AirComm Corporation Bell Air Conditioner206L L1 L3 Single Dual evap L4 Single evap only Installation Instructions Insert ORing

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-202M-1 
 
 
Revision F  Page 25 
 
Liquid R134a at normal atmospheric pressure and temperature evaporates so quickly that it 
will freeze anything that it contacts. Care must be taken to prevent any liquid refrigerant 
from coming in contact with the skin, especially the eyes. R134a is readily absorbed by 
most types of oil; therefore it is recommended a bottle of clean mineral oil and weak solution 
of boric acid be kept nearby when servicing the refrigerant system. 
 
CAUTION 
Always wear safety goggles when servicing any part of the refrigerant system. Should any liquid 
refrigerant get into the eyes, use a few drops of mineral oil to wash them out, then use a weak 
solution of boric acid to wash eyes, and seek aid from a doctor immediately even though the 
irritation has ceased. 
It is important to keep the system tightly sealed because the refrigerant 
system is always under pressure. Heat applied to any part of the 
system will cause the pressure to build up excessively. 
 
CAUTION 
To avoid explosion, never weld, use a flame-type leak detector, blow torch, solder, stem clean, 
bake on aircraft finish, or use excess amounts of heat on, or in the immediate area of any part of 
the air conditioning system or refrigerant supply tank, while they are closed to the atmosphere. 
 
4. TOOLS, EQUIPMENT, AND CONSUMABLES 
A. Service Equipment: (Suggested) 
Recovery / Recycling / Recharging Station. 
Robinair Model 34700 or Equivalent 
Montpelier, OH 
1-800-822-5561 
B. Electronic Leak Detector: (Suggested) 
Micron – Tech III or Equivalent 
Model 209907 
Murray (NAPA) 
C. O-ring:  
CAUTION 
This system is charged with R134a Refrigerant and must be fitted with HSN O-rings (green in 
color).  
						

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Revision F  Page 26 
D. Lubricant 
This system may be serviced with either Polyolester (POE) or Double End Capped 
Polyalkylene Glycol (DEC PAG).  Polyalkylene Glycol is preferred due to its superior 
lubricating properties and improved compressor service life.  There are several types of 
PAG available. Only the “Double End Capped” type is permissible in Air Comm Corporation 
air conditioning systems.  Double End Capped PAG oil is available from Air Comm 
Corporation in 8 ounce bottles (P/N ES94006-13).  Mixing of POE and PAG is acceptable.  
Disregard previous statements to the contrary. They referenced PAG oil that was not 
“Double End Capped”.  Current versions of compressors are designed to be operated using 
PAG oil.  Testing by Air Comm Corporation has shown that “Double End Capped” PAG is 
compatible with POE and can therefore be mixed. “Double End Capped” is a reference to 
the chemical structure of the molecule and not to the container. 
 
Do not use Mineral oil in this system with R134a refrigerant. Do not use any 
refrigerant oil other than Double End Capped Polyalkylene Glycol (also known as 
“ULTRA PAG”) or Polyolester (also POE). 
 
Containers of DEC PAG or POE will absorb moisture if left open (hygroscopic). Keep 
containers tightly capped when not in use and keep all system components capped while 
servicing system. 
 
The quantity of lubrication in the system is critical. If too little lubrication is in the system the 
compressor life may be reduced. No other component in the A/C system requires 
lubrication. Too much lubricant in the system will retard heat transfer in the evaporator and 
condenser coils and reduce the cooling capacity of the system.  
 
The  following  chart  may  be  used  to  calculate  the  amount  of  oil  to  be  added  in  case  a 
component is being replaced with a new part.  
 
