recommends the first observation be performed at 300 hours pump time in service with future observations every 100 hours until vane is at its service limit Once vane is at its service limit REPLACE Pump See page 10 of this manual or refer to Aero Accessories Inc Service Letter SL 007 availiable at www aeroaccessories com The recommended TBO for AA240 amp AA400 series pumps without the WIP is 600 hours Pumps incorporating the WIP should be removed from service according to the wear indicator port observations AA 9 It is the pilot s operator s responsibility to determine that the entire pneumatic system is in a safe serviceable and airworthy condition Use the aircraft manufacturer s maintenance instructions and recommendations to determine the status of the entire pneumatic system 1 Recommended Vane Wear Observation Intervals for AA240 amp AA400 Series Dry Air Pumps 1st Observation 300 hours pump time in service Subsequent observations each 100 hours time in service or at annual inspection whichever comes first after the initial observation 2 Safety For maximum safety it is recommended to perform the vane wear inspection during procedures that require the spark plugs be removed such
13. with proper wrench no more than one 1 full turn to aa eer 4 Install pump with new mounting gasket and if required a LRT Diverter 5 Secure pump with proper mounting hardware and tighten Refer to Aircraft Engine Service Maintenance Manual for specified torque requirements 6 Attach hose to correct fittings being careful not to cut the I D of the hoses when sliding over end of fittings Secure hoses with proper hardware CAUTION WHEN INSTALLING PUMP FITTINGS SECURE PUMP IN VISE BY DRIVE END PAD AS SHOWN IN FIG 2 SECURING PUMP BY PUMPING CHAMBER FIG 3 COULD AFFECT INTERNAL CLEARANCES CAUSING PUMP FAILURE FINAL SYSTEMS CHECK After new pump is installed and secured before running engine to check pneumatic system inspect all hoses filters and regulator s for proper installation Run engine s and ehck operation to verify that pneumatic system is operating within aircraft specificaitons Refer to Aircraft Service Maintenance Manual i8 A Figure 3 Figure 2 Figure 1 19 Remove Port Plug AND Starwasher BE SURE to REMOVE BOTH the PLUG AND the STARWASHER Figure 4 AA442CW Shown others similar 20 AA442CW Shown others similar NOTE Edges of rotor slot visible in inspection port hole Figure 5 21 240 amp 400 Series Wear Indicating Tool P N 82 580122 2A6 Plunger Figure 7 Insert thisend into the Barrel Inspection Po
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