AirComm Corporation Beechcraft Bonanza Maintenance Manual
Have a look at the manual AirComm Corporation Beechcraft Bonanza Maintenance Manual online for free. It’s possible to download the document as PDF or print. UserManuals.tech offer 74 AirComm Corporation manuals and user’s guides for free. Share the user manual or guide on Facebook, Twitter or Google+.
Products, L.P. CR-36-10 System Service Manual C. Evacuating Procedure 1) Connect R134a compatible recycling/recovery unit to the R134a service valves on the aircrafts air conditioning system. If recovery unit does not have pressure gauges, connect service pressure to air conditioning system. 2) Evacuate the air conditioning system in accordance with the recovery units instructions for a minimum of 15 minutes. 3) Once the air conditioning system has been evacuated, it is then ready for charging with new/recycled R134a refrigerant. 4. CHARGING SYSTEM A. General Use only R134a refrigerant when charging air conditioning system. Federal law prohibits discharging refrigerant into the atmosphere. Use only R134a compatible recycling/recovery unit when charging the air conditioning system. B. Tools and Equipment Designation Ref. No. Qty Remarks R134a Compatible Recycling/Recovery Unit Comm. Avail. 1 None R134a refrigerant Comm. Avail 1.8 lbs. None Polyolester Oil Comm. Avail 5 fl. oz. Viscosity ISO 68 C. Charging Procedure 1) Connect R134a compatible recycling/recovery unit to the R134a service valves on the aircrafts air conditioning system. If recovery unit does not have pressure gauges, connect service pressure gauges to air conditioning system. 2) Add new polyolester oil, viscosity grade (ISO) 68 to the compressor oil fill port. (only if the oil has been previously drained) 3) Charge the air conditioning system in accordance with the recovery units instructions, until the sight glass just clears of bubbles. (System must be operating for the sight glass bubble inspection to be performed) Page 7
Products, L.P. CR-36-10 System Service Manual GENERAL SERVICING 1. GENERAL General service procedures are provided to keep the air conditioning system operating at peek efficiency. Procedures are provided for general maintenance tips, inspection intervals, maintenance of the plumbing system, to repair hoses, and to clean coils. Procedures are also provided for removal and installation of the expansion valve. CAUTION: Do not operate air conditioning system with condenser air inlet and outlet blocked. 2. INSPECTION INTERVALS A. General Periodic inspections of the air conditioning system will keep the system operating at peek efficiency. The inspections are simple visual inspections requiring a minimal amount of time. B. Inspection Intervals ITEM INSPECT FOR INTERVAL ACTION Air Conditioning System Components Dirt , Damage Every 100 hours or 3 months Clean or replace component as necessary Compressor Belt Tension, Wear Within 5 hours of installing new belt, then every 100 hours or 3 months Tension or replace as necessary Sight Glass Proper refrigerant level When problem is suspected Discharge/charge as necessary Evaporator and condenser coils Dirt Every 100 hours or 3 months Clean as necessary Compressor Installation cracks, contact with cylinders or crankcase Every 100 hours or 3 months Replace as necessary Propeller O-ring Cracks, signs of Pinching, improper seating Every time the propeller is removed Immediately replace Page 8
