AirComm Corporation Bell Air Conditioner206L4 Installation Instructions Insert ORing Dual Fwd Evaps

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-208M-1 
 
 
Revision D Page 35 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Figure 
13
:  Compressor Drive 
Coupler Details
 – 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  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-208M-1 
 
 
Revision D Page 36 
7. REMOVE AND REPLACE COMPRESSOR DRIVE PULLEY (Figure 13) 
 
7.1 REMOVE COMPRESSOR DRIVE PULLEY 
a. Remove forward T/R driveshaft per section 6. 
b. Remove drive flange from oil cooler blower shaft. 
c. Remove safety wire and 4ea. S-3522EC-10 Bolts from drive ring. 
d. Remove drive ring.   
e. Unscrew drive pulley from oil cooler blower shaft. 
 
7.2 REPLACE COMPRESSOR DRIVE PULLEY 
a. Apply light coat of spline grease to pulley and shaft. 
b. Screw pulley onto shaft and torque to 200-300 in-lbs. 
c. Replace S-2500EC-31 O-Ring. 
d. Install drive ring over shaft and install 4 ea. S-3522EC-10 bolts and washers. 
 
8. REMOVE AND REPLACE FORWARD EVAPORATOR (Figure 14) 
 
8.1 REMOVE FORWARD EVAPORATOR 
a. Recover refrigerant using Robinair Model 34700 Recover/Recycling/Recharge Station or 
equivalent. 
b. Remove instrument side panel just aft of evaporator. 
c. Remove Suction and Pressure hoses from evaporator. 
d. Install caps and plugs over outlets and hoses.   
e. Disconnect electrical connector. 
f. Disconnect air outlet duct from evaporator. 
g. Remove and retain evaporator mounting hardware. 
h. Remove evaporator. 
 
8.2 REPLACING FWD EVAPORATOR 
a. Re-install the evaporator and its mounting hardware. 
b. Reconnect air outlet duct to evaporator. 
c. Reconnect electrical connectors. 
d. Remove caps and plugs over outlets and hoses. 
e. Replace the ES44012-2 and -4 O-Rings in hose fittings and install hoses per instructions 
on pg. 28. 
f. Reconnect suction and pressure hoses to evaporator. 
g. Re-install instrument side panel just aft of evaporators. 
h. Service with R134a refrigerant per Chapter 6.  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-208M-1 
 
 
Revision D Page 37 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
9. REMOVE AND REPLACE AFT EVAPORATOR (Figure 15) 
 
9.1 REMOVE AFT EVAPORATOR 
a. Remove plastic Hat Rack from aft end of cabin. 
b. Open baggage door and remove oval ceiling panel. 
c. Recover refrigerant using Robinair Model 34700 Recover/Recycling/Recharge Station or 
equivalent. 
d. Remove Suction and Pressure hoses from evaporator. 
e. Install caps and plugs over outlets and hoses.   
f. Disconnect electrical connector. 
g. Disconnect air inlet and outlet ducts from evaporator. 
h. Remove and retain evaporator mounting hardware. 
i. Remove evaporator. 
 
9.2 REPLACING AFT EVAPORATOR 
a. Reinstall the evaporator and mounting hardware. 
b. Reconnect air inlet and outlet ducts to evaporator. 
c. Reconnect electrical connectors. 
d. Remove caps and plugs over outlets and hoses. 
e. Reconnect suction and pressure hoses to evaporator. 
f. Replace the ES44012-2 and -4 O-Rings in hose fittings and install hoses per instructions 
on pg. 28. 
g. Service with R134a refrigerant per Chapter 6. 
h. Reinstall oval ceiling panel in baggage compartment. 
i. Reinstall plastic hat rack in aft end of cabin. 
Figure 14:  Forward Evaporator - VIEW G-G S-6106EC-1 Evaporator
Air Outlet Ducting
5X AN525-10R12 Screw
5X NAS1149F0332P Washers
Drain Tube  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-208M-1 
 
 
Revision D Page 38 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
10. REMOVE AND REPLACE AFT EVAPORATOR BLOWER (Figure 15) 
 
10.1 REMOVE AFT EVAPORATOR BLOWER 
a. Open baggage door and remove oval ceiling panel. 
b. Disconnect electrical connector on blower. 
c. Remove all three flex ducts from blower housing and adapter. 
d. Remove AN525-10R8 screws that support blower. 
e. Remove blower through access panel opening in baggage compartment ceiling. 
 
