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AirComm Corporation Bell 407 Air Conditioner Instructions for Continued Airworthiness User Manual
AirComm Corporation Bell 407 Air Conditioner Instructions for Continued Airworthiness User Manual
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AIR CONDITIONER SERVICE MANUAL 407EC-200M-2 Revision 11 Page 44 3. REMOVAL, REPLACEMENT & ADJUSTMENT OF COMPRESSOR DRIVE BELT REMOVAL A. It is necessary to access the engine compartment to remove, replace, or adjust the Compressor Drive Belt. B. Cut safety wire on the Compressor Belt Tensioning Link and the Belt Tensioning link Jam Nuts, and loosen the respective Jam Nut(s). C. Before attempting to adjust the drive belt tension, ensure that the compressor mounting / attaching bolts have been loosened, to allow free movement of the compressor body on the compressor mount. D. Remove the Compressor Drive Pulley in accordance with the instructions given in section 5 below. Removal, Installation / Replacement of Compressor Drive Pulley of this manual. E. Adjust the Belt Tension Link to loosen the belt, and remove belt from the compressor & drive pulley. REPLACEMENT A. Install the drive belt on the compressor & drive pulleys. B. Replace the Compressor Drive Pulley in accordance with the instructions given in section 5. Removal, Installation / Replacement of Compressor Drive Pulley of this manual. C. Adjust belt tension (See Adjustment below). D. Tighten the Belt Tensioning Link Jam Nuts and re-safety using .032 safety wire. E. Re-torque the Compressor Mounting / Attaching bolts to 80 to 100 inch lbs. (9.04 – 11.30 Nm). NOTE Care should be taken to ensure that the new belt is not damaged (nicked or cut) during installation. ADJUSTMENT NOTE Proper belt tension is important to ensure a long belt service life and to avoid excessive loads on the compressor, and bearing assemblies. A. The correct belt tension for the 7270 belt is 52 lbs. (23.3 kg.) This can be achieved with the aid of a belt tensioning tool (Kent-Moore® BT-33-73F Belt
AIR CONDITIONER SERVICE MANUAL 407EC-200M-2
Revision 11 Page 45
Tension Gauge or Equivalent). (This is the preferred method of obtaining
proper belt tensioning).
B. An alternate method is to observe a .1” (2.5 mm) belt deflection when 3 lbs.
(1.3 kg.) of force is applied at the midpoint of the belt.
Tail rotor drive shaft pulley
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.
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 6 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 end of the compressor housing.
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.
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.
Apply 3 lbs. (1.3 kg.) at midpoint
Deflection should be .1” (2.5 mm)
AIR CONDITIONER SERVICE MANUAL 407EC-200M-2 Revision 11 Page 46 INSTALLATION / REPLACEMENT A. Locate the compressor on the mount and install fasteners. 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 link 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 42 E. Recharge the refrigerant per the servicing instructions on Page 31. 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 ensure trouble free operation of the air conditioner system. 5. REMOVAL, INSTALLATION / REPLACEMENT OF COMPRESSOR DRIVE PULLEY REMOVAL (Refer to Figure 20 through Figure 26) A. See Removal, Replacement & Adjustment of Compressor Drive Belt (Page 40) prior to the removal of the air conditioner tail rotor driveshaft compressor drive pulley. See Removal, Installation / Replacement of Compressor Assembly (Page 43) prior to the removal of the air conditioner tail rotor driveshaft compressor drive pulley. B. Remove the (4) four tailrotor driveshaft coupling retaining bolts forward of the compressor drive pulley installation. CAUTION Ensure that the driveshaft assembly is supported prior to the removal of the retaining bolts to prevent damage to the driveshaft, and the driveshaft coupling. NOTE It will be necessary to remove the Flywheel Assembly from the driveshaft on aircraft Serial Numbers prior to S/N 53443.
