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PR-407AC-120M Rev. 8, 02/02/2009

PARAVION TECHNOLOGY, INC.

2001 AIRWAY AVENUE FT. COLLINS, COLORADO 80524

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 407AC-110 INSTALLATION

BELL MODEL 407 HELICOPTERS

Cover PR-407AC-120M Rev. 6, 11/30/2005

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Rev. 8, 02/02/2009

RECORD OF REVISIONS

REVISION NO. ISSUE DATE DATE INSERTED BY

ORIGINAL 10/01/1997 10/09/1997 1 12/05/1997 12/05/1997 2 08/09/1999 08/09/1999 3 02/09/2001 02/09/2001 4 02/28/2002 5 03/06/2003 6 01/09/2006 7 08/01/2006 8 02/02/2009

REVISION CONTROL PROCEDURE Revisions to this document are mailed to owner of record. Before inserting a change, ensure this manual is correct. Check the existing List of Effective Pages in this manual to ensure that all prior revisions are inserted. Do not insert this revision if prior revisions are not inserted.

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Rev. 8, 02/02/2009 LIST OF EFFECTIVE PAGES

PAGE NO. REVISION DATE PAGE NO. REVISION DATE

COVER 8 02/02/2009 24 6 11/30/2005COVER 6 11/30/2005 25 8 02/02/2009

A 8 02/02/2009 26 6 11/30/2005 B (BLANK) 6 11/30/2005 27 6 11/30/2005

i 8 02/02/2009 28 8 02/02/2009 ii 8 02/02/2009 29 7 08/01/2006 1 8 02/02/2009 30 7 08/01/2006 2 6 11/30/2005 31 6 11/30/2005 3 6 11/30/2005 32 6 11/30/2005 4 6 11/30/2005 33 6 11/30/2005 5 6 11/30/2005 34 8 02/02/2009 6 6 11/30/2005 35 6 11/30/2005 7 6 11/30/2005 36 6 11/30/2005 8 6 11/30/2005 37 6 11/30/2005 9 6 11/30/2005 38 6 11/30/2005

10 6 11/30/2005 39 6 11/30/2005 11 6 11/30/2005 40 6 11/30/2005 12 6 11/30/2005 41 6 11/30/2005 13 6 11/30/2005 42 6 11/30/2005 14 6 11/30/2005 43 6 11/30/2005 15 6 11/30/2005 44 6 11/30/2005 16 6 11/30/2005 45 7 08/01/2005 17 6 11/30/2005 46 7 08/01/2005 18 6 11/30/2005 47 7 08/01/2005 19 6 11/30/2005 48 6 11/30/2005 20 6 11/30/2005 49 6 11/30/2005 21 6 11/30/2005 50 6 11/30/2005 22 6 11/30/2005 51 6 11/30/2005 23 6 11/30/2005 52 6 11/30/2005

These Instructions for Continued Airworthiness (ICA) except for the Airworthiness Limitations Section, have been reviewed and found to comply with the applicable requirements of Appendix A to the Federal Aviation Regulations Part 27. FAA Acceptance Manuel Perez Date 03-06-03 . Fort Worth Aircraft Evaluation Group

Page ii PR-407AC-120M Rev. 8, 02/02/2009

TABLE OF CONTENTS ITEM PAGE(S)

RECORD OF REVISIONS ................................................................................................................... A

LIST OF EFFECTIVE PAGES ............................................................................................................... i

TABLE OF CONTENTS ....................................................................................................................... ii

AIRWORTHINESS LIMITATIONS ..................................................................................................... 1

1.0 SYSTEM DESCRIPTION ......................................................................................................... 2

2.0 INSPECTION AND MAINTENANCE .................................................................................... 2

3.0 COMPONENT REMOVAL AND REPLACEMENT .............................................................. 8

4.0 SYSTEM CHARGING ............................................................................................................ 11

5.0 ADDING REFRIGERANT TO A PARTIAL EXISTING CHARGE .................................... 12

6.0 SYSTEM LEAK CHECK ........................................................................................................ 12

7.0 FIGURES ................................................................................................................................. 15

LIST OF TABLES TABLE

I TROUBLESHOOTING PROCEDURES .................................................................................. 5

II WEIGHT AND BALANCE DATA; 407AC-110 ..................................................................... 7

LIST OF FIGURES FIGURE

A COMPRESSOR OIL LEVEL MEASUREMENT .................................................................... 8

1 AIR CONDITIONING SYSTEM CONFIGURATION .......................................................... 17

2 CONDENSER INSTALLATION ..................................................................................... 18-19

3 COMPRESSOR INSTALLATION ................................................................................... 20-25

4 FORWARD EVAPORATORS INSTALLATION ........................................................... 26-28

5 AFT EVAPORATOR INSTALLATION .......................................................................... 29-32

6 PLUMBING INSTALLATION ......................................................................................... 33-44

7 ELECTRICAL INSTALLATION ..................................................................................... 45-47

8 PLACARDS ............................................................................................................................. 48

LIST OF APPENDICES APPENDIX

A TORQUE VALUE CHART - REMOVED 11/30/05 .............................................................. 49

B ANNUAL/300 HOUR INSPECTION CHECKLIST .............................................................. 51

Page 1 PR-407AC-120M PR-407AC-120M

Rev. 8, 02/02/2009 Rev. 8, 02/02/2009

AIRWORTHINESS LIMITATIONSAIRWORTHINESS LIMITATIONS The Airworthiness Limitations Section is FAA approved and specifies inspections and other maintenance required under §§ 43.16 and 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA approved. No airworthiness limitation associated with this type design change. This system has no life-limited components.

