AirComm Corporation Airbus EC145 Cabin Air Conditioner Instructions for Continued Airworthiness User Manual

							AIR CONDITIONER SERVICE MANUAL EC145-200M-1 
 
Revision 13  Page 25 
 
CHAPTER 6 
STANDARD PRACTICES INFORMATION 
 
1.  FITTING TORQUING PROCEDURES AND TORQUE VALUES 
 
INSERT O-RING FITTINGS        TORK-LOK FITTINGS 
 
 
 
 
 
 
Apply a thin coating of refrigerant oil to O-ring and 
Female side of fitting. 
Confirm there is no damage (nicks, dirt, etc.) on fittings. 
Slide B-nut back away from the end of the tube so you can see the O-ring as you slide the 
fitting together. 
 
Be careful not to pinch O-ring during assembly. 
 
Engage the male end into the female fitting being careful to maintain alignment. 
 
The male flange should seat fully against the female fitting with out the O-ring being 
pinched. 
 
It is important to hold the fitting together while sliding the B-nut forward and engaging the 
threads. Tighten the B-nut by hand and then torque as follows. 
 
     # 6 Fittings: 30 – 35 in/lbs. (3.4-4.0 Nm) 
     # 8 Fittings: 40 – 45 in/lbs. (4.6-5.1 Nm)    DO NOT OVER TORQUE! 
     #10 Fittings: 50 – 55 in/lbs. (5.7-6.3 Nm) 
 
               ALWAYS USE BACK UP WRENCH 
 
 
 
 
 
 
 
 
Once the system is charged, check each fitting with an electronic leak detector. 
(An electronic leak detector is the only reliable method of checking for refrigerant leaks) 
Once the fittings have been checked and are found to be free of leaks, torque seal as 
appropriate. 
 
 
 
 
 
 
  
						

							AIR CONDITIONER SERVICE MANUAL EC145-200M-1 
 
Revision 13  Page 26 
 
CHAPTER 6 
STANDARD PRACTICES INFORMATION (continued) 
 
2.  REMOVAL & REPLACEMENT OF CONDENSER BLOWER MOTOR & FAN ASSEMBLY. 
 
REMOVAL 
CAUTION 
It is recommended that the battery and external power be disconnected before starting work. 
 
A.   Remove the cowling aft of the engine compartment on the left hand side of the aircraft to 
gain access to the condenser & blower assembly. 
 
CAUTION 
Be sure to support the blower assembly when removing the attaching hardware to prevent 
damage to the condenser housing, blower assembly, or the aircraft. 
 
B.  Remove safety wire that secures the (4) AN3H-3A bolts (2) two on each side that attach the 
ES73186-4 Blower motor & Fan assembly to the condenser assembly, and remove bolts. 
 
C.  Disconnect the ES73186-4 Blower motor & Fan assembly at the Molex connector. 
 
D.  Once the mounting bolts have been removed, the blower can be removed and replaced as 
required 
 
REPLACEMENT  
 
A.  Install the new blower assembly in the reverse order of its removal, torquing the blower 
attaching bolts to 50 to 70 inch lbs (5.7-8.0 Nm) and safety using .032 safety wire. 
 
B.  Reconnect the Molex connector. 
 
C.  Apply power, and operate the Air conditioner by placing the control switch in the A/C position 
several times to insure there is no binding and for proper operation of the Blower motor & 
Fan assembly. 
 
D.  Reinstall the cowling to the upper left hand side of the aircraft. 
 
3.  REMOVAL, REPLACEMENT & ADJUSTMENT OF COMPRESSOR DRIVE BELT 
 
REMOVAL 
 
A. It is necessary to access the upper transmission compartment to remove, replace, or adjust 
the Compressor Drive Belt. 
 
B. Cut safety wire on the Compressor Belt Tensioning Link and the Compressor housing & Jam 
Nuts, and loosen the respective Jam Nut(s). 
 
C. Before attempting to adjust the drive belt tension, insure that the compressor mounting / 
attaching bolts have been loosened, to allow free movement of the compressor body on the 
compressor mount. 
 