AIR CONDITIONER SERVICE MANUAL 407EC-200M-2 Revision 11 Page 47 C. Remove the safety wire from the (4) four S-3532EC-11 Bolts that retain the S-3532EC-5 Drive Ring to the S-3532EC-4 Pulley, and remove retaining bolts and Drive Ring. D. Remove the S-3532EC-4 Pulley using a .257 Dia. X .13 Deep Spanner Wrench, utilizing one of the (4) four holes on the pulley body. NOTE Removal of the pulley is done by turning the pulley Counter Clockwise. (Facing the rear of the aircraft). CAUTION As the driveshaft will need to be held during the removal of the Compressor Drive Pulley, care should be taken not to damage the driveshaft, or other drive train components. INSTALLATION / REPLACEMENT NOTE Proper performance of this step is critical to proper installation. Improper installation can lead to damage of the splines of the fan shaft. Torque range for the S-3532EC-4 Pulley is 450-600 in-lbs. A. Install the Compressor Drive Pulley S-3532EC-4 onto the Tail Rotor Driveshaft (oil cooler blower), threading the pulley tightly against the face of the Driveshaft Hanger Bearing Retainer. NOTE Installation of the pulley is done by turning the pulley Clockwise. (Facing the rear of the aircraft). CAUTION As the driveshaft will need to be held during the installation of the Compressor Drive Pulley, care should be taken not to damage the driveshaft, or other drive train components. B. Torque the S-3532EC-4 Compressor Drive Pulley to 450 in lbs., utilizing one of the (4) four available holes on the pulley body. C. Apply grease (bell item # C-525 or C-561) to the splines of the S-3532EC-5 drive ring. D. Install Drive Ring S-3532EC-5 on to the Driveshaft Spline, and slide into place aligning (4) four of the twelve holes provided in the Drive Ring with the (4) four threaded holes located in the Compressor Drive Pulley.
AIR CONDITIONER SERVICE MANUAL 407EC-200M-2 Revision 11 Page 48 CAUTION Always ensure that the Drive Ring is installed with the flanged portion facing aft, and a minimum clearance of .05 inch between the Drive Ring and the Driveshaft Coupler. NOTE Alignment of the (4) four holes in the Drive Ring that match those in the Compressor Drive Pulley is accomplished by a “trial and error” method of placing the Drive Ring on to the Driveshaft spline to check for hole alignment. Several rotations of the Drive Ring may be necessary to find the desired hole alignment. If rotation of the pulley is required to achieve the Drive Ring hole alignment, the pulley torque must be increased. The maximum increase in torque is to the level of 600 in lbs. E. Slowly tighten the pulley further by rotating it in the clockwise direction ONLY (looking aft) until 4 holes of both components are fully aligned. CAUTION Never back the torque off the Compressor Drive Pulley to aid in the alignment of the Drive Ring. F. Once the correct hole alignment is accomplished between the Drive Ring and the Compressor Drive Pulley. G. Verify the final pulley torque is in the range of 450-600 in-lbs. H. Install the (4) four S-3532EC-11 Bolts and NAS143-4C washers into the aligned holes. NOTE Do not make any fastener substitutions. I. Torque the bolts to 60 – 80 in lbs. (6.77 – 9.03 Nm) and safety bolts using .032 safety wire. NOTE Safety wire must be routed so that it does not contact the spline or drive coupler. J. Reinstall Driveshaft coupler, (Flywheel if applicable), and existing Drive Shaft mounting Bolts, torquing the MS21042L5 Nuts to 150 – 180 in lbs. (16.94 – 20.33 Nm). NOTE Minimum clearance between the Driveshaft/Flywheel Drive Coupler and the Drive Ring is .05 in.
AIR CONDITIONER SERVICE MANUAL 407EC-200M-2 Revision 11 Page 49 6. 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 6 Servicing. B. Using your fingers, gently remove Temperature Control Capillary Tube from Evaporator Fins by pulling straight out. (Note: In the dual forward evaporator configuration the capillary tube is located in the left hand evaporator. Single forward evaporator configurations right or left hand, capillary will be mounted in respective evaporator assembly). CAUTION Excess force may cause damage to the Temperature Control Capillary Tube, caution should be used when removing or installing this component. 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. Remove side panel from center pedestal aft of the evaporator housing to gain access to the refrigerant fittings. G. Disconnect refrigerant plumbing from Y-fittings located under the center pedestal area for dual evaporator configuration. (See Figure 17) H. Remove (4) four AN525-10R8 Screws from the Evaporator Support Bracket and remove Evaporator assembly from aircraft. CAUTION Always use a backup wrench when removing or installing refrigerant line fittings. INSTALLATION / REPLACEMENT A. Locate the forward evaporator in place with the fasteners and hand tighten the refrigerant lines. 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 backup wrench when removing or installing refrigerant line fittings.
