AIR CONDITIONER SERVICE MANUAL A119-206M-1

CHAPTER 3 .................................................................................................................... 9 INSPECTIONS AND OVERHAUL ............................................................................... 9 1. Inspection Requirements ................................................................................ 9 2. Component Overhaul / Replacement Schedule ............................................ 10 CHAPTER 4 .................................................................................................................. 11 LOCATION AND ACCESS ........................................................................................ 11 1. Location of Air Conditioner Components ...................................................... 11 CHAPTER 5 .................................................................................................................. 23 PLACARDS AND MARKINGS ................................................................................... 23 1. Placard and Marking Information .................................................................. 23 CHAPTER 6 .................................................................................................................. 25 SERVICING ............................................................................................................... 25 AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page vii 1. Safety Precautions ........................................................................................ 25 2. Servicing Information .................................................................................... 25 3. Lubrication Information ................................................................................. 27 4. System Leak Check ...................................................................................... 27 5. Suggested Equipment for Servicing .............................................................. 28 6. Consumable Materials .................................................................................. 28 7. Suggested Spares List .................................................................................. 29 CHAPTER 7 .................................................................................................................. 31 STANDARD PRACTICES AND INFORMATION ....................................................... 31 1. Fitting Torque Procedures and Values.......................................................... 31 2. Removal and Replacement of Forward Evaporator Assembly ...................... 32 3. Removal and Replacement of Forward Evaporator RH Blower Assembly.... 32 4. Removal and Replacement of Aft Evaporator Assembly .............................. 33 5. Removal and Replacement of Aft Evaporator Blower Assembly .................. 33 6. Removal and Replacement of Air Box Assembly .......................................... 34 7. Removal and Replacement of Condenser Assembly .................................... 34 8. Removal and Replacement of Condenser Vane Axial Blower Assembly ...... 35 9. Removal and Replacement of Compressor Drive Belt .................................. 35 10. Removal and Replacement of Compressor Assembly .................................. 36 11. Removal and Replacement of Receiver Drier Bottle ..................................... 37 12. Removal and Replacement of Bypass Valve ................................................ 37 13. Removal and Replacement of Binary Switch ................................................ 38 CHAPTER 8 .................................................................................................................. 39 TROUBLESHOOTING............................................................................................... 39 1. System Troubleshooting ............................................................................... 39 Figure 8-1 – Electrical Schematic (IDS Equipped Aircraft) ..................................... 41 Figure 8-2 – Electrical Schematic (Non IDS Equipped Aircraft) ............................. 41 APPENDIX A ................................................................................................................. 46 WEIGHT AND BALANCE INFORMATION ................................................................ 46 AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 1 CHAPTER 1 INTRODUCTION 1. Scope The scope of this manual encompasses scheduled and unscheduled maintenance procedures for continued airworthiness of Air Comm Corporation air conditioning system installed in the Agusta A119 and Agusta Westland AW119 MKII series helicopter. 2. Purpose The purpose of this manual is to provide aircraft field mechanic necessary information to maintain the air conditioning system. 