 D. After loosening the belt tension remove the compressor attaching bolts from around the base 
of the compressor body. 
 
 
  
						

							AIR CONDITIONER SERVICE MANUAL EC145-200M-1 
 
Revision 13  Page 27 
 
CHAPTER 6 
STANDARD PRACTICES INFORMATION (continued) 
 
3. REMOVAL, REPLACEMENT & ADJUSTMENT OF COMPRESSOR DRIVE BELT (continued) 
 
E. Loosen the belt and remove belt from the compressor & drive pulley from the compressor housing. 
 
 
REPLACEMENT 
 
A.  Install the drive belt on the compressor pulley & drive pulley. 
 
B.  Adjust belt tension (See Adjustment below). 
 
C.  Tighten the Belt Tensioning Link Jam Nuts and re-safety using .032 safety wire. 
 
D.  Re-torque the Compressor Mounting / Attaching bolts to 80 to 100 inch lbs. (9.04 – 11.30 Nm). 
 
NOTE 
Care should be taken to insure that the new belt is not damaged (nicked or cut) during 
installation. 
 
 
ADJUSTMENT 
 
NOTE 
Proper belt tension is important to insure a long belt service life and to avoid excessive loads on the 
compressor, and bearing assemblies. 
 
A.  The correct belt tension for the belt is 5 lbs. This can be achieved with the aid of a belt 
tensioning tool (Gates 7401-0076 Belt Tension Gauge or Equivalent). 
(This is the preferred method of obtaining proper belt tensioning). 
 
B. An alternate method is to observe a .10” belt deflection when 5 lbs  of force is applied at the 
midpoint of the belt.  
 
 
 
Drive shaft pulley assy. 
 
 
         Compressor drive pulley 
 
                         
 
 
 
 
 
 
NOTE 
The belt tension should be checked, and re-adjusted, if necessary after the first two hours of operation for 
a newly installed belt. 
 
 
Apply 5 lbs at midpoint 
Deflection should be .10”   
						

							AIR CONDITIONER SERVICE MANUAL EC145-200M-1 
 
Revision 13  Page 28 
CHAPTER 6 
STANDARD PRACTICES INFORMATION (continued) 
 
4. REMOVAL, INSTALLATION / REPLACEMENT OF COMPRESSOR ASSEMBLY. 
 
REMOVAL 
 
A.  See Removal, Replacement, & Adjustment of Compressor Drive Belt prior to the removal of the 
air conditioner compressor assembly.  
 
B. It will be necessary to evacuate (discharge) the refrigerant from the system to remove and replace 
the air conditioner compressor. Instructions for servicing of the system are found in Chapter 5 
Servicing of this manual. 
CAUTION 
Refrigeration servicing should be performed by qualified personnel only! 
 
C. Disconnect the refrigerant hoses from the suction and discharge ports located on the aft top of the 
compressor housing. 
 
D. Remove the attaching hardware from the top of the belt tensioning link and the compressor mount 
assembly. Remove the mounting bolt that attach the compressor body to the top of the compressor 
mount, and remove compressor assembly. 
CAUTION 
Before removing the compressor attaching hardware it is necessary to seek assistance in supporting 
the compressor, due to the weight and position of this component. Failure to do so may result in 
damage to the aircraft. 
 
INSTALLATION / REPLACEMENT 
 
A. Install the compressor assembly in the reverse order of its removal. Torque attaching hardware to 
80 to 100 inch lbs (9.04 – 11.30 Nm).  
 
B. Replace the O-rings on the refrigerant hoses, and re-connect the hoses to the compressor 
housing. Torque the #10 hose fitting to 50 – 55 inch lbs. (5.7-6.3 Nm) and torque the #8 hose fitting to 
40 – 45 inch lbs (4.6-5.1 Nm). 
 
C. Re-install the belt tension bolt attaching hardware to the compressor, and torque to 95 – 110 inch 
lbs (10.9-12.6 Nm).  
     
D. Adjust the belt adjustment per the procedure shown on Page 6-3  
 
E. Recharge the refrigerant per the servicing instructions on Page 5-1, steps A through I. 
 
CAUTION 
Refrigeration servicing should be performed by qualified personnel only! 
 