AIR CONDITIONER SERVICE MANUAL 407EC-200M-2 Revision 11 Page 50 B. Recharge the refrigerant per the servicing instructions on Page 31. 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 ensure trouble free operation of the air conditioner system. 7. REMOVAL, INSTALLATION / REPLACEMENT OF AFT EVAPORATOR ASSEMBLY REMOVAL A. Remove the access panel on the roof of the baggage compartment. B. Cut the ty-wraps that connect the CAT Ducting to both sides of the Aft Evaporator Assembly C. Disconnect the drain line from the bottom of the Aft Evaporator Assembly. D. 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 6 Servicing. E. 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 backup wrench when removing or installing refrigerant line fittings. F. Disconnect wiring to freeze switch on the Aft Evaporator assembly by removing spade connectors from terminals. G. Remove (4) AN525-10R6 Screws that penetrate the baggage compartment roof into the bottom of the Aft Evaporator Assembly and remove the Evaporator from the aircraft. INSTALLATION / REPLACEMENT A. Locate the aft evaporator assembly and install the fasteners. Connect the refrigerant lines, CAT ducting, drain line, and mate the electrical connector. B. Recharge the refrigerant per the service instructions on Page 31. CAUTION Refrigerant servicing should be performed by qualified personnel only.
AIR CONDITIONER SERVICE MANUAL 407EC-200M-2 Revision 11 Page 51 CAUTION Always use a backup wrench when removing or installing refrigerant line fittings. 8. REMOVAL, INSTALLATION / REPLACEMENT OF CONDENSER ASSEMBLY REMOVAL A. It is necessary to remove the Condenser Scoop Assembly S-7062EC-1 prior to removing the Condenser Assembly. See Page 54 for the removal, and installation of the Condenser Scoop Assembly. B. 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 6 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. C. Remove the (13) AN525-10R12 Screws that attach the S-7062EC-1 Condenser Scoop Assembly to the lower contour of the belly panel. This will allow the Condenser Scoop Assembly to pivot on the forward hinged support plate. 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. D. Remove the aft baggage compartment closeout panel, to access the refrigerant plumbing. E. Disconnect the Condenser Assembly from the refrigerant lines that attach to the condenser assembly. CAUTION Always use a backup wrench when removing or installing refrigerant line fittings. F. Remove the (12) twelve AN525-10R12 Screws that attach the Condenser to the belly of the aircraft, and remove the Condenser Assembly by sliding it forward and out through the opening provide by the removal of the Condenser Scoop Assembly.
AIR CONDITIONER SERVICE MANUAL 407EC-200M-2 Revision 11 Page 52 INSTALLATION / REPLACEMENT A. Install the condenser assemblies and the mounting hardware. Torque all attaching hardware to 50 – 70 inch lbs. (5.7-8.0 Nm), and replace all O-rings. B. Attach and torque the refrigerant lines. Mate the blower electrical connector. C. Recharge the refrigerant per the servicing instructions on Page 31 CAUTION Refrigerant servicing should be performed by qualified personnel only. CAUTION Always use a backup wrench when removing or installing refrigerant line fittings. NOTE There should be no air leakage other than inlet and outlet. Seal all other openings, including those around the Condenser Refrigerant tubes. 9. REMOVAL, INSTALLATION / REPLACEMENT OF RECEIVER DRIER BOTTLE REMOVAL A. Remove the aft baggage compartment closeout panel, to access refrigerant plumbing. 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 6 Servicing. CAUTION Refrigerant servicing should be performed by qualified personnel only. C. Disconnect refrigerant lines from both sides of the receiver drier connection fittings. CAUTION Always use a backup wrench when removing or installing refrigerant line fittings. D. Loosen the retaining clamp holding the receiver drier bottle to the support bracket. E. Remove the receiver drier bottle.
AIR CONDITIONER SERVICE MANUAL 407EC-200M-2 Revision 11 Page 53 INSTALLATION / REPLACEMENT A. Install the receiver drier bottle into the retaining clamp. Replace all O-rings and torque plumbing lines to the bottle. 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 31. CAUTION Refrigerant servicing should be performed by qualified personnel only. CAUTION Always use a backup wrench when removing or installing refrigerant line fittings. 10. REMOVAL, INSTALLATION / REPLACEMENT OF BINARY SWITCH REMOVAL A. Remove the aft baggage compartment closeout panel, to access refrigerant plumbing. B. Disconnect electrical connectors from bottom of binary switch. C. 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. Place switch as appropriate and screw onto the Schrader valve located on outlet tube from receiver drier bottle. B. Reconnect electrical connectors on bottom of binary switch. C. Install aft baggage compartment closeout panel.