REVISION DATE APPROVED

0 10/09/1997

1 12/05/1997

2 08/27/1999

3 04/04/2001 Melissa Sandow

4 05/06/2002 Satish Lall

5 07/02/2003 David Grossman

6 01/03/2006 David Grossman

7 08/01/2006 Approved by Letter dated 03/12/2007 Melissa Sandow, Senior Engineer, Denver ACO

8

PR-407AC-120M Rev. 6, 11/30/2005 1.0 YSTEM DESCRIPTIONS

1.1 Air Conditioner Installation General

The cabin air conditioner system operates on the vapor cycle principal and includes a compressor, condenser, drier bottle, and evaporators. The compressor pumps high pressure gaseous refrigerant into the condenser, which cools and liquifies the refrigerant, then through a drier bottle, and to the evaporators. In the evaporators, the refrigerant evaporates, and cools the evaporator coils, and the cabin air which is orced through them by the fan. The refrigerant is then returned to the compressor. f

1.2 Air Conditioner Components, Reference Figure 1

1.2.1 The compressor is located above the upper deck, forward of the aft firewall in the engine compartment. It is belt-driven by the Tail Rotor drive shaft.

1.2.2 The condenser is located under the baggage compartment. Air is drawn through the belly fairing and the condenser coils, then exhausted through panels on the side of the aircraft.

1.2.3 The drier bottle is located on the first bulkhead aft of the baggage compartment. The HI-LO switch, located on the drier bottle will disengage the compressor if system pressure is greater than 384 psi or less than 28 psi. This protects the system against over-pressure or refrigerant loss.

1.2.4 Refrigerant lines are routed between the compressor and condenser, to the drier bottle, the evaporators, and back to the compressor. These lines are made from 1/4", 3/8", 1/2", and 3/4" aluminum tubing according to the volume of refrigerant which flows in each.

1.2.5 The Evaporators are mounted on each side of the instrument console and on the electrical equipment rack, aft of the passenger cabin.

1.2.6 The Electrical system powers the evaporator and condenser fans, as well as the compressor clutch. The air conditioner controls are located in the overhead switch panel.

1.3 Air Conditioner Controls

Electrical power for the air conditioner system is provided by the “AIR COND.” push/pull breaker located forward of the Avionics breaker panel. The air conditioner system is controlled by switches located in the forward overhead panel. The 3-position BLO/OFF/AIR COND. switch at the left is used to choose fan only or cooled air. The HIGH/LOW switches are used to choose high or low fan pm for the forward and aft evaporators. r

2.0 INSPECTION AND MAINTENANCE

It is the objective of this inspection and maintenance procedure to ensure that component installations are secure and that the electrical system is airworthy. Table I, TROUBLESHOOTING PROCEDURES, refers to the most likely problems which may be encountered, and outlines the appropriate corrective actions Torque all loose and/or replaced fasteners and fittings per standardized torque values as shown in AC43-13.1, as revised. NOTE: Servicing of CFC and HCFC Systems should be preformed by Licensed, Qualified

Personnel only.

PR-407AC-120M

Rev. 6, 11/30/2005

2.1 Safety Precautions The refrigerant used in the air conditioner system is HFC-134a. Other refrigerants, uch as R-12, must not be introduced into the system. s

HFC-134a is nonflammable at ambient temperature and atmospheric pressure. However, tests have indicated that at pressures above atmospheric pressure and with air concentrations greater than 60% by volume, combustible mixtures can be formed. Under no circumstance should any Bulk Storage Cylinder, Filling Equipment, Refrigerant Reclaim or Recovery system be pressure tested with AIR/HFC-134a mixtures. NEVER charge an air conditioning system which has not been evacuated first (This does not mean that additional charge cannot be added, but all lines should be vented so that they are filled with refrigerant before adding charge to the system). NEVER use compressed air to flush the refrigerant from an air conditioning system. The following further precautions should be observed: 2.1.1 The work area should be well ventilated. Route relief and purge vent piping

outdoors, away from air intakes. Be certain that the work area is clear of vapors prior to beginning work. WARNING: INTENTIONAL INHALATION MAY CAUSE DEATH WITHOUT WARNING.

2.1.2 Always wear protective clothing when there is a risk of exposure to liquid refrigerant. Wear eye protection and a face shield when servicing any part of the refrigerant system. Liquid refrigerant at atmospheric pressure evaporates quickly and rapidly cools anything that it contacts. To avoid frostbite, care must be taken to prevent liquid refrigerant contact with skin or eyes. If contact does occur, soak the exposed area in lukewarm water and seek medical attention immediately.

2.1.3 Avoid operations with high temperatures, such as welding or baking of aircraft finish, in the immediate area of the air conditioning system or refrigerant supply tank. WARNING: Avoid areas where open flame or chemical vapors are

resent when using refrigerant. p

2.2 Tools, Equipment And Consumables Servicing of an air conditioning system requires the use of certain special tools. These tools are: 2.2.1 Service equipment for recovery, recycling, and charging operations.

Robinair Model 34700 or equivalent is suggested (Robinair; Montpelier, OH, 800-822-5561).

2.2.2 Charging Cylinder equipped with an electrically powered heating element. 2.2.3 Electronic Leak Detector for HFC-134a. (TIF 5550 is suitable). 2.2.4 Vacuum Pump. 2.2.5 Heat Exchanger Cooling Fin Comb. 2.2.6 Consumables:

2.2.6.1 HFC-134a, bulk cylinder. 2.2.6.2 Refrigerant Oil; Sanden SP-10 or SP-20 PAG oil, or

equivalent. 2.2.6.3 MIL-S-8802F Class B2 sealant or equivalent. 2.2.6.4 HYSOL EA9309, A-4 Metalset or equivalent. 2.2.6.5 Contact Cement, Scotch 1300L or equivalent. 2.2.6.6 0.032" Stainless Lock Wire (Ref.: MS20995C32). 2.2.6.7 Virginia # D10E2 Cleaning solvent or equivalent.