3. Arrangement This manual is arranged by chapters which are broken down into paragraphs and sub- paragraphs. All chapters and paragraphs are listed in the front of this manual in the Table of Contents, and are further identified by their individual page number. 4. Applicability This manual is applicable to Agusta Helicopter models A119 & Agusta Westland AW119 MKII which are equipped with the Air Comm Corporation kit number A119-206 & A119- 208 & A119-210 & A119-212 & A119-214 air conditioner systems. The kit Serial Number is engraved on the compressor mount assembly. Mandatory Service Bulletin SB A119- 306 requires that all Agusta A119s equipped with ACC air conditioners require the use of this ICA. 5. Definitions The following terms are provided to give a ready reference to the meaning of some words contained within this manual. These definitions may differ from those given by a standard dictionary. a. Ambient air temperature: Temperature of the air surrounding a person or object. b. Charging station: An air conditioning system service unit which is capable of evacuating and charging an air conditioner. c. Cold: The absence of heat. d. Condensation: The process of changing a vapor into a liquid. e. Desiccant: Material used in a receiver/drier bottle, designed to absorb moisture from refrigerant. f. Evaporate: To change from a liquid into a vapor. g. Heat load: The amount of heat which the air conditioner is required to remove from the aircraft cabin. h. Inches of mercury: A measurement of pressure, normally used for pressures below atmospheric, one inch of mercury is equal to approximately one half pound per square inch. i. Pressure, ambient: The pressure of the air surrounding a body, normally measured in pounds per square inch, or PSIG. j. Refrigerant: A fluid which is used in an air conditioning system to absorb heat from the cabin and carry it outside the helicopter where it can be transferred to the outside air. k. Relative humidity: The ratio of the amount of water vapor in the air to the AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 2 amount of water vapor required to saturate the air at the existing temperature. l. Thermostat: An air conditioning control which senses the temperature of the evaporator coil and causes the system to cycle or by-pass to maintain the proper temperature of cooling air. m. Vacuum: A negative pressure, or pressure below atmospheric; it is usually expressed in inches of mercury. n. Vapor: The gaseous state of a material. 6. Abbreviations gm: Gram kg: Kilograms inHg: Inches of Mercury In-lbs: Inch pounds Kg/cm: Kilograms Per Centimeter lbs: Pounds ml: Milliliters mm: Millimeters Nm: Newton-meters oz: Ounces Psig: Pounds Per Square Inch (gauge) 7. Precautions The following precautions are found throughout this manual, and will vary depending on the seriousness of the Hazard or Condition: WARNING: May be a maintenance procedure, practice, condition, etc., which could result in personal injury or loss of life. CAUTION: May be a maintenance procedure, practice, condition, etc., which could result in damage or destruction of equipment. NOTE: May be a maintenance procedure, practice, condition, etc., or a statement which needs to be highlighted. 8. Units of Measure All measurements contained within this manual are given in United States standard measurement, followed by metric conversion in parentheses. 9. Information Essential to Continued Airworthiness This manual provides information which is required for operation and maintenance of the Air Comm air conditioning system installed in Agusta model A119 & Agusta Westland AW119 MKII series helicopter. After completion of the air conditioner installation this document must be placed with the appropriate existing aircraft documents. 10. Reference Documents The approval basis of the system covered by this ICA is Supplemental Type Certificate SR00463DE. 11. Distribution This document is to be placed with the aircraft maintenance records at the time of system installation. AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 3 Changes will be made to this document in response to safety-of-flight or non-safety-of- flight issues. Any changes will result in a revision to this document. Revisions shall be noted in the Record of Revisions and on the List of Revisions of this manual. In addition to the revision of the manual, those changes categorized as safety-of-flight shall have a Service Bulletin issued to the operator providing the necessary information to comply with or to correct the safety-of-flight issue. Replacement or revised copies of this manual can be obtained by contacting: Air Comm Corporation Service Department 1575 W. 124 th Ave, Suite 210 Westminster, CO 80234 Phone No. 303-440-4075 Fax No. 303-440-6355 Email: Service@aircommcorp.com 12. Changes to Instructions for Continued Airworthiness Changes made to a line or paragraph of this document will be indicated by a vertical bar in the right hand margin. A complete page change will be indicated by a vertical bar next to the page number. (Example: Any change will appear with a vertical bar next to that change). 