AirComm Corporation Bell Air Conditioner 206L4 Installation Instructions with TORQLOK Plumbing

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 
 
Revision H   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).  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 
 
Revision H   Page 26 
 
D. Lubricant 
CAUTION 
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-210  Air  Conditioner 
system, Single FWD evap 
2.4 lbs. 1.1 kg. 8.0 fl oz. 238 ml. 
206EC-210  Air  Conditioner 
system, Dual FWD evap 
2.6 lbs. 1.2 kg. 8.0 fl oz. 238 ml. 
 
  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 
 
Revision H   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 fittings together while sliding the B-nut forward and engage 
threads.  Tighten B-nut and 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  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 
 
Revision H   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  WIRE  HARNESS  ELECTRICAL 
CONNECTORS FOR THE EVAPORATOR AND CONDENSER BLOWERS 
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 for 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-270M-1 
 
Revision H   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  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 
 
Revision H   Page 30 
 
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-270M-1 
 
Revision H   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  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. 
 
6.2 REPLACE COMPRESSOR DRIVE BELT 
a. Install new drive belt over drive pulley and compressor pulley then reinstall tail rotor 
drive shaft.  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 
 
Revision H   Page 32 
b. Ensure that all of the washers are installed correctly.  Torque all coupling nuts to 150-
180 In-lbs. 
c. Reinstall tension link to S-8001EC-12 rod and safety lock wire bolt. 
d. Rotate turn barrel to tighten drive belt. 
e. Proper belt tension in important to ensure a long belt service life and to avoid 
excessive side load on the tailrotor driveshaft bearing. 
f. 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. 
g. 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-270M-1 
 
Revision H   Page 33 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Figure 
12
:  Compressor Drive Belt 
- VIEW H
-H 
(7265 ALT)  AN960-516 Washer
Torque 150-180 in-lbs
NAS6605-8 Bolt
MS21042L5 Nut
214-040-611-3 Washer
S-3526EC-2 Washer
 AN960-516 Washer
S-3522EC-1Drive Pulley
7270 Belt  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 
 
Revision H   Page 34 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Figure 
13
:  
Compressor Drive Cou
pler 
- VIEW H
-H Torque 150-180 in-lbs
4X MS21042L5 Nut
S-3522EC-1 Drive PulleyRemove existing nut.Torque Drive Pulley 200-300 in-lbs.REMOVE S-3522EC-2 DRIVE RING PRIORTO TORQUING.
S-3522EC-2 Drive Ring4X S-3522EC-10 Bolt4X AN960-416L WasherLock wire - Single wiremethod per AC43.13-1A.Torque 60-80 in-lbs.
Oil Cooler Blower Shaft;P/N 206-040-320-105
S-2500EC-31 O-RingAlt: MS29561-221Apply light coat splinegrease to pulley and shaft.
  (Existing)
2X 214-040-611-3 Washer
 (Existing)
2X 214-040-611-3 Washer
2X S-3526EC-2 Washer2X AN960-516 Washer 
2X NAS6605-8 Bolt2X AN960-516 Washer
2X S-3526EC-2 Washer2X AN960-516 Washer
2X NAS6605-8 BoltTail RotorDrive Shaft