PR-407AC-120M Rev. 6, 11/30/2005

2.3 Recommended Inspection & Troubleshooting Procedures It is the objective of this inspection and troubleshooting procedure to ensure that component installations are secure and that the electrical system is airworthy. The following checklist describes the most likely problem sources which may be encountered: 2.3.1 Electrical - With engine off, make sure evaporator blowers work in HI and

LOW modes. Check fuses in evaporator and condenser circuits. Check that the condenser blower is working and that the compressor clutch is engaged.

2.3.2 System Charge - Connect service manifold to service fittings and purge the air from the manifold lines. The static pressure should read approx. 57 psig (60°F, Sea Level) to 104 psig (90°F, Sea Level). Gage pressure increases by about 1/2 psi per thousand feet. If the pressure is significantly lower than expected, the system may be leaking, and should be checked with the compressor running (see "adding refrigerant to an partial existing charge").

2.3.3 Expansion Valve Malfunction - If the cooling loss is limited to only one evaporator it is most likely a blockage or defective expansion valve. Confirmation of an expansion valve (TXV) problem can be made by touching the valve. If system pressures are correct, and the TXV is warm, the problem is in the valve. Loss of cooling in all evaporators (assuming that there were no problems identified during the steps above), could be caused by excessive loss of refrigerant, or refrigerant flow blockage at the expansion valves. This blockage could be due to ice (see "charging an evacuated system", Section 4.1), or material contamination.

2.3.4 Compressor Malfunction - When the compressor is running, HISIDE pressure should be in the range from 220 to 240 psig., and suction pressure should be no more than about 30 psig. If the system will not maintain the pressure differential, and there are no system leaks, the problem could be system contamination or a failed compressor. The compressor must then be replaced, (Ref.: Table 1).

CAUTION: Lack of lubrication may cause compressor failure. If this

occurs, the drive belt will fail. The forward short shaft, adjacent disc packs, and #1 Tail Rotor (TR) bearing must be examined for serviceability in accordance with BHT-407-MM-7 before replacing the compressor and belt.

2.3.5 There may be a time when the system does not operate and/or perform in

accordance with information contained herein. Therefore, it is necessary for the service personnel to diagnose the discrepancy by troubleshooting the system and its components. To assist in this diagnosis the following troubleshooting chart is provided.

PR-407AC-120M

Rev. 6, 11/30/2005

TABLE I

TROUBLESHOOTING PROCEDURES

INDICATION PROBABLE CAUSE POSSIBLE SOLUTION A. No system power 1. Gnd power not connected

2. Aircraft power switch off 1. Plug in gnd power cart 2. Energize power switch

B. Power on but system will not operate

1. Air cond. Circ.Brkr. off 2. Air cond. Circ.Brkr. failed 3. Aircond. mode SW failed 4. Vented system

1. Energize aircond. Circ.Brkr. 2. Replace 3. Replace 4. Press. Check, evacuate and

charge system C. System operates but does not

cool.

1. Low refrig. Charge 2. Overcharged system cutout (Hi-

Low Switch) 3. Failed compressor 4. Broken belt 5. Failed expansion valve(s) 6. Evap. blower switch(s) failed 7. Evap. blower(s) motor failed 8. Evap. blower(s) fuses blown 9. Evap. module air inlet clogged

10. Ex. valve inlet clogged 11. Excessive moisture in system 12. Excessive oil in system

1. Charge as required 2. Reclaim refrig. As required 3. Replace 4. Replace 5. Replace 6. Replace 7. Replace 8. Replace 9. Remove debris

10. Remove debris 11. Replace rec-dryer assy 12. Drain excessive oil

D. Evaporator noisy 1. Blower Wheel hitting scroll 2. Defective blower motor bearing 3. Air inlet clogged

1. Replace 2. Replace motor 3. Remove debris

E. No low evap. fan speed (hi speed ok)

1. Failed switch 2. Failed resistor

1. Replace 2. Replace

F. No evaporator(s) air flow 1. Circ.Brkr. off 2. Circ.Brkr. failed 3. Mode SW failed 4. Fan speed SW failed 5. Seized motor(s) 6. Blower wheel failed 7. Blocked air outlet duct 8. Blocked air inlet duct 9. Aircraft power not on

10. Ground power not on

1. Turn on 2. Replace 3. Replace 4. Replace 5. Replace 6. Replace 7. Remove debris 8. Remove debris 9. Turn on

10. Turn on

(CONTINUED, NEXT PAGE)

PR-407AC-120M Rev. 6, 11/30/2005

TABLE I (Cont’d) TROUBLESHOOTING PROCEDURES

INDICATION PROBABLE CAUSE POSSIBLE SOLUTION G. Evap. module coil freezing 1. Expansion valve failed or

clogged 2. Expansion valve setting low

1. Remove debris or replace 2. Reset to obtain 26-30 suction

pressure H. Pressure switch cycles (high

press. Cutout) 1. System over charged 2. Cond. coil inlet air extremely

hot 3. Cond. inlet clogged 4. Discharge line clogged or

kinked 5. Excessively high ambient

temperature

1. Reclaim refrig. As required 2. Normal condition 3. Remove debris 4. Replace hose 5. Normal condition

I. Compressor will not operate 1. Circ.Brkr. failed on off 2. Hi-Lo pressure switch failed 3. Broken clutch power wire 4. Low refrigerant charge 5. Loose belt tension or broken

belt 6. Clutch failure

1. Turn on or replace 2. Replace Hi-Lo switch 3. Replace wire 4. Re-charge system 5. Tighten or replace belt 6. Replace compressor