13. Air Conditioner Features The vapor cycle air conditioner features one forward mounted evaporator assembly (cockpit), one aft mounted evaporator assembly (above main cabin), one condenser assembly, and a compressor driven by the fan drive shaft just aft of the aft main transmission, aircraft left. These components and associated plumbing combine to provide conditioned air through the existing air distribution system when the engines are operating during both ground and flight operations. This system can be operated in either the air condition (A/C), or blower mode. In the A/C mode, conditioned air is provided by the forward and aft evaporator assemblies to the cockpit and main cabin areas respectively. In blower mode, the evaporator blowers are used to circulate and mix cabin air and fresh air, while the compressor clutch remains disengaged. When using the cabin heater it is acceptable to operate the air conditioner if desired, to defog the cabin windows. The air conditioning system is connected electrically to the aircraft’s DC Power Panel 28 VDC Bus. The control panel for the air conditioner system is located on the existing overhead switch panel between the pilot’s and copilot’s seats. The control panel consists of an A/C & Blower switch, two switches for the control of cockpit and cabin evaporator blower speed, and a temperature control rheostat. Temperature control is achieved by means of a refrigerant bypass valve, thus eliminating compressor cycling. The blower motors feature dual fan speed. This feature can be used in both the A/C or fan modes. A “COMP ON” light, located on the upper main instrument panel, provides a visual status of compressor operation. For aircraft equipped with an Interactive Display System (IDS), compressor engagement is displayed on the IDS as a green "ECS ON" annunciation. For aircraft equipped with a Garmin G1000, the indication will show on the screen. AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 4 Figure 1-1 – Air Conditioning System Control Panel The compressor is mounted on the surface of the transmission drain pan, in the aft aircraft center portion of the transmission compartment and is driven by a Poly V-Belt and a pulley which is mounted to the oil cooler blower drive shaft. Access to the compressor is provided by the transmission compartment access doors. The condenser assembly is mounted below the baggage floor and features a blower assembly and a separate heat exchanger to reject system heat overboard. Airflow through the condenser heat exchanger is provided by two 28 volt DC high performance blowers. The forward evaporator is mounted on the left side of the instrument panel console. Conditioned air is delivered to the crew by means of air ducts, mounted to the sides of the instrument panel console. An optional RH mounted blower may be installed. The aft evaporator assembly is mounted above the cabin top and is enclosed by the transmission cowling. Cabin return air is ducted to the evaporator through a cutout in the cockpit closeout panel at fuselage station 2050. Conditioned air is pumped to the existing headliner ducting through the existing fresh air inlet in the cabin top. The aft evaporator assembly is equipped with a freeze switch. The freeze switch probe is located in the core of the evaporator heat exchanger. This unit prevents coil freeze-up by limiting the minimum coil temperature to 32º F (0º C). AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 5 The system is also equipped with a Binary switch. This switch is designed to protect the system against over-pressure situations, or under-pressure in the event of refrigerant loss from the system. The switch also prevents the system from operating in low ambient temperatures below 50º F (10º C). The switch operating pressures are: Low Pressure Function: Cut-out at 28 +/- 2.8 psig (1.97 +/- .2 kg/cm2 ) Cut-in at 29 +/- 4.3 psig (2.04 +/- .3 kg/cm2 ) High Pressure Function: Cut-out at 384 +/- 30 psig (27.0 +/- 2.1 kg/cm2 ) Cut-in at 298 +/- 43 psig (20.95 +/- 3 kg/cm2 ) 14. Description of Vapor Cycle Air Conditioner and Installation This section contains a general overview of a vapor-cycle air conditioning system and how it functions. This type of system operates in a closed loop, in which the refrigerant absorbs heat from the cabin and rejects it into the outside air. The refrigerant then returns to the cabin to repeat the cycle. The operation of the system is described below (See Figure 1-2). Liquid refrigerant is contained in the receiver-drier under pressure from the