Products, L.P. CR-36-10 System Service Manual ITEM INSPECT FOR INTERVAL ACTION De-ice (if applicable) Resin cracking and crazing Brush contact per Beech service manual Every 100 hours or 3 months Immediately replace or adjust brush contact Idler pulley bearing Resistance to rotation and any abnormalities Every time the propeller is removed Immediately replace Condenser Install. Run the cond. fan with battery pwr. and inspect for closed loop system air leaks. Every 100 hours or 3 months. Immediately seal or replace components. Any leaks could result in carbon monoxide entering the cabin. 3. PLUMBING SYSTEM MAINTENANCE PROCEDURES A. General The following procedures are used to perform typical maintenance on the air conditioning system plumbing. Procedures are provided for hose or fitting replacement. Keith Products air conditioning systems use swaged hose fittings with o-ring type connections. B. Tools and Equipment Designation Ref. No. Qty Remarks R134a Compatible Hose Swaging Kit Available from Keith Products 1 None Sharp Knife Comm. Avail. 1 None Impact Wrench Comm. Avail. 1 None Light Machine Oil Comm. Avail. A/R None Polyolester Oil Comm. Avail. A/R Viscosity ISO 68 C. Hose or Fitting Replacement NOTE: If it is found that a hose or fitting has a leak, it will be necessary to replace the entire hose assembly. Follow the Hose Swaging Instruction below: Page 9
Products, L.P. CR-36-10 System Service Manual 1. Hose should only be cut with a sharp knife. (Note: Use of serrated blades or saws to cut hose will leave particles that can contaminate system.) 2. Insert the proper size die in the swaging tool. 3. Insert fitting in swaging tool so that it is centered in the die and hand tighten. 4. Insert hose in fitting until it bottoms (Note: Indicating hole is in base of fitting). 5. Using impact wrench, tighten nut until die housings contact. (Note: It is important to keep hose pushed into fitting while swaging). 6. Reverse impact and back off nut until housing contacts rubber stops. D. Connection to Components - O-Ring Replacement 1. Place the appropriate o-ring over the tube O end of the fitting. 2. Lubricate o-ring with polyolester oil or sealant prior to assembly. 3. Apply sealant to all fitting mating surfaces prior to assembly. Recommended Standard Torque Specifications- O-Ring Connections. Thread Size Ft-Lb N-M 5/8” 11-13 15-18 3/4 15-20 20-27 7/8” 21-27 29-37 1 1/16” 28-33 38-45 E. Receiver/Drier Replacement 1. Replace receiver/drier whenever the compressor is replaced or when the air conditioning system plumbing is left open to the atmosphere for a period of time greater than one (1) hour. 4. COIL CLEANING MAINTENANCE PRACTICES A. General The following procedure is used for cleaning either evaporator or condenser coils. B. Tools and Equipment Designation Ref. No. Qty Remarks Vacuum Cleaner Comm. Avail. 1 None Coil Cleaner Comm. Avail. A/R Non-acid based Page 10
Products, L.P. CR-36-10 System Service Manual C. Coil Cleaning Procedure 1. Use vacuum cleaner to remove large debris from upstream and downstream coil faces. 2. Spray coil cleaner on both coil faces. Wash off with water. 3. Allow coil to dry thoroughly prior to additional maintenance. 5. EXPANSION VALVE REMOVAL AND INSTALLATION A. General The following procedure is used to remove or install the air conditioning system expansion valve, located on the inlet side of the evaporator coil. B. Tools and Equipment Designation Ref. No. Qty Remarks Sealant ES49000-3 A/R None Polyolester Oil Comm. Avail. A/R Viscosity ISO 68 C. Expansion Valve Replacement 1. Discharge system in accordance with recovery equipment’s instructions. 2. Disconnect liquid line from inlet of expansion valve, and cap. Remove the thermal sense bulb from its clamp located on the suction tube of the evaporator and carefully remove insulation covering bulb. 3. Disconnect the fitting that connects the valve to the coil and plug coil fitting. 4. Install new expansion valve and o-ring (for o-ring fitting systems) in the reverse order. 5. Lubricate o-ring with polyolester oil or apply sealant to fitting mating surfaces prior to assembly. 6. Install the thermal sense bulb such that it makes contact with the suction tube along its entire length. Insulate the bulb thoroughly with insulation. Page 11