J. Drive Belt Failure 1. Worn or deteriorated belt 2. Improper belt tension 3. Poor belt alignment 4. System over charge 5. Compressor failure

1. Replace 2. Follow correct belt tension

procedure 3. Re-align compressor 4. Recharge system 5. Replace

K. Condensor Fan will not run 1. No power to condenser 2. Fan motor failed 3. Poor ground 4. Broken power wire

1. Turn on system power or Circ.Brkr.

2. Replace fan assembly 3. Properly ground fan 4. Replace wire

L. Condenser Fan Noisy 1. Retainer clip broken 2. Exhaust screen bent or loose

1. Replace clip and damaged components

2. Replace or straighten screen

PR-407AC-120M Rev. 6, 11/30/2005

TABLE II WEIGHT AND BALANCE DATA; 407AC-110

RUNNING

ITEM

WT. (LB).

F.S. (IN). B.L. (IN). WT (LB).

F.S. (IN). B.L. (IN).

FORWARD

EVAPORATORS 13.2 15.5 0.40 13.2 15.50 0.40

AFT. EVAPORATOR 7.5 162.6 -8.00 20.7 68.80 -2.64

DRYER BOTTLE 1.3 202.0 8.00 22.0 76.67 -2.01

CONDENSER INST'N. 13.4* 170.0 0.00 35.4 112.00 -1.25

LOUVER INST'N -0.9* 178.0 0.00 34.5 110.28 -1.28

COMPRESSOR ASSY. 16.4 188.0 -5.90 50.9 135.32 -2.77

COMPRESSOR BRKT 1.3 188.0 -5.90 52.2 136.63 -2.85

DRIVE PULLEY INST'N 0.7 191.0 0.00 52.9 137.35 -2.81

PLUMBING INST'N 8.1 106.6 0.00 61.0 133.27 -2.44

ELECTRICAL INST'N 1.5** 106.6** 0.00** 62.5 132.63 -2.38

REFRIGERANT 3.5** 128.0** 0.00** 66.0 132.38 -2.25

MISC. CLAMPS, FASTENERS

0.2** 106.6** 0.00** 66.2 132.30 -2.25

* Net Weight Addition ** Estimated, Overall Net

2.4 Compressor Oil Level Measurement; (In Aircraft)

It is not necessary to check the oil level as routine maintenance. Oil level should be checked when a system component has been replaced, when an oil leak is suspected, or when it is specified as a diagnostic procedure. 2.4.1 Run the compressor for 10 minutes with the engine at idle. 2.4.2 Recover all refrigerant from the system, slowly so as not to lose any oil. 2.4.3 Remove the oil filler plug. Using a socket wrench on the armature-retaining

nut, turn the shaft clockwise until the counterweight is positioned as shown. (Reference: Figure A below)

2.4.4 Insert the oil dipstick up to the stop, as shown in the Figure A. 2.4.5 Remove the dipstick and count the number of notches covered by oil. Oil

should cover 3 to 5 notches. NOTE: This oil level is based on the assumption that the compressor is

upright and is approximately level. 2.4.6 Add or remove oil as necessary. 2.4.7 Recharge the system utilizing the procedures contained in Chapter 4.0.

PR-407AC-120M Rev. 6, 11/30/2005

Figure A: Compressor Oil Level Measurement View looking forward at aft or pulley end of compressor.

3.0 COMPONENT REMOVAL AND REPLACEMENT

NOTE: BEFORE REMOVING ANY COMPONENT WHICH REQUIRES LOOSENING THE REFRIGERANT LINE, THE REFRIGERANT MUST BE REMOVED AND RECLAIMED. WHEN RECLAIMING REFRIGERANT, OIL REMOVED FROM THE SYSTEM SHOULD BE MEASURED AND MUST BE

EPLACED IN THE SYSTEM PRIOR TO RECHARGING. R 3.1 Components, Removal And Replacement - General

Gain access to component location. Refer to aircraft maintenance manual BHT-407-MM-3, BHT-407-MM-5, BHT-407-MM-7, BHT-407-MM-10 as applicable.

3.2 Refrigerant Plumbing Components Removal Remove any clamps and attaching hardware. Refer to Figure 6 (12 sheets) for tube or hose assembly removal, loosen fittings and remove.

3.3 Refrigerant Plumbing Components Installation Reinstall the tubes and hose assemblies reference Figure 6, in accordance with the instructions in the applicable manual outlined in Section 3.1 of this document.

einstall and tighten clamps and attaching hardware. R

NOTE: Apply a light film of refrigerant oil to the mating surfaces of flare fittings before assembly. Tighten fittings according to the ollowing chart. f

Tube O.D. Torque

( in.) (ft-lb) 1/4 11-15 3/8 18-25 1/2 36-45 3/4 71-97

PR-407AC-120M

Rev. 6, 11/30/2005

3.4 Compressor Removal Reference: Figure 3. Remove the hoses from their fittings at the drain pan and compressor. Cap all open lines and ports to prevent intrusion of foreign matter. Remove the safety strut from the compressor installation and loosen the tensioner. Remove the compressor mounting bolts. Remove drive belt. Lift the compressor from the bracket.

