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AirComm Corporation Bell 412 Air Conditioner Instructions for Continued Airworthiness User Manual
AirComm Corporation Bell 412 Air Conditioner Instructions for Continued Airworthiness User Manual
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AIR CONDITIONER SERVICE MANUAL 412AC-208M Revision 14 Page 31 (Removal & Replacement of the compressor drive belt guards) Figure 10 : COMPRESSOR DRIVE ILLUSTRATION 412EP & 412HP Drive Pulley 412 & 412SP Drive Pulley 412 -3500 & 412 -3504 Drive Pulley Belt Guard Installation NOTE: Use aft coupling bolts for shaft balance adjustment
AIR CONDITIONER SERVICE MANUAL 412AC-208M Revision 14 Page 32 (Removal & Replacement of the speed reducer pulley) Figure 11: COMPRESSOR DRIVE ILLUSTRATION X-X Direction
AIR CONDITIONER SERVICE MANUAL 412AC-208M Revision 14 Page 33 (Removal & replacement of the speed reducer bearing) Speed Reducer Pulley and Bearing Assembly Figure 12 : COMPRESSOR DRIVE ILLUSTRATION
AIR CONDITIONER SERVICE MANUAL 412AC-208M Revision 14 Page 34 4. REMOVAL, INSTALLATION / REPLACEMENT OF AIR CONDITIONER COMPRESSOR ASSEMBLY REMOVAL A. See Removal, Replacement, and Adjustment of Compressor Drive Belt (pages 27-30) prior to the removal of the air conditioner compressor assembly, following Steps A-D under the Removal section. B. It will be necessary to evacuate (discharge) the refrigerant from the system to remove and replace the air conditioner compressor. Instructions for servicing the system are found in Chapter 6 Servicing. CAUTION Refrigeration servicing should be performed by qualified personnel only. C. Disconnect the refrigerant hoses from the suction and discharge ports located on the top of the compressor housing. D. Remove and retain the attaching hardware from the top of the belt tensioning link and the compressor mount assembly. E. Remove and retain the two (2) mounting bolts that attach the compressor body to the top of the compressor mount, and remove compressor assembly. INSTALLATION / REPLACEMENT A. Install the compressor assembly to the top of the compressor mount. B. Reinstall the two (2) mounting bolts that attach the compressor body to the top of the compressor mount. C. Re-install the belt tension link attaching hardware to the compressor mount and torque to 95-110 inch lbs. D. Adjust the belt tension per the procedure on Page 27. E. 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, and torque the #8 hose fitting to 40- 45 inch lbs. CAUTION Refrigeration servicing should be performed by qualified personnel only. F. It will be necessary to refill the refrigerant in the system to replace the air conditioner compressor. Instructions for servicing the system are found in chapter 6 Servicing. G. See Removal, Replacement, and Adjustment of Compressor Drive Belt (page 27-30), prior to the replacement of the air conditioner compressor assembly, following Steps A-H under the Replacement section. H. Torque all attaching hardware to 95-110 inch lbs. I. Recharge the refrigerant per the servicing instructions on Page 14. CAUTION Refrigeration servicing should be performed by qualified personnel only. NOTE The use of 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.
AIR CONDITIONER SERVICE MANUAL 412AC-208M Revision 14 Page 35 5. REMOVAL, INSTALLATION / REPLACEMENT OF THE AIR CONDITIONER COMPRESSOR DRIVE PULLEY FROM THE MAIN TRANSMISSION DRIVE SHAFT REMOVAL A. See Removal, Replacement & Adjustment of Compressor Drive Belt (Page 27 and 28) prior to the removal of the air conditioner drive shaft pulley. B. It should be noted that the air conditioner drive pulley is a two-piece assembly, and the main transmission drive shaft need not be removed. It is necessary however to remove the attaching hardware from the drive shaft assembly that attaches it to the transmission input quill, as well as the hardware that attaches the split ring to the drive pulley for its removal. C. Once the split ring has been removed from the pulley assembly, the pulley halves may be separated, and removed. INSTALLATION / REPLACEMENT A. Attach the pulley halves. B. Secure the pulley halves using a split ring. This makes up the pulley assembly. C. Install the air conditioner drive pulley assembly by reinstalling the attachment hardware to the drive shaft assembly that attaches it to the transmission input quill. D. Use the BHT service manual for torquing the attaching hardware. E. Re-install and adjust the drive belt per the instructions given on page 27 and 28. 6. REMOVAL, INSTALLATION / REPLACEMENT OF THE FORWARD EVAPORATOR(S) ASSEMBLY REMOVAL A. It will be necessary to evacuate (discharge) the refrigerant from the system to remove or replace the forward evaporator assembly(s). Instructions for servicing the system are found in Chapter 5 Servicing. CAUTION Refrigerant servicing should be performed by qualified personnel only. B. Disconnect the refrigerant lines that attach closest to the evaporator assembly(s). CAUTION Always use a backup wrench when removing or installing refrigerant line fittings. C. Disconnect the ducting that attaches the forward evaporator to the forward blower assemblies. D. Remove and retain the two (2) retaining nuts on the inboard side of the evaporator assembly, and remove the evaporator assembly. INSTALLATION / REPLACEMENT A. Install the forward evaporator assembly and reinstall the two (2) retaining nuts on the inboard side of the assembly.