compressor. The receiver-drier also filters the refrigerant through a material know as desiccant. The desiccant insures that the liquid refrigerant leaving this component is free of any water or other contaminants. The low pressure (suction) line from the compressor is attached to the evaporator lines, and causes the refrigerant to be pulled out of the receiver-drier and through the expansion valves. The expansion valves serve as a controlled spray orifice, to spray the correct amount of refrigerant into the evaporator. This regulation of refrigerant allows the liquid to absorb the heat from the cabin air, and transform it to a vapor state just prior to its exiting the evaporator assembly. The low pressure vapor is then drawn into the compressor where its pressure is raised to approximately 200 psig (14.06 kg/cm) and its temperature to around 200º F (93.3º C). This high pressure/high temperature vapor then travels to the condenser (a heat exchanger cooled by a flow of outside air). Heat is extracted from the refrigerant, and as it cools it condenses back into a liquid and flows into the receiver-dryer, ready to repeat the cycle. AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 6 Figure 1-2 – Refrigeration Cycle Illustration (NOTE: This illustration is provided as a reference only and may not match actual installation) High pressure liquid Low pressure vapor Low pressure liquid High pressure vapor Compressor Condenser Aft Evaporator Receiver- Drier Bypass Valve Expansion Valves Fwd Evaporator AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 7 CHAPTER 2 AIRWORTHINESS LIMITATION SECTION 1. Airworthiness Limitations The Airworthiness limitations section is FAA approved and specifies inspections and other maintenance required under Sections 43.16 and 91.403 of Federal Aviation Regulations unless an alternative program has been FAA approved. “No airworthiness limitations associated with this type design change.” FAA approval: ACO Representative Date AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 8 THIS PAGE INTENTIONALLY LEFT BLANK AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 9 CHAPTER 3 INSPECTIONS AND OVERHAUL 1. Inspection Requirements PERIODIC INSPECTIONS (Hours are aircraft time) Item Annual Every 100 Hours of Operation Every 400 Hours of Operation Special Inspection Information Evaporator Blower Hi/Lo Operation X X Check for operation Condenser Blowers X X Check for operation Forward Evap Blower Motor ES61064-1 FASCO Aft Evap Blower Motor ES61142-1 X X X X Check for operation in Hi and Lo settings Check for operation in Hi and Lo settings Compressor Drive Belt X X X Check belt tension, and for signs of excessive wear (example: Glazing, Cracks, and exposed fibers) Air Conditioner Placards & Markings (see chapter 5) X X Check for security and legibility Air Conditioner Compressor Assembly X X X Check for operation, security of attaching hardware, and signs of oil or refrigerant leaks. Air Conditioner Compressor Mount X X X Check for cracks on compressor lugs, support doubler, WL1156.6 engine deck area, and rivet condition and cracks on lower surface of WL1156.3 engine deck. No cracks allowed. Check for condition and security of pivot and belt tension arm bolts. Plumbing and Fittings X X Check for security and signs of oil or refrigerant leaks Air Conditioner Compressor drive pulley (mounted to oil cooler shaft) X X Check for security of attaching hardware. Compressor Isolator Mounts X X X Check for security, and condition Aft Evaporator mounting brackets & upper deck area X Check for security and condition of attaching hardware & mounting brackets. No chaffing is allowed between aft evaporator brackets and upper deck of aircraft. Forward Evaporator mounting brackets & isolators X X Check for security, and condition AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 10 2. Component Overhaul / Replacement Schedule Description Part Number Overhaul / Replacement Hours Condenser Blower (deployable scoop intake) & Forward / Aft Evaporator Blower Motor ES73190-1(Condenser Blower) ES73192-1 (Condenser Blower) ES61064-1 (Fwd Evap Motor) ES61142-1 (FASCO Aft Evap Motor) The blower manufacturer recommends TBO is 500 hrs. At the discretion of the operator it is acceptable to operate the blower until failure. A blower failure will result in a reduction in cooling, but no safety-of-flight issues are involved. Compressor Isolator Mounts ES36096-1 Isolator The manufacturer requires replacement of the compressor isolators every two (2) years Condenser Blower (High Output) (Fixed intake grille) A119-7008-1 Blower S-6501EC-3 Blower (alt.) The blower manufacture recommends a TBO of 1000 hrs. At the discretion of the operator it is acceptable to operate the blower until failure. A blower failure will result in a reduction in cooling, but no safety-of-flight issues are