Component Oil Amount 
Compressor See Instructions  
Evaporator 1.0 oz. per evaporator 
Condenser 1.5 oz. 
Receiver Drier 1.5 oz. 
Hose - Vapor 1.0 oz. per 10 foot 
Hose – Liquid 1.0 oz. per 20 foot 
 
E.      Refrigerant   DuPont HFC R134a 
 
SYSTEM REFRIGERANT & OIL CHARGE 
System Description Refrigerant Charge Oil Charge 
206EC-202    Air Conditioner 
system, Single FWD evap 
2.4 lbs. 1.1 kg. 8.0 fl oz. 238 ml. 
206EC-202    Air Conditioner 
system, Dual FWD evap 
2.6 lbs. 1.2 kg. 8.0 fl oz. 238 ml. 
  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-202M-1 
 
 
Revision F  Page 27 
 
CHAPTER 7  
STANDARD PRACTICES 
 
1. O-RING TYPE FITTINGS 
Shown below are the TORQ LOK® type fittings on the left and the insert O ring type 
fittings on the right.  These two types of fittings are used throughout the refrigerant 
plumbing system.  When connecting either type of fittings always lubricate the O-Rings 
with refrigerant oil before installing. Slide B-Nut back from end of tubing and inspect 
formed end of tube for defects.  Confirm there are no nicks or debris on connection.  
Engage male end into female fitting being careful to maintain alignment and not pinch the 
O-Ring during this step.  Hold fitting together while sliding the B-nut forward and engage 
threads.  Tighten B-nut to the following torque specifications.  Always use a backup 
wrench while tightening the B-nut. 
 
NOTE 
 
TORQ LOK® fittings always use ES44012-(x) O-Rings 
and Insert O-Rings are ES44010-(x). 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
a. TORQ LOK® Fittings: Must be hand snug (metal to metal) and then add an additional 30 
degrees (one half flat). 
b. Insert O-Ring Fittings: Must be hand snug against O-ring, and then an additional 60 
degrees (one flat). 
 
CAUTION: 
Excessive torque will damage fitting. 
TORQ LOK® Insert O-ring 
ES44012-(x) 
O-Ring 
ES44010-(x) 
O-Ring ES44012-(x)O-Ring
ES44010-(x)O-Ring  
						

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Revision F  Page 28 
 
2. SYSTEM LEAK CHECK. 
Identification and elimination of any system fitting leaks is extremely important to ensure a 
trouble free system.  A system that contains a partial charge can be leak tested and 
recharged without evacuating the system.  The system can be pressurized with nitrogen 
or R134a refrigerant.  A system which has been evacuated should be filled to a pressure 
of at least 50 psig of refrigerant or 150 psig nitrogen prior to the leak survey (See 
CHAPTER 8). 
 
3. TORQUE SEAL. 
Once system is charged, check each fitting with an electronic leak detector.  Once fittings 
have been checked and are leak free, torque Seal as appropriate. 
 
4. INSTALLATION  &  REPLACEMENT  OF  THE  EVAPORATOR  AND  CONDENSER 
BLOWER ELEC CONNECTORS 
To avoid potentially serious overheating issues the Molex style connectors (identified by 
their white plastic housing) installed on the aircraft harness for connecting to the evaporator 
and condenser blowers in kits prior to 2015 must be installed per ACC procedure PPP23 
and only using the appropriate terminal crimp tool. This document is available on the ACC 
website www.aircommcorp.com/customer-support/service-manuals. 
  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-202M-1 
 
 
Revision F  Page 29 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Figure 10:  Air Conditioning System Component 
General Arrangement HH
GG
FF
E
D
E
D
Section B-B
Section A-A
CC
BB
AA  
						

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5. REMOVE AND REPLACE COMPRESSOR (Figure 11) 
 
