AirComm Corporation Beechcraft Bonanza Maintenance Manual
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Products, L.P. CR-36-10 System Service Manual LIST OF EFFECTIVE PAGES SUBJECT PAGE DATE Title i July 29/02 List of Revisions ii July 29/02 List of Effective Pages iii July 29/02 Table of Contents iv January 20/99 Introduction 1 January 20/99 Air Conditioning System Description 2 March 25/99 3 January 20/99 4 January 20/99 Refrigerant Servicing 5 January 20/99 6 January 20/99 7 March 25/99 General Servicing 8 March 25/99 9 July 6/99 10 July 29/02 11 January 20/99 Troubleshooting 12 January 20/99 13 March 25/99 14 January 20/99 15 January 20/99 16 January 20/99 17 January 20/99 Checks 18 January 20/99 19 January 20/99 20 January 20/99 Page iii
Products, L.P. CR-36-10 System Service Manual
TABLE OF CONTENTS
Subject Page
INTRODUCTION 1
AIR CONDITIONING SYSTEM DESCRIPTION
1. Air Conditioning System Description 2
2. System Operation 4
REFRIGERANT SERVICING
1. General 5
2. Discharging System 5
3. Evacuating System 6
4. Charging System 7
GENERAL SERVICING
1. General 8
2. Inspection Intervals 8
3. Plumbing System Maintenance Procedures 9
4. Coil Cleaning Maintenance Procedures 10
5. Expansion Valve Removal & Installation 11
TROUBLESHOOTING
1. General 12
2. Air Conditioning System Diagnosis Chart 12
3. Air Conditioning System Troubleshooting 14
4. Compressor Troubleshooting 17
CHECKS
1. General 18
2. Refrigerant Level Check 18
3. Refrigerant System Leakage Check 19
4. Compressor Oil Level Check 19
5. Compressor Drive Belt Adjustment 21
Page iv
Products, L.P. CR-36-10 System Service Manual INTRODUCTION 1. PURPOSE The purpose of this System Service Manual is to provide detailed instructions for the servicing, troubleshooting, checking and maintaining of the Beech Bonanza models F33A, V35/35A/35B, 36/A36/A36TC with Keith Products, Inc. air conditioning system installed. The System Service Manual supplements the Maintenance Manual supplied by Beechcraft for your particular aircraft. 2. SCOPE The scope of the System Service Manual provides the maintenance technician with detailed information covering: - Overall system level description and theory of operation. - Component level description and theory of operation. - System level checking and troubleshooting procedures. - Procedures for servicing the air conditioning system refrigerant. - The identification of special equipment to accomplish the specific tasks. 3. ARRANGEMENT This System Service Manual is arranged similar to Air Transport Association (ATA) Specification 100 and provides general servicing and maintenance instructions. 4. GLOSSARY Nonstandard abbreviations and symbols used in the Maintenance Manual are described below. A/C - Air Conditioning A/R - As Required Assy - Assembly Comm. Avail. - Commercially Available Evap - Evaporator Gnd - Ground GPU - Ground Power Unit SW - Switch VDC - Volts Direct Current Page 1
Products, L.P. CR-36-10 System Service Manual AIR CONDITIONING SYSTEM - SYSTEM DESCRIPTION 1. AIR CONDITIONING SYSTEM DESCRIPTION The Keith Products vapor cycle air conditioning system uses liquid refrigerant R134a to cool the aircraft cabin. The major components for the R134a air conditioning system consist of a receiver/dryer, expansion valve, evaporator, compressor and condenser to cool the aircraft cabin. The compressor on Keith Products Bonanza air conditioning system is driven by the engine. Figure 1 shows an operational schematic of the air conditioning system. The receiver/drier stores liquid R134a refrigerant under pressure. The drier portion of the assembly removes any traces of moisture that may have accumulated in the system. Liquid refrigerant flows from the receiver drier through the expansion valve where the refrigerant pressure is reduced, allowing it to spray into the evaporator. At the same time, air is passed over the evaporator by a blower driven by a 14VDC or 28VDC motor. This air is cooled since heat is removed from the air by the evaporation of the refrigerant in the evaporator. The evaporator produces water due to condensation. This water drains overboard through a line attached to the evaporator cover. The refrigerant leaves the evaporator as a gas. This gas is pumped by the compressor, raising its pressure and temperature. This high temperature gas then flows to the condenser. Cooling air, driven by another 14VDC or 28VDC blower motor, passes through the condenser, cooling and therefore condensing the refrigerant to a liquid. The liquid refrigerant then enters the receiver/drier, repeating the process. The plumbing which connects the compressor, condenser and the evaporator, consists of rubber based hoses with a nylon barrier. The fittings are permanently swaged onto the hoses. Fittings are o-ring type connections. Refrigerant oil is used on the fitting mating