involved. AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 11 CHAPTER 4 LOCATION AND ACCESS 1. Location of Air Conditioner Components Nomenclature Description of Location Air Conditioner Circuit Breaker & Relay Panel Right side forward bulkhead of baggage compartment Air Conditioner Control Panel Existing overhead circuit breaker / switch panel Forward (Cockpit) Evaporator and Blower LH side center console below instrument panel in chin bubble area – blower is integral to forward evaporator Forward Evaporator Blower Assembly RH center console below instrument panel in chin bubble area Aft (Main Cabin) Evaporator, Blower Assembly, and Air Box Assembly Main cabin roof area just forward of main rotor transmission Condenser Assembly and Blower Assembly Aircraft belly below aft baggage compartment Compressor Aft center section of engine compartment drain pan Refrigerant Plumbing Routes from compressor, to area below baggage compartment, and forward to nose area (As refrigerant plumbing connects compressor, condenser, and evaporators, it may be necessary to access these components through several panels and cabin headliner Hi & Lo Service Ports Aft of compressor in engine compartment, RH side Receiver Drier Bottle Adjacent to condenser assembly in aircraft belly below aft baggage compartment Bypass Valve Aft of compressor in engine compartment, RH side Binary Switch Aft of compressor in engine compartment, RH side AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 12 SIDE VIEW Figure 4-1 – Layout of A119 Air Conditioning System TOP VIEW Figure 4-2 – Layout of A119 Air Conditioning System A119-706-1,-2 Condenser Installation A119-606-1 thru -6 Forward Evaporator Instl A119-606-1 thru -6 Forward Evaporator Instl A119-706-1,-2 Condenser Installation AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 13 Figure 4-3 – Compressor Installation (Engine Deck – View Looking Down) A119-3040-1 Compressor Assembly 3X ES36096-1 Isolator ES35119-2 Belt A119-3042-11-1 Drive Pulley AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 14 Figure 4-4 – Forward Evaporator Air Outlets Non IDS Equipped Aircraft (Instrument Panel – View Looking Fwd) COMP ON Light 2X A119-6800-1 Air Outlet Assembly LH & RH S-2500EC-4 Mag Compass Deviation Placard AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 15 Figure 4-5 – Forward Evaporator Air Outlets IDS Equipped Aircraft (Instrument Panel – View Looking Fwd) 2X A119-6800-1 Air Outlet Assembly LH & RH S-2500EC-4 Mag Compass Deviation Placard (if mag compass installed) AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 16 Figure 4-6 – Forward Evaporator Installation (Cockpit – View Looking Aft) Standard Configuration shown—other configurations similar A119-6041-1 Blower Assembly, RH A119-6040-1 Evaporator Assembly Fwd ES61064-1 Blower Motor Drain Line ES61064-1 Blower Motor AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 17 Figure 4-7 – Aft Evaporator Installation (Cabin Top – View Looking Down) A119-6018-3 Blower Assembly Drain Line Drain Line ES61142-1 Blower Motor A119-6020-2 Evaporator Assembly Aft A119-6014-2 Air Box Assembly with ES39210-2 Actuator (not shown) AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 18 (Baggage Floor – View Looking Down) (View Looking Inboard) Figure 4-8 – Condenser Installation A119-7007-2 Condenser Assembly -1 2X A119-7008-1 S/S by SK-A119-120315 Condenser Blower (-2 2X S-6501EC-3) A119-7006-1 (-2 alt.) Condenser Blower Assembly AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 19 Figure 4-9 – Receiver Drier Bottle Installation (Aircraft Belly – View Looking Inbd RH Side) Figure 4-10 – Plumbing Components Location (Engine Deck – View Looking Down RH Side) ES43030-5 Receiver Drier Bottle ES57178-1 Binary Switch ES26194-24 Bypass Valve High Pressure Service Port Low Pressure Service Port -T11 Tube (#8) From Aft Evap -T12 Tube (#6) Bypass to Aft Evap -T5 Tube (#6) To Aft Evap -H1 Hose (#8) From Compressor -H11 Hose (#10) To Compressor Pressure relief valve (2015 kits & newer) AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 20 Figure 4-11 – Plumbing Schematic For 2015 & newer kits: S-5009EC-1 Y fitting w/ Pressure Relief Valve AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 21 Figure 4-12 – A/C Control Panel Location (Overhead Circuit Breaker Panel – View Looking Up) A119-8000-3 Control Panel AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 22 Figure 4-13 – A/C Relay Panel Location (Baggage Compartment Forward Bulkhead – View Looking Fwd) A119-8430-1 A/C Relay Panel AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 23 CHAPTER 5 PLACARDS AND MARKINGS 1. Placard and Marking Information Placard Version up through July, 2013 Placard version from July, 2013 onward Charging Instructions Placard (Upper Deck Adjacent to Charging Ports) 2.5 1.13 AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 