Products, L.P. CR-36-10 System Service Manual TROUBLESHOOTING 1. GENERAL The procedures below present troubleshooting charts for the air conditioning system and the compressor. A diagnosis chart is presented for insufficient air conditioning system cooling. The performance characteristics of an aircrafts particular system is dependent upon the design parameters of the systems components. The performance of any one particular system varies with ambient temperature and humidity. The information below presents possible air conditioning system problems and solutions. CAUTION: Do not operate air conditioning system with condenser air inlet and outlet blocked. 2. AIR CONDITIONING SYSTEM DIAGNOSIS CHART Figure 2 shows a procedure for diagnosing air conditioning system problems. Following this procedure will expedite the troubleshooting process. Page 12
Products, L.P. CR-36-10 System Service Manual CHECK REFRIGERATION LINE FOR GAS LEAKS, AND REPAIR LEAKS IF ANY. CHARGE REFRIGERANT TO CORRECT LEVEL. IN CASE OF TOO MANY LEAKS, STOP COMPRESSOR, DISCHARGE THE SYSTEM, EVACUATE AND RECHARGE THE SYSTEM. AS NECESSARY, REPLACE RECEIVER DRIER. AIR IN THE SYSTEM MAY CAUSE BUBBLES IN SIGHT GLASS. BUBBLES IN SIGHT GLASS CONDENSER AIR TEMP TOO HIGH EVAPORATOR DISCHARGE AIR TEMP TOO HIGH CLEAN OR REPLACE EVAPORATOR CLEAN OR REPLACE CONDENSER TEMPERATURE OF DISCHARGE AIR IS ABNORMAL, BUT SYSTEM PRESSURE IS NORMAL. EXPANSION VALVE IS OPEN EXCESSIVELY. CHECK SENSING BULB INSTALLATIO IF SECURE & WELINSULATED, THEN REPLACE EXPANSION VALVE. IF NOT, THEN SECURE AND PROPERLY INSULATE N. L ANDRETEST SUCTION PRESSURE IS HIGH HEAD PRESSURE IS HIGH SUCTION PRESSURE IS HIGH, WHILE HEAD IS LOW REPAIR OR REPLACE COMPRESSOR. OVERCHARGE OF REFRIGERANT. DISCHARGE SOME OF REFRIGERANT TO CORRECT LEVEL OR AIR IS MIXED IN. DISCHARGE SYSTEM, AND REPLACE DRIER. EVACUATE AND RECHARGE SYSTEM OR, CONDENSER’S FIN IS DENTED OR CLOGGED WITH DUST. CLEAN PER SERVICING INSTRUCTIONS. SYSTEM PRESSURES ARE NORMAL. OPERATE AIR CONDITIONING SYSTEM. WITH MANIFOLD GAUGE, CHECK SYSTEM SUCTION AND DISCHARGE PRESSURES. MEASURE TEMPERATURE OF EVAPORATOR AND CONDENSER DISCHARGE AIR. NO BUBBLES IN SIGHT GLASS INSUFFICIENT COOLING FINS AND TUBES OF EVAPORATOR HAVE SOME DENTS. REPLACE OR REPAIREVAPORATOR. EXPANSION VALVE IS TOO RESTRICTIVE OR GAS LEAKAGE FROM SENSING ELEMENT. REPLACEEXPANSIONVALVE. PLUMBING AT RECEIVER DRIER OUTLET HAS LOW TEMPERATURE. RECEIVER DRIER IS RESTRICTED. REPLACE RECEIVER DRIER. SUCTION PRESSURE IS LOW Figure 2: Air Conditioning System Diagnosis Chart Page 13
Products, L.P. CR-36-10 System Service Manual
3. AIR CONDITIONING SYSTEM TROUBLESHOOTING
CONDITION
SERVICE
PRESSURE
GAUGE READING
PROBABLE CAUSE
CORRECTIVE
ACTION
INSUFFICIENT
REFRIGERANT
CHARGE
Insufficient cooling.
Bubbles appear in
sight glass.
SUCTION
PRESSURE: below
normal
DISCHARGE
PRESSURE: below
normal
Refrigerant is low, or leaking
a little.
1. Leak test.
2. Repair leak.
3. Charge system.
Evacuate as necessary
and recharge system.
ALMOST NO
REFRIGERANT
No cooling action. A
lot of bubbles or
something like mist
appears in sight
glass.
SUCTION
PRESSURE: much
below normal
DISCHARGE
PRESSURE: much
below normal
Serious refrigerant leak.
Stop compressor
immediately.
1. Leak test.
2. Discharge system.
3. Repair Leak(s).
4. Replace receiver
drier, if necessary.