NOTE 
An electronic leak detector should be used any time a component is replaced or the system has been 
opened, to insure trouble free operation of the air conditioner system. 
 
 
 
 
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							AIR CONDITIONER SERVICE MANUAL EC145-200M-1 
 
Revision 13  Page 29 
 
CHAPTER 6 
STANDARD PRACTICES INFORMATION (continued) 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
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							AIR CONDITIONER SERVICE MANUAL EC145-200M-1 
 
Revision 13  Page 30 
CHAPTER 6 
STANDARD PRACTICES INFORMATION (continued) 
 
5. REMOVAL, INSTALLATION / REPLACEMENT OF FORWARD EVAPORATOR ASSEMBLY. 
 
REMOVAL 
 
A.  It will be necessary to evacuate (discharge) the refrigerant from the system to remove or replace 
the forward evaporator assembly. Instructions for servicing of the system are found in Chapter 5 
Servicing. 
CAUTION 
Refrigerant servicing should be performed by qualified personnel only! 
 
B. Remove attaching hardware in mounting brackets on aft of evaporator assembly. 
 
C. Disconnect the ducting that attaches the forward evaporator to the forward blower outlets. 
 
D. Disconnect the electrical connector from the forward evaporator assembly. 
 
E. Disconnect drain line from bottom of evaporator housing. 
 
F. Disconnect refrigerant plumbing from fittings and hoses located under the evaporator assembly area.  
 
 
CAUTION 
Always use a back up wrench when removing, or installing refrigerant line fittings. 
 
 
INSTALLATION / REPLACEMENT 
 
A.  Install the forward evaporator assembly in the reverse order of its removal. Torque the refrigerant line 
connections to 30 – 35 inch lbs (3.4-4.0 Nm) for the #6 fitting, and 40 – 45 inch lbs (4.6-5.1 Nm) for 
the #8 fitting, and replace all O-rings. 
 
CAUTION 
Always use a back up wrench when removing, or installing refrigerant line fittings. 
 
B. Recharge the refrigerant per the servicing instructions on Page 5-1, steps A through I 
 
CAUTION 
Refrigerant servicing should be performed by qualified personnel only! 
 
NOTE 
 
An electronic leak detector should be used any time a component is replaced or the system has been 
opened, to insure trouble free operation of the air conditioner system. 
 
 
 
 
 
 
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							AIR CONDITIONER SERVICE MANUAL EC145-200M-1 
 
Revision 13  Page 31 
 
CHAPTER 6 
STANDARD PRACTICES INFORMATION (continued) 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
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FOR FURTURE USE 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
  
						

							AIR CONDITIONER SERVICE MANUAL EC145-200M-1 
 
Revision 13  Page 32 
 
CHAPTER 6 
STANDARD PRACTICES INFORMATION (continued) 
 
6. REMOVAL, INSTALLATION / REPLACEMENT OF AFT EVAPORATOR ASSEMBLY. 
 
REMOVAL 
 
A.  Remove the overhead ceiling panel above the main cabin area to access the aft evaporator 
assembly. 
 
B.  Remove the (4) four AN3-10A bolts that retain the Aft Evaporator to the support bracket. 
 
C.  It will be necessary to evacuate (discharge) the refrigerant from the system to remove or replace 
the aft evaporator assembly. Instructions for servicing of the system are found in Chapter 5 
Servicing. 
 
D.  Disconnect the refrigerant lines at the fittings to the evaporator housing. 
 
CAUTION 
Refrigerant servicing should be performed by qualified personnel only! 
 
CAUTION 
Always use a back up wrench when removing or installing refrigerant line fittings. 
 
E.  Disconnect wiring to Temperature control module on the Aft Evaporator assembly by 
disconnecting the Molex connector. 
F.  Slide Evaporator Assembly forward and down to remove the assembly from the aircraft. 
 
INSTALLATION / REPLACEMENT 
 
A. Install the aft evaporator assembly in the reverse order of its removal.  
 
B. Recharge the refrigerant per the service instructions on Page 5-1, steps A through I.  
 
CAUTION 
Refrigerant servicing should be performed by qualified personnel only! 
 
