AirComm Corporation Bell 412 Air Conditioner Instructions for Continued Airworthiness with Ground Cooling User Manual

							                                                                      AIR CONDITIONER SERVICE MANUAL 412AC-210M 
Revision 7 Page 51 
(412AC-820 ELECTRICAL SCHEMATIC CONTINUED) 
 
  
						

							                                                                      AIR CONDITIONER SERVICE MANUAL 412AC-210M 
Revision 7 Page 52 
(412AC-820 ELECTRICAL SCHEMATIC CONTINUED)  
						

							                                                                      AIR CONDITIONER SERVICE MANUAL 412AC-210M 
Revision 7 Page A-1 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
APPENDIX A 
 
Ground Cooling Unit 
 
Maintenance Instructions 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
  
						

							                                                                      AIR CONDITIONER SERVICE MANUAL 412AC-210M 
Revision 7 Page A-2 
1. REMOVAL, INSTALLATION / REPLACEMENT OF GROUND COOLING DRIVE 
MOTOR 
 
 REMOVAL 
 
CAUTION 
It is recommended that the battery and external power be disconnected before starting work. 
 
A. Disconnect the power cables from terminal post located on the top of the Ground 
 Cooling Drive Motor. 
 
B. Cut safety wire on Ground Cooling Unit Compressor Belt Tensioning Link; loosen 
 Compressor Mounting bolts, and Turn Belt Tensioning Link to remove the Compressor 
 Drive Belt. 
 
C. Remove and retain six (6) each AN3-4A Bolts From the base of the 412AC-9020-1 
 Ground Cooling Pallet Assy. 
 
CAUTION 
 The Ground Cooling Drive Motor is extremely heavy; care should be taken to support the 
 Drive Motor during removal and installation to prevent damage to the motor or the 
supporting structure. 
 
D. Lift Ground Cooling Pallet Assembly to gain access to the four (4) Compressor Drive 
 Motor Mounting bolts located on the base of the Ground Cooling Pallet Assembly, and 
 remove and retain bolts. 
NOTE 
 It is not necessary to discharge the refrigerant system, or remove the compressor hoses 
in order to remove the compressor drive motor from the ground cooling unit. 
 
E. Remove the Ground Cooling Drive Motor from the aircraft. 
 
 
 INSTALLATION / REPLACEMENT 
 
A. Install the Ground Cooling Drive Motor in the appropriate location.  
 
B. Reinstall, and Torque the four (4) Compressor Drive Motor Mounting bolts to 60 to 85 
 inch lbs., and safety wire per MIL-P-8564 Paragraph 3.3.7 using MS20995C-32 safety 
 wire. 
 
C. Reinstall the six (6) AN3-4A Bolts in the base of the 412AC-9020-1 Ground Cooling 
 Pallet Assembly and torque to 60 to 85 inch lbs. (6.77 to 9.60 Nm.). 
 
D. Reinstall the Compressor Drive Belt on the Compressor Drive Motor Pulley and the 
 Compressor Pulley.  Tension the Drive Belt as shown in Figure A-1.  On completion of 
 Belt Tensioning, torque Compressor mounting bolts to 95 to 110 inch Lbs (10.74 to 
 12.43 Nm.). 
 
E. Reconnect the Power Cables to the terminals located on the top of the Ground Cooling 
 Compressor Drive motor and torque nuts to 30 to 40 inch lbs (3.38 to 4.52 Nm.). 
 
F. Perform Maintenance Operational Check of system to insure proper function of Ground 
 Cooling System.  
						

							                                                                      AIR CONDITIONER SERVICE MANUAL 412AC-210M 
Revision 7 Page A-3 
 
2. REMOVAL, INSTALLATION / REPLACEMENT OF GROUND COOLING 
COMPRESSOR 
 
 REMOVAL 
 
CAUTION 
Refrigeration servicing should be performed by qualified personnel only. 
 