24 THIS PAGE INTENTIONALLY LEFT BLANK AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 25 CHAPTER 6 SERVICING 1. Safety Precautions CAUTION Refrigeration servicing should be performed by qualified personnel only. The refrigerant used in the air conditioning system is the environmentally safe HFC R134a. This refrigerant is non-explosive, non-flammable, and non-corrosive, has practically no odor, and is heavier than air. Although R134a is classified as a safe refrigerant, certain precautions must be observed to protect the parts involved and the person working on the system. Liquid R134a at normal atmospheric pressure and temperature evaporates quickly and tends to freeze anything that it contacts. Care must be taken to prevent any refrigerant from coming into contact with the skin and the eyes. WARNING Always wear safety goggles when servicing any part of the refrigerant system. Should any liquid refrigerant contact the skin or eyes, seek medical attention immediately even if the irritation ceases. WARNING Never weld, use a flame-type leak detector, blow torch, solder, steam clean, bake on aircraft finish, or use excess amounts of heat on, or in the immediate area of refrigerant supply tank. 2. Servicing Information A list of suggested servicing equipment is provided later in this chapter. Servicing Procedure A. Connect the service manifold and vacuum pump to the service ports located in the upper deck aft of the compressor assembly. B. Turn on the vacuum pump and open both valves to evacuate the system. When the pressure drops to 29.40 InHg (1.9 KgCm) moisture vaporizes and is drawn out of the system by the vacuum pump. Complete removal of moisture is important to prevent blockage of the expansion valves with ice. Leak check the system as described later in this chapter. NOTE Due to the drop in atmospheric pressure with an increase in altitude, the normal vacuum reading will drop approximately 1” InHg (1 KgCm) for each 1000 ft. (304.8 m) of altitude. C. After the system has been evacuated, turn off both manifold valves and turn vacuum pump off. Allow a minimum of one hour to check for vacuum leaks (if the system will not AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 26 hold a vacuum, the system has a fitting leak). It may be necessary to charge the system with one or two lbs. (.45 to .86 Kg.) of refrigerant and conduct a leak check survey using an electronic leak detector. CAUTION It is mandatory that the system be leak free to insure trouble free operation. Continuous operation of the system with insufficient charge will result in reduced compressor life. D. After the system is proven to be leak free, the system should be evacuated for a minimum of 1/2 hour before being charged with HFC R134a. E. Charging the system with 2.5 lbs. (1.13 Kg.) of R134a refrigerant is the most accurate method of charging. This should be accomplished using the suggested servicing equipment called out in this chapter. F. If a charging station is unavailable, the following procedure should be followed. Add an initial refrigerant charge of 2.0 lbs. (0.9 Kg.) then continue to add refrigerant until the evaporator outlet air temperature and system suction pressures reach a minimum. When adding the refrigerant after the initial charge, it should be done in increments of 0.2 lbs. (.09 Kg.) and two minutes allowed to elapse before adding each additional 0.2 lbs. (.09 Kg.) refrigerant charge. The optimum charge occurs when evaporator outlet temperatures are at their lowest. Any additional refrigerant will cause the outlet air temperature to increase and system performance to be degraded. WARNING If the system is to be charged by operating the compressor, it must be charged through the Lo (Blue fitting) pressure (suction) port only. Do not open the Hi (Red fitting) pressure (discharge) valve while the system is operating. G. Test-run the system after charging, to confirm the system is working properly. CAUTION When reclaiming refrigerant, be sure to note any oil that is removed from the system, and replace the lost oil before or during re-servicing. Reduced compressor life will result if the total system oil charge is not maintained. SYSTEM REFRIGERANT & OIL CHARGE System Description Refrigerant Charge Oil Charge A119 Air Conditioner 2.5 lbs. 1.13 kg. 8.0 fl. oz. 236.6 ml. AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 27 3. Lubrication Information The total system oil charge is 8.0 fl. oz. (236.6 ml.) of R134a Polyester Refrigerant Oil. The compressor is charged with a full system charge of 8.0 fl. oz. (236.6 ml.) of oil at the factory. No additional oil is to be added at the time of the system installation. If oil is spilled during installation / maintenance, or is lost due to a leak in the system, it is necessary to approximate the amount of lost oil and add this amount to the system. The oil charge is continuously circulated by the refrigerant during the operation of the system. A quantity of oil is trapped by the compressor. NOTE Maintaining the correct amount of refrigerant and refrigerant oil in the system is critical for ensuring the long life of the compressor. The Service Ports for this system are located in the upper deck aft of the compressor assembly. CAUTION This system is serviced with Polyester Based Refrigerant Oil. The use of Polyalkylene glycol (PAG), or Mineral Oil in this system will cause damage to the air conditioner compressor and expansion valves. 