10.2 REPLACING AFT EVAPORATOR BLOWER 
a. Open baggage door and remove oval ceiling panel. 
b. Install blower through access panel opening in baggage compartment ceiling. 
c. Install all three flex ducts to blower housing and adapter using CT21 cable ties. 
d. Install 6 ea. AN525-10R8 screws that support blower. 
e. Connect electrical connector on blower. 
f. Test blower to ensure blower wheel does not rub and turns the right direction. 
Figure 15:  Evaporator Blower - VIEW E-E CT21 Tywrap
Evaporator
BlowerAft Evaporator
4X AN525-10R8 Screw4X NAS1149F0332P Washer        
No. 52 Clamp
6X AN525-10R8 Screw6X NAS1149F0332P Washer          
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-208M-1 
 
 
Revision D Page 39 
 
11. REMOVE  AND  REPLACE  CONDENSER  BLOWER  ASSEMBLY  (Figure 16 and 
Figure 17) 
 
11.1 REMOVE CONDENSER BLOWER ASSEMBLY 
a. Deactivate Air Conditioner circuit breaker on overhead circuit breaker panel. 
b. Working under aircraft beneath baggage compartment floor, remove 13ea AN525-10R12 
screws. 
c. Swing blower assembly down and disconnect Molex electrical connector. 
d. Remove 6 ea. AN525-10R8 screws MS21042L3 nuts and NAS1149F0332P washers.  
Remove condenser blower assembly. 
 
11.2 REPLACING CONDENSER BLOWER ASSEMBLY 
a. Install condenser blower assembly. 
b. Install the electrical connectors.  For kits prior to 2015that use the Molex style connector 
refer to Chapter 7, Section 4, Page 29 for installation information. 
c. Secure condenser blower with retained hardware. 
d. Under aircraft beneath baggage compartment floor, install 13 AN525-10R12 screws. 
e. Activate air conditioner circuit breaker on overhead panel. 
f. Turn air conditioner switch to “ON”.  Ensure that scoop opens and blower draws air in 
through scoop and out through heat exchanger. 
 
12. REMOVE AND REPLACE CONDENSER HEAT EXCHANGER (Figure 18) 
 
12.1 REMOVE CONDENSER HEAT EXCHANGER 
a. Remove aft panel in baggage compartment. 
b. Recover refrigerant using Robinair Model 34700 Recover/Recycling/Recharge Station or 
equivalent. 
c. Remove Suction and Pressure hoses from condenser heat exchanger. 
d. Install caps and plugs over outlets and hoses.   
e. Remove condenser blower assembly per section 11 above. 
f. Remove heat exchanger retaining screws from under side of baggage compartment. 
g. When heat exchanger is loose, remove it through the blower assembly opening.  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-208M-1 
 
 
Revision D Page 40 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 Figure 17:  Condenser Install – View C-C 
Figure 16:  Condenser Install VIEW LOOKING UP
AN525-10R8 ScrewsMS21042L3 NutsNAS1149F0332P Washers          6 PlsS-7060EC-1Blower Assy
FWD
SECTION VIEW OF LEFT SIDE
155.8STA
Lower contour ofbelly panel
AN525-10R12 Screws          13 Pls  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-208M-1 
 
 
Revision D Page 41 
 
 
 
 
Figure 18:  Condenser Install - View E-E 
  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-208M-1 
 
 
Revision D Page 42 
 
13. REMOVE AND REPLACE BYPASS VALVE (Figure 19) 
 
13.1 REMOVE BYPASS VALVE 
a. Remove aft panel in baggage compartment. 
b. Recover refrigerant using Robinair Model 34700 Recover/Recycling/Recharge Station or 
equivalent. 
c. Remove 2X MS35275-240 Screws from valve mount bracket. 
d. Cut wires at splices.  
e. Disconnect tubing from valve and remove valve from aircraft. 
 