3.5 Compressor Installation Reference: Figure 3. Reinstall the compressor to the bracket. Reinstall drive belt on compressor. Reinstall the safety strut to the compressor. Tighten belt to 35 lb. tension. Reinstall hoses between drain pan bulkhead fittings and compressor. Lightly lubricate the mating surfaces of the fittings with refrigerant oil prior to assembly. IMPORTANT NOTE: Proper belt tension is critical. Over-tightening will place excessive side load on the support bearing and may shorten its life. An excessively loose drive belt may slip, resulting in frequent replacement. Use of a "KRIKIT" belt tension gauge (GATES P/N 91107) or equivalent to accurately set belt tension is recommended. Reset belt tension after two hours

f operation. o

3.6 Drive Belt Removal Refer to Section 3.4 for removal of the compressor. Refer to BHT-407-MM-7 for removal of the Number 1 Tail Rotor Drive Shaft and Flywheel from the oil cooler an shaft. f

NOTE: Due to clearance between the drive pulley and the firewall, the bevel washers on the aft side of the disc pack must be removed from the forward coupling assembly. Re-insert the bolts, without the bevel washers, to support the shaft. This is necessary to allow forward movement of the shaft and use of a short socket on the bolts through the aft shaft coupling/disc pack. Remove the drive belt from the drive pulley.

3.7 Drive Belt Installation Place the new belt over the pulley mounted to the flywheel. Reinstall the Number 1 drive shaft in the following sequence: (i) Place the compressor drive belt over the pulley. (ii) Assemble the aft end of the #1 TR drive shaft and existing coupling

components (washers and spacers, and drive shaft flange reference BHT-407-MM-7). START THE NUTS ON THE BOLTS AND HAND-TIGHTEN, DO NOT FULLY TIGHTEN THE BOLTS AT THIS TIME.

(iii) Temporally remove the two beveled washers from each side of the engine coupling-to-disc-pack stack-up, and temporarily install the forward end of the #1 TR drive shaft to the engine shaft flange.

NOTE: The beveled washers must be temporarily removed from between the engine shaft and coupling disc pack to allow completion of the #2 coupling installation using standard tools. THESE BEVELED WASHERS ARE NECESSARY AND MUST BE REINSTALLED AT A LATER TIME.

PR-407AC-120M Rev. 6, 11/30/2005

(iv) Move the #1 TR drive shaft and flywheel assembly toward the engine. This will allow use of a short socket to hold the bolt heads in the pulley recess.

(v) Complete installation of the nuts/bolts in the #2 coupling disc pack. Torque per BHT-407-MM-7 procedure.

(vi) Move the #1 TR drive shaft and flywheel assembly aft, and insert the previously removed beveled washers between the engine shaft flange and coupling disc pack.

WARNING: The beveled washers must be reinstalled per instructions in BHT-407-MM-7. Failure to insert the beveled washers may result in failure of the Tail Rotor drive shaft installation.

(vii) Complete coupling bolt installations in accordance with BHT-407-MM-7. Refer to Section 3.5 for installation of the compressor. Check bearing disc pack housing alignment in accordance with BHT-407-MM-7.

3.8 Condenser Removal Reference: Figure 2. Remove the screws from the louver panel installation on each side of the aircraft, above the condenser installation. Remove lower inspection cover. Disconnect electrical harness. Loosen and detach the inlet and outlet tube assemblies from the condenser. Remove the screws from the bottom circumference of the condenser. Turn the condenser assembly 180 degrees, to locate the inlet and outlet over the inspection cover, and remove the condenser.

3.9 Condenser Installation Reference: Figure 2. Install condenser with the inlet and outlet under inspection cover opening. Lift up into opening and rotate 180° to final position. Reinstall hardware to secure condenser. Reattach inlet and outlet tube assemblies and torque according to the torque list in Section 3.3. Reconnect electrical harness. Reinstall inspection cover. Reinstall louver panels and secure using existing hardware. NOTE: Lightly lubricate fittings with refrigerant oil before assembling. Tighten fittings in accordance with Torque specifications outlined in Section

.3. 3

3.10 Drier Bottle Removal Reference: Figure 6. Loosen tube assembly fittings from drier bottle installation and move the tubes away. Loosen screws in clamps and remove drier bottle. Remove switch wires from drier assembly.

3.11 Drier Bottle Installation Reference: Figure 6. Attach switch wires to the drier bottle. Reinstall the drier bottle into clamps and tighten. Reattach tubing and torque all loose and/or replaced fasteners and fittings per standardized torque values as shown in AC43-13.1, as revised. NOTE: A new drier bottle should be installed each time the system is discharged, or if any reason exists to believe that the dessicant is saturated. To avoid saturation of the desiccant, the caps should be left on the inlet and outlet of the drier until just prior to installation.

3.12 Evaporator Removal Reference: Figures 4(FWD) and/or 5(AFT). For forward or aft evaporator installations respectively, remove inlet and outlet line fittings. Remove evaporator from its brackets.

PR-407AC-120M Rev. 6, 11/30/2005

3.13 Evaporator – Installation

Reference: Figures 4(FWD and/or 5(AFT). Reinstall evaporator to the brackets and secure. Reinstall the inlet and outlet line fittings and torque in accordance with torque list in Section 3.3.

3.14 Electrical circuits, wiring Refer to BHT-407-MM-10 for acceptable practices during electrical repair procedures. Replace electrical components with equivalent units obtained from or approved by

aravion Technology, Inc. P

4.0 SYSTEM CHARGING

NOTE: Only trained and qualified personnel should service this system. Before draining or charging any refrigeration system read the safety precautions outlined in Section 2.1. If a previously charged system is low on refrigerant, the system should be checked for leaks. Repair procedures are outlined in Chapters 2.0 and 3.0 herein. Charge the Air Conditioning System according to the following procedures. 4.1 Charging An Evacuated System

The following instructions outline the procedures applicable to a manually operated refrigerant manifold/supply system. If automatic recovery/recycling/recharging equipment is used, follow manufacturer's recommendations for charging the system. 4.1.1 Air Conditioner System charging should be accomplished in an area where

the helicopter can be run for final charge determination. 4.1.2 Connect the service manifold and vacuum pump to the service fittings on

the compressor. 4.1.3 Turn on vacuum pump and open both valves to evacuate system for a

minimum of two hours. System absolute pressure, before charging, should be less than 1/2 in. Hg.