AIR CONDITIONER SERVICE MANUAL 412AC-208M Revision 14 Page 36 B. Reconnect the ducting that attaches the forward evaporator to the forward blower assemblies. CAUTION Refrigerant servicing should be performed by qualified personnel only. (Removal & Replacement of the forward evaporator(s) assembly continued) CAUTION Always use a backup wrench when removing or installing refrigerant line fittings. C. Reconnect the refrigerant lines that attach closest to the evaporator assembly. D. Torque the refrigerant line connections to 30-35 inch lbs for the #6 fitting, and 40-45 inch lbs for the #8 fitting, and replace all O-rings. CAUTION Always use back up wrench when removing or installing refrigerant line fittings. E. Recharge refrigerant per the servicing instructions on Page 15, steps A-I. NOTE The use of 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 THE AFT EVAPORATOR ASSEMBLY REMOVAL A. Remove the forward transmission cowling to gain access to the Aft Evaporator assembly. B. It will be necessary to evacuate (discharge) the refrigerant from the system to remove or replace the aft evaporator assembly. Instructions for servicing the system are found in Chapter 6 Servicing. CAUTION Refrigerant servicing should be performed by qualified personnel only. C. Disconnect the refrigerant lines that connect to the expansion valve located on the right hand side of the evaporator assembly. Note it is not necessary or advised to remove the expansion valve from the aft evaporator, unless absolutely necessary. CAUTION Always use a backup wrench when removing or installing refrigerant line fittings. D. Remove and retain the five (5) mounting bolts that attach the aft evaporator assembly to the cabin roof. E. Disconnect the wires to the aft evaporator blower motors on the aft side of the evaporator assembly. F. Disconnect the drain tube from the bottom aft section of the aft evaporator housing, and remove the aft evaporator assembly by lifting the evaporator housing up.
AIR CONDITIONER SERVICE MANUAL 412AC-208M Revision 14 Page 37 INSTALLATION / REPLACEMENT A. Install the aft evaporator assembly in the evaporator housing. B. Reconnect the drain tube to the bottom of the aft section of the aft evaporator housing. C. Reconnect the wires to the aft evaporator blower motors on the aft side of the evaporator assembly. D. Reinstall the five (5) mounting bolts that attach the aft evaporator assembly to the cabin roof. CAUTION Refrigerant servicing should be performed by qualified personnel only. CAUTION Always use a backup wrench when removing or installing refrigerant line fittings. E. Reconnect the refrigerant lines that connect to the expansion valve located on the right hand side of the evaporator assembly. NOTE: The expansion valve should not have been removed from the aft evaporator. F. Torque all attaching hardware to 50-70 inch lbs, replace all O-rings, and torque the refrigerant fittings per standard practices Page 23. G. Recharge the refrigerant per the service instructions on Page 14. H. Reinstall the forward transmission cowling. 8. REMOVAL, INSTALLATION / REPLACEMENT OF THE AIR CONDITIONER CONDENSER ASSEMBLY REMOVAL A. Remove the forward transmission cowling to gain access to the air conditioner condenser assembly. B. It will be necessary to evacuate (discharge) the refrigerant from the system to remove or replace the condenser assembly. Instructions for servicing the system are found in Chapter 6 Servicing. CAUTION Refrigerant servicing should be performed by qualified personnel only. C. Disconnect the electrical connections to the condenser blower motor (See removal of condenser blower motor & fan assembly Page 24.) D. Disconnect the refrigerant lines that connect closest to the condenser assembly. CAUTION Always use a backup wrench when removing or installing refrigerant line fittings. E. Remove and retain the eight (8) mounting bolts from the condenser assembly support legs and remove the condenser assembly.