13.2 REPLACE BYPASS VALVE 
a. Install valve in aircraft and connect tubing. 
b. Re-connect wires using new M81824/1-2 splices. 
c. Reinstall retained screws in valve mount bracket. 
d. Service with R134a refrigerant per Chapter 6 
e. Always install new O-Rings in fittings. 
f. Always use back-up wrenches when tightening tube or hose fittings. 
g. Reinstall aft panel in baggage compartment. 
 
14. REMOVE AND REPLACE BINARY SWITCH (Figure 19) 
 
14.1 REMOVE BINARY SWITCH 
a. Remove aft panel in baggage compartment. 
b. Remove electrical connectors from switch. 
c. Remove switch from tube.  
NOTE 
Not Necessary to discharge system. 
d. Place cap over tube fitting. 
 
14.2 REPLACE BINARY SWITCH 
a. Remove cap from tube fitting and install switch. 
NOTE 
Do not over tighten switch. 
b. Re-connect wires to Binary Switch. 
c. Reinstall aft panel in baggage compartment. 
  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-208M-1 
 
 
Revision D Page 43 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Figure 19:  Binary Switch – View F-F 
 
 Binary Switch
Solenoid Bypass Valve
2X MS35275-240 Screw  
Drier/Receiver  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-208M-1 
 
 
Revision D Page 44 
Chapter 8  
TROUBLESHOOTING 
1. System Troubleshooting 
 
Prior to troubleshooting a defective system, it is advisable conduct a visual inspection for general 
condition. Inspect condenser fins for damage, comb out bent fins, and check circuit breakers in 
baggage compartment. 
 
The following matrix lists the easiest checks, and most likely problem sources, first. 
 
Problem Cause Solution 
Premature Belt 
Failure 
a. Belt too loose 
b. Compressor misalign. 
c. System over charged 
a. Adjust belt tension 
b. Re-install/align compressor 
c. Adjust system charge 
Condenser blower 
motor Circuit 
Breaker “Pops” 
a. Probable cause- 
Overheating of condenser blower motor 
a. Check for loose or rubbing of fan 
blade, or possible replacement of 
motor 
3. Water 
(Condensate) in area 
of the aft evaporator 
a. Condensate drain fitting on 
evaporator not sealed 
b. Evaporator housing not sealed 
c. Drain line / check valve not installed 
properly 
d. Condensate forming on plumbing 
fittings 
a.b.c. Verify that installation conforms 
to drawing requirements. (remove 
evaporator inlet duct, and pour 1/2 ltr. 
Of water into housing assy. To check 
for leaks & drainage. 
d. apply cork insulation to all exposed 
refrigerant lines. 
Water in chin bubble 
area of forward 
evaporator 
a. Forward evaporator housing not 
sealed 
b. Condensate drain line fittings not 
secure at evaporator connection. 
c. Drain line check valve not installed 
a. Same as above. 
Conditioned air 
outlet louvers broken 
/ loose 
 a. Replace Louvers 
6. Evaporator Coil 
freeze up 
a. System suction pressure 
(temperature) too low. System suction 
pressure should not be below 20 psi. 
a. Adjust system charge to obtain 25 – 
32 psi. 
System not Cooling a. Loss of refrigerant 
b. Water in system 
a. Leak check, evacuate system and 
recharge. 
b. Evacuate system, replace receiver 
drier bottle, & recharge  
System with Poor 
Cooling 
a. By-pass Valve a. Check to ensure the temperature 
control knob is in the full cold position, 
and the temperature control circuit 
breaker has not tripped. If the valve 
remains open (by-passing refrigerant) 
the valve will need replacement. 
 
2. ELECTRICAL 
 
With the engine off turn switch to “Blower” and make sure all evaporator blowers operate 
in both Hi and Low modes. Pull evaporator circuit breaker in battery compartment, and 
turn switch to A/C. Check that the condenser blower and actuator assembly is working, 
and the compressor clutch is engaging.