surfaces to prevent refrigerant leaks. Two R134a service valves are sized differently to avoid incorrect cross-connecting when gaining access to the plumbing for system recharging. The entire air conditioning refrigerant loop is protected against over pressure conditions by two separate safety devices. The first device is a binary high/low pressure switch. This switch will open at approximately 350 PSIG and will interrupt power to the compressor clutch at which point the system pressures will drop. The switch will also interrupt power to the compressor clutch under low pressure conditions. The second overpressure safety device is a fuse plug which will vent the system refrigerant in the event of a system pressure in excess of 425PSIG. It is located on the receiver/drier. Page 2
Products, L.P. CR-36-10 System Service Manual Figure 1. Air Conditioning Vapor Cycle System Page 3
Products, L.P. CR-36-10 System Service Manual 2. SYSTEM OPERATION The air conditioning system is operated with the engine operating and the aircraft electrical system providing 14VDC or 28 VDC to the main buss. To operate the system proceed as follows: 1) Position the bowden cable so that the butterfly valve in the aft-most-part of the ducting allows only air conditioning air to blow through the ducting. Incorrect positioning of the valve will result in warm outside air mixing with air conditioned air. 2) Turn on air conditioning system by placing the upper-left hand control switch in the AIR COND position. 3) For maximum cooling, place the FAN control knob in the HI position, place the CABIN COOLING control knob in the MAX position, and close cabin and baggage doors. 4) Turn off air conditioning system by placing the upper-left hand control switch in the OFF position. 5) Airflow may be varied by switching the FAN control switch between the LO and HI positions. 6) Cabin air cooling may be varied by rotating the CABIN COOLING control knob between the MIN and MAX positions. 7) Cabin air may be re-circulated without the air conditioning system operating by placing the upper-left hand control switch in the FAN position. Page 4
Products, L.P. CR-36-10 System Service Manual REFRIGERANT SERVICING 1. GENERAL The air conditioning system uses refrigerant R134a and the compressor lubricating oil used is Polyolester Oil viscosity grade (ISO) 68. No other refrigerant or compressor oil should be used. Refrigerant R134a is non-explosive, non-flammable, 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 personnel and property when working with R134a refrigerant. WARNING: A. Liquid R134a, at normal atmospheric pressure and temperature, evaporates so quickly that it tends to freeze anything that it contacts. Care must be taken to prevent any liquid refrigerant from coming into contact with skin. B. Always wear safety goggles when servicing any part of the refrigerant system to prevent refrigerant from coming into contact with the eyes. C. To avoid explosion, never weld, use a blow torch, solder, steam clean, or use excessive amounts of heat on, or in, the immediate area of the air conditioning system, or refrigerant supply tank, full or empty, while they are closed to atmosphere. D. The refrigerant service cart/container has a safe strength. However, if handled incorrectly, it will explode. Therefore, always follow the instruction on the label. In particular, never store it in a hot location (above 126/F, 52/C) or drop it. CAUTION: Do not operate air conditioning system with condenser air outlet blocked. 2. DISCHARGING SYSTEM A. General The air conditioning system refrigerant must be discharged prior to disconnecting or removing and components in the refrigerant loop. Federal law prohibits discharging refrigerant into the atmosphere. Use only an R134a compatible recycling/recovery unit when discharging the air conditioning system. Page 5
Products, L.P. CR-36-10 System Service Manual B. Tools and Equipment Designation Ref. No. Qty Remarks R134a Compatible Recycling/Recovery Unit Comm. Avail. 1 None C. Discharging Procedure 1) Connect R134a compatible recycling/recovery unit to the R134a service valves on the aircrafts air conditioning system. If recovery unit does not have pressure gauges, connect service pressure to air conditioning system. 2) Discharge the air conditioning system in accordance with the recovery units instructions. 3) Disconnect recovery unit when discharging is complete. 3. EVACUATING SYSTEM A. General The air conditioning system must be evacuated prior to charging the system with refrigerant. Evacuating the system removes any moisture that may be in the system. Use only an R134a compatible recycling/recovery unit when evacuating the air conditioning system. B. Tools and Equipment Designation Ref. No. Qty Remarks R134a Compatible Recycling/Recovery Unit Comm. Avail. 1 None Page 6