AIR CONDITIONER SERVICE MANUAL 412AC-208M Revision 14 Page 38 INSTALLATION / REPLACEMENT A. Install the condenser assembly. B. Reinstall the eight (8) mounting bolts in the condenser assembly support legs. CAUTION Always use a backup wrench when removing or installing refrigerant lines. CAUTION Refrigerant servicing should be performed by qualified personnel only. C. Reinstall the refrigerant lines that connect closest to the condenser assembly. D. Reconnect the electrical connections to the condenser blower motor (See removal of condenser blower motor & fan assembly Page 24.) E. Torque all attaching hardware to 50-70 inch lbs. Torque the refrigerant line connections to 30-35 inch lbs for #6 fitting, and 40-45 inch lbs for #8 fittings, and replace all O-rings. F. Recharge refrigerant per the servicing instructions on Page 14. G. Reinstall the forward transmission cowling. NOTE The use of 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. 9. REMOVAL, INSTALLATION / REPLACEMENT OF THE RECEIVER DRIER BOTTLE REMOVAL A. Remove the forward transmission cowling to gain access to the receiver drier bottle, which is located on the forward side of the right hand condenser support leg. B. It will be necessary to evacuate (discharge) the refrigerant from the system to remove or replace the receiver drier bottle. Instructions for servicing the system are found in Chapter 6 Servicing. CAUTION Refrigerant servicing should be performed by qualified personnel only. CAUTION Always use a backup wrench when removing or installing refrigerant line fittings. C. Disconnect refrigerant lines from both sides of the receiver drier. D. Loosen the retaining clamp holding the receiver drier bottle to the support bracket. E. Remove the receiver drier bottle.
AIR CONDITIONER SERVICE MANUAL 412AC-208M Revision 14 Page 39 INSTALLATION / REPLACEMENT NOTE Never reuse a receiver drier bottle, and keep new receiver drier bottles capped until just prior to their installation. A. Install the receiver drier bottle. B. Tighten the retaining clamp holding the receiver drier bottle to the support bracket. CAUTION Refrigerant servicing should be performed by qualified personnel only. CAUTION Always use a backup wrench when removing or installing refrigerant line fittings. CAUTION Observe refrigerant flow arrow on the drier bottle for proper orientation. C. Reconnect the refrigerant lines to both sides of the drier bottle. D. Replace all O-rings and torque the refrigerant line connections to 30-35 inch lbs. E. Recharge refrigerant per the servicing instructions on Page 15. F. Reinstall the forward transmission cowling. 10. REMOVAL, INSTALLATION / REPLACEMENT OF HI/LO PRESSURE SWITCH REMOVAL A. Remove the forward transmission cowling to gain access to the Hi/Lo pressure switch, which is located on top of the receiver drier bottle on the forward right hand side of the condenser assembly. B. It will not be necessary to evacuate (discharge) the refrigerant from the system to remove or replace the Hi/Lo pressure switch from the receiver drier bottle. C. Disconnect electrical connectors from the top of the Hi/Lo pressure switch. D. Using a wrench to hold the Schrader valve in place, unscrew the Hi/Lo switch from the top of the receiver drier bottle, and remove switch. INSTALLATION / REPLACEMENT NOTE Use the flats provided on the top of the switch body to tighten, do not attempt to tighten the pressure switch by hand. A. Install the Hi/Lo pressure switch on top of the receiver drier bottle and screw in place. B. Reconnect electrical connectors on the top of the Hi/Lo pressure switch. C. Reinstall the forward transmission cowling.
AIR CONDITIONER SERVICE MANUAL 412AC-208M Revision 14 Page 40 11. REMOVAL, INSTALLATION / REPLACEMENT OF THE BY-PASS VALVE ASSEMBLY REMOVAL A. Remove the forward transmission cowling to gain access to the by-pass valve assembly, which is located on the aft side of the condenser assembly. B. It will be necessary to evacuate (discharge) the refrigerant from the system to remove or replace the by-pass valve. Instructions for servicing the system are found in Chapter 6 Servicing. CAUTION Refrigerant servicing should be performed by qualified personnel only. C. Disconnect the electrical connector to the by-pass valve assembly. D. Disconnect the refrigerant lines from both sides of the by-pass valve assembly. CAUTION Always use a backup wrench when removing or installing refrigerant line fittings. E. Remove the by-pass valve assembly. INSTALLATION / REPLACEMENT A. Install the by-pass valve assembly. CAUTION Always use a backup wrench when removing or installing refrigerant line fittings. B. Reconnect electrical connectors on the top of the bypass valve assembly. CAUTION Refrigerant servicing should be performed by qualified personnel only. C. Replace all O-rings. D. Recharge the system per the servicing instructions on Page 15. E. Reinstall the forward transmission cowling.