NOTE: Absolute pressure of 0.5 in Hg. corresponds to 29.4 in. Hg. VACUUM at sea level. The corresponding VACUUM pressure will drop approximately 1.02 in. Hg. (0.5 psi) per thousand feet of elevation.

4.1.4 When system evacuation is complete, first turn off both manifold valves. Then turn off the vacuum pump. Allow the system to set for (4) hours. If system vacuum does not remain constant, check all fittings and hoses for leaks.

4.1.5 Fill charging cylinder with at least 2.75 lbs. of HFC-134a liquid. Plug in heater and wait until pressure in the cylinder reaches 150-200 psig.

4.1.6 Connect the charging cylinder to the service manifold. Open the valve on the charging cylinder. Loosen the charging line connector at the service manifold to purge air from the line. Re-tighten connector. Open high pressure valve (at compressor discharge) on manifold, and watch for indication of pressure on low pressure gage (this proves that the expansion valves are opening.) Slowly open low pressure valve to increase charging rate. Initial charge of 1.0 lb. is recommended. Final charge determination should be accomplished with the helicopter running, and all evaporators in operation.

4.1.7 Use an electronic leak detector to check at each fitting assembly. If a leak is found, it must be corrected.

4.1.8 Ground-run the helicopter at 100% N2, and allow the Air Conditioning System to operate for 10 minutes to stabilize. NOTE: 1. Outside air temperature should be at least 75°F, and all doors

should be left open.

PR-407AC-120M Rev. 6, 11/30/2005

2. Add refrigerant until the temperature difference between inlet and outlet evaporator air is maximized. This temperature difference should be approximately 25°F.

4.1.9 Determine optimum refrigerant charge, with the Air Conditioner system in

operation, in the following steps: a. Measure the difference between evaporators inlet and outlet air temperatures

after stabilization at initial charge. b. Add a small amount of refrigerant, and allow the system to re-stabilize. c. Re-measure the difference between evaporators inlet and outlet air temperatures.

At this time the difference in temperatures will probably have increased. d. Repeat steps 4.1.9 until addition of refrigerant causes reduced temperature

difference between inlet and outlet airflow. This indicates that optimum refrigerant charge has been exceeded.

e. Recover the refrigerant overcharge. 4.1.10 Close Service Manifold valves, and disconnect both service lines being

careful to lose as little refrigerant as possible. Replace caps on service tees.

5.0 ADDING REFRIGERANT TO A PARTIAL EXISTING CHARGE

NOTE: Only trained and qualified personnel should service this system. A partial system charge can be restored to "full charge" without discharging and evacuating the system. This procedure is described below: 5.1 Check for and correct any leaks found in the system. 5.2 Connect the manifold system to the refrigerant tank and to the service fittings. The

connections at the service fittings should be loose. 5.3 Slowly open the tank valve and bleed air from between the tank and the service

manifold, tighten fittings. 5.4 Slowly open the manifold valves (2), allowing refrigerant to purge the air from the

lines. 5.5 Tighten the line fittings and close valve on manifold. 5.6 Follow steps 4.1.8 through 4.1.10 in Section 4.1 to optimize refrigerant and to

remove the charging equipment. CAUTION: A. To avoid tank rupture do not open the compressor discharge valve to

the freon tank. B. Avoid drawing liquid refrigerant into compressor suction port, this

may cause hydraulic lock and failure of the compressor.

6.0 SYSTEM LEAK CHECK

A system which contains a partial charge can be leak tested and recharged, without evacuating the system. A system which has been evacuated should be filled to a pressure of at least 50 psig, if using an electronic leak detector, or higher if using a detector solution. All leak checks should be conducted with the air conditioner "off". Since refrigerant is heavier than air, leaks are most likely detected on the underside of hoses and fittings. Refrigerant will collect in low areas and may provide an erroneous leak indication. The shop area should be well-vented prior to checking for leaks.

PR-407AC-120M Rev. 6, 11/30/2005

If a leak is detected at a fitting, check tightness and security of fitting, check for leaks again and if the fitting still leaks drain the system down. Clean, inspect for defects, and reseat the fitting. If a defective component or fitting is found, replace. Lubricate the fitting prior to reassembly. Reference Precautionary Information in Section 2.7 Plumbing Installation. A small amount of leakage (one ounce per year. past the compressor shaft seal is normal. Most leak detectors are sensitive enough to show a leak of this magnitude. 6.1 Special Tools and/or Equipment Required

The following tools and/or equipment are required to leak check a refrigerant plumbing system. NOTE: These instructions give procedures applicable to a manually operated

refrigerant manifold/supply system. If automatic recovery/recycling/ recharging equipment is used follow equipment manufacturer's recommendations.

6.1.1 Gaseous dry nitrogen, regulated source (0-500 psig). 6.1.2 R-134a refrigerant charging manifold with gauges and hoses. 6.1.3 Leak check fluid, (soap solution). 6.1.4 Assorted hand tools. 6.1.5 Hand and eye protection. 6.1.6 Thread sealant, P/N 55431 (Loctite).