A. It will be necessary to evacuate (discharge) the refrigerant from the system to remove 
 and replace the Ground Cooling Compressor. Instructions for servicing the system are 
 found in chapter 6 Servicing. 
 
B. Disconnect the refrigerant hoses from the suction and discharge ports located on the 
 back of the Compressor Assembly. 
 
C. Remove the safety wire from the Belt Tensioning link, loosen tension and remove belt. 
 
D. Remove and retain the mounting bolts that mount the compressor to the Compressor 
 Mount and the Compressor Belt tensioning link, and remove the Compressor Assembly. 
 
 INSTALLATION / REPLACEMENT 
 
A. Install the Compressor Assembly in the appropriate location. Torque all attaching 
 hardware to 95 to 110 inch lbs. (10.74 to 12.43 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 to 55 inch lbs. (5.65 to 6.21 Nm), 
 and torque the # 8 Hose fitting to 40 to 45 inch lbs. (4.52 to 5.08 Nm). 
 
C. Re-install the belt tension link attaching hardware to the compressor mount and torque 
 to 95 to 110 inch lbs. (10.74 to 12.43 Nm). 
 
D. Adjust the belt tension per the procedure on Page A-4. 
 
E. Recharge the refrigerant per the servicing Instructions on Page 15. 
 
NOTE 
 The use of 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.  
						

							                                                                      AIR CONDITIONER SERVICE MANUAL 412AC-210M 
Revision 7 Page A-4 
 
3. REMOVAL, INSTALLATION / REPLACEMENT OF GROUND COOLING DRIVE BELT 
 
 REMOVAL 
 
A. Cut safety wire on the Compressor Belt Tensioning Link, and loosen the Jam Nuts. 
 
B. Loosen Compressor retaining hardware to allow the compressor to pivot freely. 
 
C. Loosen Belt Tensioning Link, and remove Drive Belt from the Compressor Drive Motor 
 and Compressor Pulley. 
 
 
 INSTALLATION / REPLACEMENT 
 
NOTE 
 Proper belt tension is important to insure a long belt service life and to avoid excessive 
loads on the Compressor, and Drive Motor Bearings. 
 
NOTE 
 The belt tension should be checked, and re-adjusted, if necessary after the first two 
hours of operation for a newly installed belt. 
 
A. Install, and or replace the Compressor drive belt. 
 
B. Adjust the belt tension by turning the belt tension link (See Figure A-1 for belt tensioning 
 information.) 
 
C. Torque the Compressor mounting hardware to 95 to 110 inch lbs. (10.74 to 12.43 Nm). 
 
D. Safety wire the Belt Tensioning Link per MIL-P-8564 Paragraph 3.3.7 using MS20995C-
 32 Safety Wire. 
 
NOTE 
 The required belt tension is 90 lbs. (40.3 kg.). Over tensioning will shorten the belt life, 
 and may damage the clutch, or drive motor bearings. Insufficient belt tension will result 
in belt slippage, causing excess heat and reduce belt life. 
 
 The correct tension is indicated by a .10 inch deflection achieved when 6 to 8 lbs (2.7 to 
3.6 Kg.) is applied to the mid span of the Drive Belt. (See Figure A-1 below) 
 
 Apply 6 to 8 lbs (2.7 to 3.6 Kg.) to mid span of belt to achieve a .1 inch deflection 
 
 
 
 
 
 
 
Figure A-1 
  
						

							                                                                      AIR CONDITIONER SERVICE MANUAL 412AC-210M 
Revision 14                                                                                                         Page B-1 
 
 
 
 
 
 
 
APPENDIX B 
WEIGHT AND BALANCE INFORMATION 
 
 
 
 
 
 
            Weight breakdown – Bell 412 Series Air Conditioner System w/ Ground Cooling: 
 Ref. Dwg. 412AC-106-1, -2 
 
Item Wt. (lbs) ArmX (in) MX (in-lb.) ArmY (in) MY (in-lb.) 
Total (-1 or -2 
installation) 
241.90 134.6 32,560 5.0 1,210