4. System Leak Check Identification and elimination of system fitting leaks is extremely important to insure a trouble-free operation of this system. A system which contains a partial charge of refrigerant can be leak tested with the aid of an electronic leak detector, and be recharged without evacuating the system. A new or empty system can be pressurized with nitrogen 70-80 psi (5.1-5.6 kg/cm) or R134a 50 psi (3.5 kg/cm) to conduct a leak survey. CAUTION Do not use compressed air. Compressed air will introduce moisture into the system, which will degrade the operation of the system. The preferred method to conduct a leak survey is to use an electronic leak detector in conjunction with a small charge of R134a refrigerant. All checks done in this manner should be conducted with the air conditioner off. Since the refrigerant is heavier than air, leaks are most likely to be detected on the underside of hoses and fittings. Refrigerant will collect in low areas and provide erroneous leak detection. A stream of compressed air from a nozzle may be useful in clearing the area just prior to conducting a leak test. If the nitrogen method is used, it will be necessary to mix together a water and mild soap solution. Each fitting or suspected leak area should be brushed with this soap solution and watched for evidence of bubbles formed by the escaping nitrogen. AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 28 If a leak is detected at an O-ring fitting, check to insure proper torque has been applied to the fitting. If the system continues to leak, reclaim the system of refrigerant, and install new O-rings. NOTE Ensure that the O-ring is lubricated with refrigerant oil prior to its installation. A small amount of leakage (approximately one ounce per year) past the compressor shaft seal is normal. Most leak detectors are sensitive enough to show a leak of this magnitude. 5. Suggested Equipment for Servicing Recovery / Recycling / Recharging Station (Example: Snap-on Model ACT 3340, Robinair Model 34700, or equivalent) Electronic Leak Detector (R134a compatible) (Example: Micro-Tech III, Robinair, Snap-on, or equivalent) Manifold and gauge set (R134a compatible) (Example: Robinair, Snap-on, or equivalent) 6. Consumable Materials Refrigerant: This system is to be charged with Dupont, or equivalent HFC R134a refrigerant only. Lubricant: This system is to be serviced with R134a compatible Polyester Refrigerant Oil. CAUTION Do not use Polyalkylene glycol (PAG) or Mineral Oil in this system. O-rings: As this system is charged with R134a refrigerant, it must be fitted with Highly Saturated Nitriles (HSN) O-rings. This system incorporates two different O-ring fittings, TORQ LOK® and Insert. The HSN O-rings for the TORQ LOK® fittings are BLACK in color and the HSN O-ring for the Insert fittings are GREEN in color. AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 29 7. Suggested Spares List Item Part Number Effectivity Blower Motor – Fwd. Evaporator ES61064-1 Blower Motor – Aft Evaporator ES61142-1 Blower Assembly – Condenser A119-7008-1 is superseded by SK-A119-120315 Kit S/N 90 and subsequent now S-6501EC-3 Compressor Assembly A119-3040-1 Compressor Drive Belt ES35119-2 Receiver / Drier Bottle ES43030-5 Binary Switch ES57178-1 By-pass Valve ES26194-24 Blower Assembly – Condenser (Standard) ES73190-1 Kit S/N 28 thru 46 Blower Assembly – Condenser (High Output) ES73192-1 Kit S/N 47 thru 89 HSN O-rings; Insert type (Green) Size #6 O-ring ES44010-2 #8 O-ring ES44010-3 #10 O-ring ES44010-4 HSN O-rings; TORQ LOK® Type (Black) Size #6 O-ring ES44012-2 #8 O-ring ES44012-3 #10 O-ring ES44012-4 AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 30 THIS PAGE INTENTIONALLY LEFT BLANK AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 31 CHAPTER 7 STANDARD PRACTICES AND INFORMATION 1. Fitting Torque Procedures and Values INSERT O-RING FITTINGS TORQ LOK® FITTINGS Apply a thin coating of refrigerant oil to O-ring and Female side of fitting. Confirm there is no damage (nicks, dirt, etc.) on fittings. Slide B-nut back away from the end of the tube so you can see the O-ring as you slide the fitting together. Be careful not to pinch O-ring during assembly. Engage the male end into the