6.2 Procedure 6.2.1 Remove all shrouds, panels, flooring and any other covering, which

prevents access to refrigerant fittings, connections or components. 6.2.2 Verify all aircraft and/or ground power is off. 6.2.3 Remove service port caps from the A/C system. The high and low pressure

service ports are located on the compressor suction header. 6.2.4 Close all manifold gauge valves and verify hose connections are tight. 6.2.5 Connect R-134a refrigerant charging manifold. R-134a service gauges

contain quick-connect fittings to minimize refrigerant loss. To install quick-connect, push on firmly until locked (a “clicking” sound is heard). Hold the grip ring an pull to remove quick-connect fittings.

6.2.6 Connect yellow charging hose to a regulated dry nitrogen source. Note: An adapter is required to connect yellow charging hose to the nitrogen source.

6.2.7 Regulate nitrogen source to a pressure of 200 PSIG maximum. CAUTION: Do not exceed 200 psi nitrogen pressure during leak check

procedure or damage to expansion valve will result. 6.5.8 Verify all plumbing connections are tight. 6.5.9 Slowly open high pressure (red) manifold valve and allow system pressure

to increase gradually until a pressure of 200 psig is achieved. Allow time for system pressure to equalize across expansion valve and note final system pressure. CAUTION: During this procedure protective eye wear and gloves should

be worn to prevent operator injury. 6.5.10 Apply soapy leak check fluid to each connection to locate leaks.

CAUTION: Do not use any leak dye in R-134a system or damage to system may result.

6.5.11 Use thread sealant on all male fitting threads (sparingly), staying off the first two (2) threads near sealing surface. A light coating of R-134a refrigerant oil must be applied to flare to prevent metal galling damage. CAUTION: Do not apply oil to fitting threads.

PR-407AC-120M Rev. 6, 11/30/2005

6.5.12 Tighten joints as required to stop leaks. Reference Table I.

CAUTION: Do not over tighten plumbing connections. Stripped threads or cracked flares may result.

6.5.13 With system leak tight, turn off nitrogen source, disconnect yellow charging hose from source and slowly release nitrogen pressure to zero. CAUTION: Vent system pressure very slowly to assure that compressor

oil is not vented with the nitrogen. Do not let air enter the system.

6.5.14 Evacuate system to prepare for charging. 6.5.15 Close manifold valve.

PR-407AC-120M Rev. 6, 11/30/2005

7.0 FIGURES

PR-407AC-120M Rev. 6, 11/30/2005

THIS PAGE INTENTIONALLY BLANK

PR-407AC-120M

Rev. 6, 11/30/2005

Figure 1: Air Conditioning System Configuration Reference Installation Drawings: 1) 407AC-210, Condenser Install

2) 407AC-310, Compressor Installation 3) 407AC-410, Forward Evaporator Installation 4) 407AC-460, Aft Evaporator Installation 5) 407AC-510, Air Conditioning Plumbing 6) 407AC-610, Electrical Installation

PR-407AC-120M Rev. 6, 11/30/2005

Figure 2: Condenser Installation (sheet 1 of 2)

Parts List For Figure 2, Sheet 1

ITEM NO PN DESCRIPTION QTY TYP 1 206AC-2110-1 CONDENSER ASSEMBLY 1 EA 2 206AC-2610-1 FASTENER STRIP ASSEMBLY 1 EA 3 206AC-2610-2 FASTENER STRIP ASSEMBLY 1 EA 4 CT4B TYRAP 6 EA 5 MS20426AD3-4 RIVET 2 EA 6 MS21059L3 NUT PLATE 1 EA 7 MS35207-265 SCREW 8 EA 8 NAS1149F0332P WASHER 8 EA 9 NSF-51-3/8 X 1/2 HOSE 6 FT

PR-407AC-120M

Rev. 6, 11/30/2005

Figure 2: Condenser Installation (sheet 2 of 2)

Parts List For Figure 2, Sheet 2 ITEM NO PN DESCRIPTION QTY TYP 1 206AC-2511-3 LOUVER PLATE 1 EA SIDE 2 206AC-2512-1 FASTENER PLATE 2 EA SIDE 3 206AC-2512-2 FASTENER PLATE 2 EA SIDE 4 MS35206-247 SCREW 22 EA SIDE 5 NAS1149FN816P WASHER 22 EA SIDE

PR-407AC-120M Rev. 6, 11/30/2005

Figure 3: Compressor Installation (Sheet 1 of 6)

Parts List For Figure 3, Sheet 1 ITEM NO PN DESCRIPTION QTY TYP 1 130012 CINCH NUT 4 EA 2 206AC-3510-3 SUPPORT 1 EA 3 206AC-3512-1 SUPPORT ANGLE 1 EA 4 206AC-3512-2 SHIM(USBL FOR -4 INST'N ) 1 EA 5 407AC-3020-1 MOUNT BRACKET ASSEMBLY 1 EA 6 CR3553-4-3 RIVET 11 EA 7 CR3553-4-4 RIVET(USBL FOR -4 INST'N ) 8 EA (USBL FOR -2, -3 INST'N ) 1 EA. 8 CR3553-4-2 RIVET(USBL FOR -2, -3 INST'N ) 7 EA 9 407AC-3520-1 SPACER 1 EA 10 MS27039-1-15 SCREW 4 EA 11 AN3-5A BOLT 4 EA 12 NAS1149F0463P WASHER 8 EA

PR-407AC-120M

Rev. 6, 11/30/2005


Parts List For Figure 3, Sheet 2 ITEM NO PN DESCRIPTION QTY TYP 1 206AC-3525-5 RESTRAINT 1 EA 2 206AC-3525-6 RESTRAINT 1 EA 3 206AC-3526-2 TENSIONER 1 EA 4 206AC-3610-1 PLACARD 1 EA 5 407AC-3110-1 COMPRESSOR ASSEMBLY 1 EA 6 AN316-4 NUT 2 EA 7 AN6H-6A BOLT 2 EA 8 AN6H-7A BOLT 2 EA 9 MS21042L4 NUT 1 EA 10 MS35489-4 GROMMET 1 EA 11 NAS1149F0463P WASHER 1 EA 12 NAS1149F0632P WASHER 4 EA