CAUTION 
Always use a back up wrench when removing or installing refrigerant line fittings. 
 
 
 
 
 
 
 
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							AIR CONDITIONER SERVICE MANUAL EC145-200M-1 
 
Revision 13  Page 33 
CHAPTER 6 
STANDARD PRACTICES INFORMATION (continued) 
 
7. REMOVAL, INSTALLATION / REPLACEMENT OF CONDENSER ASSEMBLIY. 
 
REMOVAL 
 
 
 
A.  It will be necessary to evacuate (discharge) the refrigerant from the system to remove or replace 
the condenser assemblies. Instructions for servicing of the system are found in Chapter 5 
Servicing. 
 
CAUTION 
Refrigerant servicing should be performed by qualified personnel only! 
 
CAUTION 
It is recommended that the battery and external power be disconnected before starting work. 
 
B.  Disconnect the Condenser Assembly electrical connector from condenser blower fan assemblies. 
 
C.  Disconnect the Condenser Assembly from the refrigerant lines that attach to the condenser 
assembly. 
 
D.  Remove condenser retaining hardware from condenser base attaching points. 
 
CAUTION 
Insure the Condenser assembly is properly supported prior to removal of attaching hardware, to prevent 
damage to the condenser assembly, or aircraft. 
 
CAUTION 
Always use a back up wrench when removing or installing refrigerant line fittings. 
 
 
INSTALLATION / REPLACEMENT 
 
A.  Install the condenser assemblies in the reverse order of the removal. Torque all attaching 
hardware to 50 – 70 inch lbs (5.7-8.0 Nm), and replace all O-rings. 
 
B. Recharge the refrigerant per the servicing instructions on Page 5-1, steps A through I. 
 
CAUTION 
Refrigerant servicing should be performed by qualified personnel only! 
 
CAUTION 
Always use a back up wrench when removing or installing refrigerant line fittings. 
 
 
 
 
 
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							AIR CONDITIONER SERVICE MANUAL EC145-200M-1 
 
Revision 13  Page 34 
CHAPTER 6 
STANDARD PRACTICES INFORMATION (continued) 
 
8. REMOVAL, INSTALLATION / REPLACEMENT OF RECEIVER DRIER BOTTLE. 
 
REMOVAL 
 
A. Access refrigerant plumbing to Receiver Drier Bottle which is located next to the Condenser 
Assembly. 
 
B. It will be necessary to evacuate (discharge) the refrigerant from the system to remove or replace 
the receiver drier bottle. Instructions for servicing of the system are found in Chapter 5 Servicing. 
 
CAUTION 
Refrigerant servicing should be performed by qualified personnel only! 
 
C. Disconnect refrigerant lines form both sides of the receiver drier connection fittings. 
 
CAUTION 
Always use a back up wrench when removing or installing refrigerant line fittings. 
 
D. Loosen the retaining clamp holding the receiver drier bottle to the support bracket, and remove 
drier bottle. 
 
INSTALLATION / REPLACEMENT 
 
A. Install the receiver drier bottle in the reverse order of its removal, and replace all O-rings. 
 
NOTE 
Never reuse a receiver drier bottle, and keep new receiver drier bottles capped until just prior to their 
installation. 
 
B. Recharge the refrigerant per the servicing instructions on Page 5-1, steps A through I. 
 
CAUTION 
Refrigerant servicing should be performed by qualified personnel only! 
 
CAUTION 
Always use a back up wrench when removing or installing refrigerant line fittings. 
 
9. REMOVAL, INSTALLATION / REPLACEMENT OF BINARY SWITCH. 
 
REMOVAL 
 
A. Access refrigerant plumbing to Binary Switch. 
 
B. Disconnect electrical connectors from bottom of binary switch. 
 
B.  Unscrew switch from Schrader valve located on outlet tube from the receiver drier bottle. Remove 
switch. 
 
NOTE 
Use the flats provided on the top of the switch body to tighten, do not attempt to tighten, or loosen the 
pressure switch by hand. 
INSTALLATION / REPLACEMENT 
 
A.  Install the binary pressure switch in the reverse order of its removal.