AirComm Corporation Airbus EC135 Cabin Air Conditioner Instructions for Continued Airworthiness User Manual

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8 Page 35 
 
10. Removal, Replacement and Adjustment of Compressor Drive Belt 
(Figure 5 and Figure 7) 
 
Removal 
 
A. Remove  upper  engine  cowlings and  aft  engine  baffle  plate to  gain  access  to 
the compressor and mount assembly. 
B. Cut  the  safety  wire  that  secures MS509-8 jam  nut  to EC135-3020-1 
compressor adjustment assembly and loosen nut (Figure 7). 
C. Loosen  attaching  hardware  that  secures the  base  of  the...

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8 Page 36 
I. Tighten  MS509-8  jam  nut  to  EC135-3020-1  compressor  adjustment 
assembly.  Torque  nut  to  40-58  Ft-Lbs  and apply  safety  wire per  MIL-P-8564, 
using MS20995C-32 safety wire.  
 
Adjustment 
 
NOTE 
Proper static belt  tension  is necessary to  insure  a proper belt 
service  life  and  to  avoid  excessive  loads  on  the  compressor,  and 
bearing assemblies. 
 
A. The proper belt  tension  is achieved  when  the...

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8 Page 37 
H. Remove attaching hardware that secures the EC135-3008-1 bearing cover to 
the upper compressor mount assembly. 
I. Remove  attaching  hardware  that  secures  the  upper  compressor mount 
assembly to the lower mount assembly. 
J. Remove  attaching  hardware  from  the  two  aft  outboard  EC135-3012-1  brace 
assemblies and the upper compressor mount. 
K. Carefully  lift  the  upper  compressor  mount  assembly  and  provide...

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8 Page 38 
 
Figure 19:  Compressor and Pulley Assembly 
 
Installation/Replacement 
 
A. The  replacement  compressor  will  come  shipped  with  8  oz.  of  refrigerant  oil, 
however  that  level  will  need  to  be  reduced  to  account  for  oil  existing  in  the 
system.  To  properly  calculate  the  amount  of  oil  required  in  the  replacement 
compressor,  it  is  necessary  to  pour  the  oil  out  of  the  old  compressor...

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8 Page 39 
case is 5.5 oz. Since the new compressor comes with 8 oz. of oil, remove the 
oil  fill  plug  and  pour  out  2.5  oz.  of  oil.    Torque  compressor  oil  fill  cap  to  132-
216 in-lb. 
 
A. Install  the  compressor  assembly  in  the upper  mount  and  install 4X 
compressor bolts. Do not tighten bolts. 
B. Install and torque the compressor clutch plate retaining nut 170 to 180 In-Lbs. 
C. Align  the  pulley  and  sleeve...

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8 Page 40 
B. Disconnect  refrigerant  plumbing  from  receiver  drier  fittings  once  refrigerant  is 
evacuated. 
C. Remove  attaching  hardware  securing  receiver  drier  clamps  to  condenser 
frame. 
D. Remove the receiver drier. 
 
Installation/Replacement 
 
CAUTION 
Receiver drier is capped to prevent moisture contamination. Keep caps on 
receiver drier fittings until just prior to installation. 
 
A. Install  receiver  drier  and...

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8 Page 41 
 
14. Removal and Replacement of Binary Switch (Figure 13) 
 
Removal 
 
A. Remove  LH  aft  engine  fairing  from  aircraft  to  gain  access  to  the  condenser 
assembly and binary switch located on the receiver drier. 
B. Disconnect electrical connectors from top of binary switch. 
 
NOTE 
Use the flats provided on the top of the switch body to remove the 
switch; do not attempt to tighten or loosen the pressure switch by...

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8 Page 42 
CHAPTER 8 
TROUBLESHOOTING 
1. System Troubleshooting 
 
Prior to troubleshooting a defective system, it is advisable to conduct a visual 
inspection for general condition and obvious signs of damage or failure. 
 
The following matrix lists the easiest checks and the most likely problems. 
 
Problem Probable Cause Corrective Action 
System not Cooling 
 
(Evaporator blowers still 
operating) 
System is low or empty of...

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8 Page 43 
Problem Probable Cause Corrective Action 
System not cooling 
(Evaporator blowers not 
operating) 
Forward and aft evaporator 
blower motor(s) 
Check for power to the motor(s), 
and for the free movement of the 
blower wheel; if the motor shaft 
does not turn smoothly the motor 
must be replaced. 
Loss of cooling limited to one 
evaporator 
Expansion valve malfunction If cooling is lost in only one of the 
evaporators, and the...

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8 Page 44 
2. System Schematics 
 
 
Figure 20 – Electrical Schematic