5. Check oil level.
6. Evacuate and
recharge system.
FAULTY EXPANSION
VALVE
a) Slight cooling.
Sweating or frosted
expansion valve outlet.
b) Insufficient cooling.
Sweated suction
line.
c) No cooling.
Sweating or frosted
suction line.
a) SUCTION
PRESSURE: below
normal
DISCHARGE
PRESSURE: below
normal
b) SUCTION
PRESSURE: above
normal
DISCHARGE
PRESSURE: above
normal
c) SUCTION
PRESSURE: above
normal
DISCHARGE
PRESSURE: below
normal
a) Expansion valve
restricts refrigerant. Or,
expansion valve is clogged.
Or, expansion valve is
inoperative. Or, valve stuck
closed. Thermal bulb has
lost charge.
b) Expansion valve allows
too much refrigerant through
evaporator.
Sensing element on suction
line not well insulated or
properly attached to line.
c) Faulty expansion valve.
a) Replace expansion
valve.
b)
1. Check valve for
operation. If suction side
does not show a pressure
decrease, replace valve.
2. Check security and
insulation on sensing
element.
c)
1. Discharge system.
2. Replace valve.
3. Evacuate and replace
system.
Page 14
Products, L.P. CR-36-10 System Service Manual
CONDITION
SERVICE
PRESSURE
GAUGE READING
PROBABLE CAUSE
CORRECTIVE
ACTION
AIR IN SYSTEM
Insufficient cooling.
Sight glass shows
occasional bubbles.
SUCTION
PRESSURE: above
normal
DISCHARGE
PRESSURE: above
normal
Air mixed with refrigerant in
system.
1. Discharge system.
2. Replace receiver drier.
3. Evacuate and charge
system.
MOISTURE IN SYSTEM
After operation for a
while, pressure on
suction side may show
vacuum pressure
reading. During this
condition, discharge
air will be warm. As
warning of this,
reading shows approx.
6 psi oscillation.
SUCTION
PRESSURE: below
normal
DISCHARGE
PRESSURE: above
normal
Drier is saturated with
moisture. Moisture has
frozen at expansion valve.
Refrigerant flow is restricted.
1. Discharge system.
2. Replace receiver drier
(twice if necessary).
3. Evacuate system
completely. (Repeat 30
minute evacuating three
times.)
4. Recharge system.
FAULTY CONDENSER
Insufficient cooling.
Bubbles appear in
sight glass of drier.
Suction line is very hot.
SUCTION
PRESSURE: above
normal
DISCHARGE
PRESSURE: above
normal
Condenser air or refrigerant
flow is restricted.
Check condenser for dirt
accumulation.
Check for refrigerant
overcharge.
If pressure remains high
in spite of all above
actions taken, remove
and inspect the
condenser for possible
oil clogging.
HIGH PRESSURE LINE
BLOCKED
Insufficient cooling.
Frosted high pressure
liquid line.
SUCTION
PRESSURE: much
below normal
DISCHARGE
PRESSURE: much
above normal
Drier clogged, or restriction
in high pressure line.
1. Discharge system.
2. Remove receiver drier
and replace it.
3. Evacuate and charge
system.
Page 15
Products, L.P. CR-36-10 System Service Manual
CONDITION
SERVICE
PRESSURE
GAUGE READING
PROBABLE CAUSE
CORRECTIVE
ACTION
FAULTY
COMPRESSOR
Insufficient cooling.
SUCTION
PRESSURE: much
below normal
DISCHARGE
PRESSURE: much
below normal
Internal problem in
compressor, or damaged
gasket and valve.
1. Discharge system.
2. Remove and check
compressor.
3. Repair or replace
compressor.
4. Check oil level.
5. Replace receiver drier.
6. Evacuate and charge
system.
TOO MUCH OIL IN
SYSTEM (Excessive)
Insufficient cooling.
SUCTION
PRESSURE: above
normal
DISCHARGE
PRESSURE: above
normal
Too much oil circulates with
refrigerant, causing the
cooling capacity of the
system to be reduced.
Refer to Oil Level Check
for correcting oil level.
Page 16