5.1 REMOVE COMPRESSOR  
a. Recover refrigerant using Robinair Model 34700 or equivalent. 
Recover/Recycling/Recharge Station. 
b. Remove Suction and Pressure hoses from Compressor. 
c. Install caps and plugs over outlets and hoses.   
d. Remove safety wire from belt S-3018EC-7 Link turnbarrel.  
e. Remove inboard AN4 bolt from S-3018EC-7 Link. 
f. Remove AN6H34A bolt and washer from Compressor mount. 
g. Remove Compressor, then remove AN4H3A bolt and S-3001EC-12 rod. 
h. Retain S-3001EC-12 rod and all hardware for installation. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 Figure 11:  Compressor - VIEW D-D S-3018EC-7 Link
S-3001EC-12 Rod
AN4H10A Bolt
NAS1149F0432P Washer
AN4H3A Bolt
NAS1149F0432P Washer
AN4H6A Bolt
Pressure Line
ES44010-2 O-Ring
Suction Line
ES44010-4 O-Ring
.50 Dist from belt
to belt guard
S-3501EC-5 Sleeve
AN6H34A Bolt
AN960-616 Washer
S-3008EC-6 
Compressor  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-202M-1 
 
 
Revision F  Page 31 
 
 
5.2 REPLACE COMPRESSOR 
a. Install S-3001EC-12 rod, AN4H3A bolt and NAS1149F0432P washer. 
b. Install belt S-3018EC-7 Link on end of S-3001EC-12 rod and safety both bolts. 
c. Install inboard bolt through S-3018EC-7 Link and collar. 
d. Replace drive belt with new belt. 
e. Adjust belt tension per Figure 2. 
f. Safety all drilled head bolts and the S-3018EC-7 Link. 
g. Replace the ES44010-2 and -4 O-Rings in hose fittings and install hoses per  
instructions on pg. 27. 
h. Service  with  R134a  refrigerant  per CHAPTER  6. To  properly  calculate  the  amount  of 
oil required in the replacement compressor, it is necessary to pour the oil out of the old 
compressor  into  a  clean  container.  Drain  the  oil  out  of  the  fill  plug  hole  and  then  pour 
oil  out  of  the  suction  and  discharge ports  while  rotating  the  center  shaft  clockwise. 
Measure  the  total  amount  of  oil  removed  from  the  old  compressor.  Add  ½  oz.  to  the 
total  measured  to  account  for  unrecoverable  oil  in  the  old  compressor.  This  total  is 
what  is  needed  in  the  new  compressor.  New  compressors  come  from  Air  Comm 
charged  with  8  oz.  (240  cc) of  oil. This should  be  adjusted  according  to  the  amount of 
oil recovered from the old compressor and any other components being replaced. The 
receiver drier should always be replaced when the compressor is replaced or when the 
system  has  been  open  for  an  appreciable  time,  which  accounts  for  another  1.5  oz.  of 
oil that should be added. 
 
  Below is an example of a compressor (and receiver drier) replacement for illustration: 
 
Evacuating  the  system recovers  1.5  oz.  of  oil.    Draining  the  old  compressor 
recovered  2.0  oz.  of  oil.    Adding  0.5  oz.  of  residual  unrecoverable  oil  in  the 
compressor gives  2.5  oz.  The  new  receiver/drier requires  an  additional 1.5  oz.,  plus 
1.5  oz.  lost  when  the  refrigerant  was evacuated  from  the  system.  So  the  total  oil 
needed in the replacement compressor for this case is 1.5 + 2.0 + .5 + 1.5 = 5.5 oz. 
Since  the  new  compressor  comes  with  8  oz.  of  oil,  remove  the  oil  fill  plug  and  pour 
out 2.5 oz. of oil.  Torque compressor oil fill cap to 132-216 in-lb. 
 
 
6. REMOVE AND REPLACE COMPRESSOR DRIVE BELT (Figure 12) 
 
6.1 REMOVE COMPRESSOR DRIVE BELT 
a. To remove the compressor drive belt it is necessary to remove the tail rotor drive shaft 
segment between the engine gearbox and the air conditioner drive pulley. (see BHT 
Service Manual). 
b. Remove safety wire from belt S-3018EC-7 Link turnbarrel.  
c. Loosen jam nuts on both ends of turn barrel. 
d. Rotate turn barrel to loosen drive belt. 
e. Remove outboard AN4H3A bolt from S-3018EC-7 Link. 
f. Pivot compressor inboard, then remove drive belt. 
  
