AirComm Corporation Airbus EC135 Cabin Air Conditioner Instructions for Continued Airworthiness User Manual

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8 Page 25 
 
SYSTEM DESCRIPTION REFRIGERANT CHARGE OIL CHARGE 
EC135 Air Conditioner system 
Single Fwd Evaporator 
 
3.8 lbs 
 
1.73 Kg 
 
8.0 oz. 
 
238 ml 
EC135 Air Conditioner system 
Dual Fwd Evaporator 
 
4.0 lbs  
 
1.82 Kg  
 
 8.0 oz. 
 
238 ml 
 
3. Lubrication Information 
CAUTION 
This system is serviced with either Polyester Based Refrigerant Oil (POE) or Double 
end capped Polyalkylene oil (DEC PAG, aka Ultra PAG). The use of...

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8 Page 26 
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...

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8 Page 27 
some  cases,  leaking  refrigerant  gas  may  collect  in  low  areas  of  the  aircraft  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. 
 
B. 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...

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8 Page 28 
7. Suggested Spares List 
 
 
 ITEM  PART NUMBER 
 
Blower Motor – Aft Evaporator ES61142-3 
 
Blower Motor – Forward Evaporator ES61064-1 
 
Compressor Assembly         EC135-3040-1 
 
Compressor Drive Belt ES35135-1 
 
Receiver / Drier Bottle ES43030-6 
 
Binary Switch ES57178-1 
 
By-pass Valve ES26194-24 
 
Condenser Blower ES73186-9 
 
Compressor Drive Bearings ES33100-3 
 
 HSN O-Rings; Insert Type (Green) 
 # 6 O-Ring...

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8 Page 29 
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...

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8 Page 30 
2. 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. 
 
3. General Information 
 
A. Refer  to Airbus Model  EC135  Maintenance  Manual  for  general  removal  and 
installation  procedures  associated  with  basic  aircraft  equipment  and 
components. 
B. Prepare  helicopter  for  maintenance.  Disconnect...

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8 Page 31 
B. Connect blower motor electrical connector and secure as needed. 
C. Connect drain line at bottom of evaporator and secure with cable tie. 
D. Replace  all  O-Rings  before  connecting  refrigerant  plumbing  to  evaporator 
tube  and fittings.  Torque  refrigerant  line  connections per  tightening 
instructions pg.29. 
E. Connect  outlet  flex  ducts  to the  outlet adapter  on the evaporator  and  secure 
with cable ties. 
F....

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8 Page 32 
B. Install  blower motor and  wheel assembly in  evaporator enclosure  and  secure 
with attaching hardware. 
C. Install  M81824/1-3  or  equivalent  splices  to  motor  wires  and  retained 
connector leads. Observe correct polarity of connections. 
D. Connect  blower motor electrical connector and  secure  to  cable  tie mounts  as 
required. 
 
6. Removal and Replacement of Aft Evaporator Assembly 
(Figure 10) 
 
Removal 
 
A....

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8 Page 33 
E. Note the clearance between blower wheel and forward mount assembly on 
motor. Record clearance for reference (Figure 18). 
F. Loosen retaining set screw and remove blower wheel from blower motor 
shaft. Retain blower wheel. 
 
NOTE 
It  may  be necessary  to  apply  heat  to  the  set  screw  of  the  blower 
wheel in order to separate the two parts. 
 
G. Remove forward and aft mount assemblies and cooling tube from motor....

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8 Page 34 
F.  
8. Removal and Replacement of Condenser Assembly (Figure 11) 
 
Removal 
 
A. Discharge the refrigerant. See Chapter 6 Servicing for instructions. 
B. Remove  LH  aft  engine  fairing  from  aircraft  to  gain  access  to  the  condenser 
assembly. 
C. Disconnect both condenser blower assembly electrical connectors. 
D. Disconnect  refrigerant  plumbing  from  condenser and  receiver  drier fittings 
once refrigerant is...