female fitting being careful to maintain alignment. The male flange should seat fully against the female fitting without the O-ring being pinched. It is important to hold the fitting together while sliding the B-nut forward and engaging the threads. Tighten the B-nut by hand and then torque as follows. # 6 Fittings: 30 – 35 in-lbs (3.4-4.0 Nm) # 8 Fittings: 40 – 45 in-lbs (4.6-5.1 Nm) #10 Fittings: 50 – 55 in-lbs (5.7-6.3 Nm) DO NOT OVER TORQUE ALWAYS USE BACK UP WRENCH INSERT O-RING FITTINGS TORQ LOK® FITTINGS Once the system is charged, check each fitting with an electronic leak detector. (An electronic leak detector is the only reliable method of checking for refrigerant leaks) Once the fittings have been checked and are found to be free of leaks, torque seal as appropriate. AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 32 2. Removal and Replacement of Forward Evaporator Assembly (Figure 4-6) NOTE It will be necessary to evacuate (discharge) refrigerant from the system to remove or replace forward evaporator assembly. Instructions for servicing are found in Chapter 6. Removal a. Disconnect refrigerant plumbing from evaporator fittings once refrigerant is evacuated. Always use a back-up wrench. Cap open lines to prevent contamination. b. Remove flex duct coming from LH outlet and RH blower assembly by removing cable ties to evaporator. c. Disconnect drain line from bottom of evaporator by removing cable tie. d. Disconnect blower motor electrical connector. e. Remove attaching hardware securing evaporator assembly to support brackets. Remove evaporator. Replacement a. Install evaporator and secure with attaching hardware to support brackets. b. Connect blower motor electrical connector and secure as needed. c. Connect drain line at bottom of evaporator and secure with cable tie. d. Connect flex duct from LH outlet and RH blower assembly and secure with cable ties. e. Replace all O-rings before connecting refrigerant plumbing to evaporator fittings using a back-up wrench. Torque 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. f. Service air conditioning system with refrigerant. 3. Removal and Replacement of Forward Evaporator RH Blower Assembly (Figure 4-6) Removal a. Remove flex duct coming from RH outlet and evaporator assembly by removing cable ties at RH blower assembly. b. Disconnect blower motor electrical connector. c. Remove attaching hardware securing blower assembly to mounting bracket. Remove blower assembly. Replacement g. Install blower assembly and secure with attaching hardware to mounting bracket. h. Connect blower motor electrical connector and secure as needed. i. Connect flex duct from RH outlet and evaporator assembly and secure with cable ties. AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 15 Page 33 4. Removal and Replacement of Aft Evaporator Assembly (Figure 4-7) NOTE It will be necessary to evacuate (discharge) refrigerant from the system to remove or replace aft evaporator assembly. Instructions for servicing are found in Chapter 6. Removal a. Disconnect refrigerant plumbing from evaporator fittings once refrigerant is evacuated. Always use a back-up wrench. Cap open lines to prevent contamination. b. Remove attaching hardware and disconnect elbow duct from inlet of evaporator. Remove flex duct from outlet of evaporator by removing cable ties. c. Disconnect drain line from bottom of evaporator by removing cable tie. d. Disconnect wiring to temperature control module in the evaporator assembly by disconnecting electrical connector. e. Remove attaching hardware securing evaporator assembly to cabin top. Remove evaporator. Replacement j. Install evaporator and secure with attaching hardware to cabin top. k. Connect drain line at bottom of evaporator and secure with cable tie. l. Connect elbow duct and flex duct to inlet and outlet of evaporator and secure with cable ties. Seal elbow duct joint to evaporator with black RTV. m. Connect wiring to temperature control module in the evaporator assembly by connecting electrical connector. n. Replace all O-rings before connecting refrigerant plumbing to evaporator fittings using a back-up wrench. Torque 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. o. Service air conditioning system with refrigerant. 5. Removal and Replacement of Aft Evaporator Blower Assembly (Figure 4-7) Removal a. Remove flex duct coming from evaporator assembly by removing cable ties at blower assembly inlet. b. Remove attaching hardware securing blower assembly outlet to air box assembly. c. Disconnect blower motor electrical connector. d. Remove attaching hardware securing blower assembly to angle mounting brackets. Remove blower assembly. Replacement p. Install blower assembly and secure with attaching hardware to angle mounting brackets. q. Connect blower motor electrical connector and secure as needed.