AirComm Corporation Cessna Citation 500 501 Maintenance Manual
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Products, Inc
Maintenance Manual
21-50-02
May 15/95
Page 201
MAINTENANCE PRACTICES
1. GENERAL
The following procedures are used to perform typical maintenance on the air
conditioning system plumbing.
2. 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
Polyol Ester Oil
Comm. Avail.
A/R
Viscosity Grade 68
Sealant
ES49000-1
A/R
None
3. PLUMBING MAINTENANCE PROCEDURES (REF. IPL Fig. 1)
A. 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:
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.
Products, Inc
Maintenance Manual
21-50-02
May 15/95
Page 202
B. Connection to Components - O-Ring Replacement
1. Place the appropriate o-ring (REF. IPL Fig. 1) over the tube O end of the
fitting.
2. Lubricate o-ring with polyol ester oil or sealant prior to assembly.
3. Apply sealant to all fitting mating surfaces prior to assembly.
C. 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.
Products, Inc Maintenance Manual 21-50-02 May 15/95 Page 601 INSPECTION/CHECK 1. GENERAL The following procedures are used for checking and inspecting the air conditioning system plumbing. 2. TOOLS AND EQUIPMENT Designation Ref. No. Qty Remarks Electronic R134a Refrigerant Leak Detector Comm. Avail. 1 None 3. PLUMBING CHECK PROCEDURES (REF. IPL Fig. 1) A Plumbing Installation Preventive Maintenance Check NOTE: All O-rings should be lubricated with polyol ester oil or sealant applied to all fittings mating surfaces before assembly. 1. Check that all hoses are properly supported and do not chafe. Check that all clamps remain secure and that the hose and fitting are well supported at connections with fixed units such as evaporator, condenser etc. to prevent fatigue cracking in tubing headers or fittings. B. Plumbing System Refrigerant Leak Check 1. Connect service pressure gauge set to service ports, located near the compressor/condenser assembly. 2. Check that the gauges are reading the proper static pressure. Both gauges should read approximately 55 psig @ standard temperature (59°F) with a properly charged system when the system is not operating. 3. Using leak detector, check entire plumbing system including hose fittings and coil assemblies for leaks. There shall be no leaks. Repair or replace leaking component per the appropriate maintenance manual section and its IPL.
Products, Inc Maintenance Manual 21-50-02 May 15/95 Page 1001 Figure 1. Plumbing System
Products, Inc Maintenance Manual 21-50-02 May 15/95 Page 1002 FIG. ITEM PART NUMBER NOMENCLATURE EFFECT UNITS PER ASSY 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 - - - - 82-75-106-3 88-00-431-2 ES48012-2 ES49008-1 MS28775-114 85-75-105 JBS5005-2 ES48149-3 ES41061-1 ES48149-1 ES49011-1 ES49011-3 ES40149-3 ES41061-2 ES40151-1 ES40149-3 ES40151-3 JBS6009-1 ES49016-1 JBS10-64 ES40158-3 ES40158-1 JBS6009-3 AN6289-10D MS28775-211 MS21919WDG 9 MS21919WDG 12 ES48004-4 ES06022-1 Plumbing Installation Drain Instl Tube Tee O-ring Blower Evap Instl Comp/ Cond Assy Hose Adapter Tee Hose O-ring O-ring Straight Fitting Adapter Tee 90° Fitting Straight Fitting 90° Fitting Bulkhead Fitting Bkhd Fitting Nut Placard Service Valve Service Valve Bulkhead Fitting Nut O-ring Clamp Clamp Spiral Wrap Insulation Tape RF 1 ref 48 in 1 1 1 ref 1 ref 200 in 1 200 in 8 8 5 1 4 4 3 1 1 4 1 1 1 1 1 8 8 24 in 36 in Air Conditioning System - Plumbing System IPL FIGURE 1
Products, Inc Maintenance Manual 21-50-03 May 15/95 Page 1 COMPRESSOR/CONDENSER ASSEMBLY DESCRIPTION AND OPERATION 1. GENERAL The compressor/condenser assembly is located forward of the rear baggage door. This unit consists of a drive motor, compressor, condenser fan assembly, condenser coil, and pressure switch. The drive motor via a multi V flat belt, turns the compressor which compresses the refrigerant gas at which it will condense at ambient temperatures. This gas is directed to the condenser where its heat is removed by air flow from the condenser fan. The fan is attached to the long shaft of the drive motor. This air is exhausted overboard via exhaust duct located on the air cycle exhaust plenum or on the R/H side of the aircraft if Service Bulletin SB135 has been accomplished. The condenser condenses the refrigerant gas to a liquid. This liquid is collected by the receiver/drier where moisture is removed. A binary pressure switch monitors the refrigerant gas pressure. This switch will open at a condenser over pressure of 350 psi and under pressure conditions of 30 psi. This will interrupt the signal to the control board and stop the compressor/condenser unit. This section of the maintenance manual discusses troubleshooting and maintenance practices used for the compressor/condenser assembly portion of the air conditioning system. An Illustrated Parts List is included in Figure 1.