						

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Revision F  Page 32 
6.2 REPLACE COMPRESSOR DRIVE BELT 
g. Install new drive belt over drive pulley and compressor pulley then reinstall tail rotor 
drive shaft. 
h. Ensure that all of the washers are installed correctly.  Torque all coupling nuts to 150-
180 In-lbs. 
i. Reinstall tension link to S-8001EC-12 rod and safety lock wire bolt. 
j. Rotate turn barrel to tighten drive belt. 
k. Proper belt tension in important to ensure a long belt service life and to avoid 
excessive side load on the tailrotor driveshaft bearing. 
l. For proper belt tension add a 3 lb. force at a point mid-way between both pulleys. 
Tension is correct when the belt deflects 0.1 inch. 
m. Tighten jam nuts against turn barrel.  Safety lock wire turn barrel. 
 
CAUTION 
 
RESET BELT TENSION AFTER TWO HOURS OF OPERATION OF 
NEW BELT.  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-202M-1 
 
 
Revision F  Page 33 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Figure 
12
:  
Compressor Drive Belt 
- VIEW H
-H 
(7265 ALT)
 Max Pulley Shesveoffset is ±.08
206-040-320 Shaft Assy Ref
S-3520EC-1 Drive PulleyS-3016EC-1 Belt Guard7270 BeltAft Firewall (Ref)
4X AN174-6A Bolt
32721-1 Disc Assy
Existing
3X 206-040-340-329-1 
Washer  
206-040-325 Shaft Assy  
Ref
AN320-6 Nut
AN380-3-3 Cotter KeyTorque to 40-60 in lbs
NAS1149F0663P & NAS1149F0632P
Washer A/R
S-3014EC-10 Plug
192.3Sta±2° Max
S-3014EC-1 Bolt Assy
.305 Max. Between SplineAdapter & Oil Cooler Shaft  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-202M-1 
 
 
Revision F  Page 34 
 
 
7. REMOVE AND REPLACE COMPRESSOR DRIVE PULLEY (Figure 12) 
 
7.1 REMOVE COMPRESSOR DRIVE PULLEY 
a Remove compressor drive belt per section 6.  Retain all hardware and disc (See page 
31). 
b Remove cotter pin from fwd end of S-3014EC-1 bolt assembly and remove AN320-6 
nut. 
c Remove drive pulley from 206-040-320 shaft assembly. 
 
7.2 REPLACE COMPRESSOR DRIVE PULLEY 
a Apply anti seize lubricant to inside spline of drive pulley and install on 206-040-320 
shaft assembly. 
b Torque AN320-6 nut to 40-60 in/lbs and install new AN380-3-3 cotter key. 
c Re-install belt and driveshaft per section 6.  (Page 31). 
 
8. REMOVE AND REPLACE FORWARD EVAPORATOR (Figure 13) 
 
8.1 REMOVE FORWARD EVAPORATOR 
a. Recover refrigerant using Robinair Model 34700 Recover/Recycling/Recharge Station 
or equivalent. 
b. Remove instrument side panel just aft of evaporator. 
c. Remove Suction and Pressure hoses from evaporator. 
d. Install caps and plugs over outlets and hoses.   
e. Disconnect electrical connector. 
f. Disconnect air outlet duct from evaporator. 
g. Remove and retain evaporator mounting hardware. 
h. Remove evaporator. 
 
8.2 REPLACING FWD EVAPORATOR 
a. Re-install the evaporator and its mounting hardware. 
b. Reconnect air outlet duct to evaporator. 
c. Reconnect electrical connectors. 
d. Remove caps and plugs over outlets and hoses. 
e. Replace the ES44012-2 and -4 O-Rings in hose fittings and install hoses per 
instructions on pg. 27. 
f. Reconnect suction and pressure hoses to evaporator. 
g. Re-install instrument side panel just aft of evaporators. 
h. Service with R134a refrigerant per CHAPTER 6.