Products, Inc
Maintenance Manual
21-50-03
May 15/95
Page 101
TROUBLESHOOTING
1. GENERAL
The following procedures are used for troubleshooting the comp/cond assembly.
2. TOOLS AND EQUIPMENT
Designation
Ref. No.
Qty
Remarks
Service Pressure Gauge
Comm. Avail.
1
None
28vdc Source
A/R
None
3. COMP/COND TROUBLESHOOTING PROCEDURES (REF. IPL Fig. 1)
With the air conditioning system operating, do any of the following conditions occur:
NOTE: Always attach a service gauge set to system prior to being trouble
shooting to insure proper refrigerant charge is present.
Trouble
Probable Cause Correction
1. Unusually high
suction pressure
with low discharge
pressure.
2. Unusually low
suction and
discharge pressure.
3. High compressor
discharge pressure.
4. Rough running.
Internal problem with
compressor body.
System or compressor
Leak.
(a) Air exhaust duct
collapsed or restricted.
(b) Refrigerant
overcharge.
Internal compressor
problem.
Replace compressor.
Repair leak or replace
compressor.
(a) Inspect/replace
exhaust duct.
(b) Discharge refrigerant
until only occassional
bubbles are present in
sight glass.
Replace compressor.
Products, Inc Maintenance Manual 21-50-03 May 15/95 Page 102 Trouble Probable Cause Correction 5. Low air flow across condenser coil. Dirty condenser coil. Clean condenser coil.
Products, Inc Maintenance Manual 21-50-03 May 15/95 Page 202 MAINTENANCE PRACTICES 1. GENERAL The following procedures are used to perform typical maintenance on the compressor/condenser assembly. 2. TOOLS AND EQUIPMENT Designation Ref. No. Qty Remarks Feeler Gage Comm. Avail. 1 None Oil Dipstick Make from metal wire. 1 See Fig. 201. Coil Cleaner Comm. Avail. A/R Non Acid Based Polyol Ester Oil Comm. Avail. A/R Viscosity Grade 68 3. COMPRESSOR/CONDENSER MAINTENANCE PROCEDURES (REF. IPL Fig. 1) A. Compressor Drive Belt Adjustment 1. Adjust belt for moderate tension and then rotate large pulley through 2 revolutions. 2. Tension belt to deflect 0.16 inch with a 2 - 3 lb. force applied at midspan location. 3. Rotate belt 2 revolutions, retention as required. B. Compressor Pulley Installation; Pulley - Bearing Carrier Air Gap Check NOTE: This procedure should be accomplished when installing the pulley on a new compressor to ensure proper pulley installation. 1. Add combination of shims from nut and shim kit (item 2) to ensure air gap between pulley and bearing carrier. Use .005 shim with stack. 2. Temporarily install pulley to shaft holding against shims. 3. Measure air gap between pulley and bearing carrier flange with feeler gauge, remove pulley. 4. Remove shim material .005 inch more than measured air gap. 5. Install pulley and woodruff key. 6. Install locknut from kit; torque to 25-30 ft lbs.
Products, Inc Maintenance Manual 21-50-03 May 15/95 Page 203 C. Condenser 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 condenser coil to dry thoroughly prior to additional maintenance. D. Compressor Oil Level Check NOTE: It is not necessary to check the compressor oil level during routine maintenance. It only needs to be checked when a system component is replaced or when incorrect oil level is suspected. Only polyol ester oil viscosity grade 68 should be used. 1. Operate air conditioning system for 10 minutes. This will collect as much oil as possible in the compressor. 2. Discharge air conditioning system and remove compressor from aircraft. 3. Place compressor on table such that the oil fill plug is up. 4. Remove oil fill plug. 5. Insert dipstick into oil fill port. 6. Check that the oil level is 5 fluid ounces (at the 5th increment). Add or subtract oil in 1 fluid ounce increments until 5 fluid ounces is obtained. 7. Clean oil fill port area and install oil fill plug. Torque plug to 6 - 9 ft-lbs. Figure 201. Make Dipstick as Shown Above.