PR-407AC-120M Rev. 6, 11/30/2005


Parts List For Figure 3, Sheet 3 ITEM NO PN DESCRIPTION QTY TYP 1 407AC-2900-1 STRUT SUPPORT 2 EA 2 407AC-3010-1 PULLEY 1 EA 3 ES10600-2 DRIVE BELT 1 EA 4 MS21250-05-018 BOLT 2 EA 5 MS24665-153 COTTER PIN 1 EA 6 NAS6604D56 BOLT 1 EA

PR-407AC-120M

Rev. 6, 11/30/2005


Parts List For Figure 3, Sheet 4 ITEM NO PN DESCRIPTION QTY TYP 1 407AC-2900-1 STRUT SUPPORT 2 EA 2 407AC-3010-1 PULLEY 1 EA 3 ES10600-2 DRIVE BELT 1 EA 4 MS21250-05-018 BOLT 2 EA 5 MS24665-153 COTTER PIN 1 EA 6 NAS6604D56 BOLT 1 EA

PR-407AC-120M Rev. 6, 11/30/2005

Figure 3: Compressor Installation (Sheet 5 of 6) APPLICABLE TO AIRCRAFT S/N 53001 - 53579 BEFORE TB 407-03-53 COMPLIANCE NOTE: WHEN TECHNICAL BULLETIN 407-03-53 IS INCORPORATED, 407AC-310-4

INSTALLATION IS REQUIRED.

Parts list for Figure 3, Sheet 5 ITEM NO PN DESCRIPTION QTY TYP 1 407AC-2900-1 STRUT SUPPORT 2 EA 2 350CM-2900-2 BRACKET 2 EA 3 369IR-1002-1 STRUT ASSEMBLY 2 EA 4 AN3-5A BOLT 2 EA 5 AN3-11A BOLT 2 EA 6 AN3-10A BOLT 2 EA. 7 NAS6604D56 BOLT 1 EA 8 AN970-3 WASHER 1 EA 9 NAS1149C0363R WASHER 5 EA 10 NAS1149F0332P WASHER 23 EA 11 NAS1149F0363P WASHER 4 EA 12 MS21042L3 NUT 11 EA 13 MS24665-153 COTTER PIN 1 EA

PR-407AC-120M

Rev. 8, 02/02/2009

Figure 3: Compressor Installation (Sheet 6 of 6) APPLICABLE TO MODEL 407 S/N53001-53579 AFTER COMPLIANCE TO TB 407-03-53 MODEL 407 S/N53580 AND SUBSEQUENT

Parts list for Figure 3, Sheet 6 ITEM NO PN DESCRIPTION QTY TYP 1 350CM-2900-2 BRACKET 2 EA 2 350CM-1010-1 STRUT ASSEMBLY 2 EA. 3 AN3-4A BOLT 2 EA 4 AN3-10A BOLT 2 EA 5 AN3-7A BOLT 2 EA 6 NAS1149CO363R WASHER 2 EA 7 NAS1149FO332P WASHER 10 EA. 8 NAS1149FO363P WASHER 4 EA. 9 MS21042L3 NUT 6 EA

PR-407AC-120M Rev. 6, 11/30/2005

Figure 4: Forward Evaporators Installation (Sheet 1 of 3)

CONFIGURATION (Right-Hand Side Installation, opposite)

PR-407AC-120M

Rev. 6, 11/30/2005


Parts list for Figure 4, Sheet 2 ITEM NO PN DESCRIPTION QTY TYP

1 407AC-4110-1 EVAPORATORS ASSEMBLY 1 EA 2 407AC-4110-2 EVAPORATORS ASSEMBLY 1 EA 3 407AC-4111-1 BEAM 1 EA 4 407AC-4111-2 BEAM 1 EA 5 407AC-4111-3 ANGLE 1 EA 6 ES49008-2 ELBOW 2 EA 7 MS21042L3 NUT 5 EA 8 MS35207-266 SCREW 2 EA 9 MS35207-264 SCREW 7 EA 10 NAS1149F0363P WASHER 14 EA 11 NSF-511-3/8 X 1/2 DRAIN HOSE 35 IN

PR-407AC-120M Rev. 8, 02/02/2009

Fig. 4A: Plenum Assy Configuration Fig. 4B: OPTIONAL Plenum Assy Config.


Parts list for Figure 4, Sheet 3

Fig 4A Fig 4B ITEM NO PN DESCRIPTION QTY QTY TYP 1 206AC-4300-1 OPT. PLENUM ASSEMBLY (LEFT) - 1 EA 2 206AC-4300-2 OPT. PLENUM ASSEMBLY (RIGHT) - 1 EA 8 CAT-12 DUCT 96 48 IN 9 MS3367-7-0 TIE WRAP 4 4 EA 17 AN525-10R10 SCREW 10 - EA 18 NAS1329A3K80 RIVNET 10 - EA 19 MS21919WDG48 ADEL CLAMP 2 - EA 20 206AC-4300-3 PLENUM ASSEMBLY 2 - EA

PR-407AC-120M

Rev. 7, 08/01/2006

Figure 5: Aft Evaporator Installation (Sheet 1 of 4)


ITEM NO PN DESCRIPTION QTY TYP 1 206AC-4560-1 BRACKET 2 EA 2 206AC-4560-3 SHIM 2 EA 3 206AC-4600-2 EVAP. ASSY (Shown, USBL on S/N 7, Subs.) 1 EA 206AC-4600-1 EVAP. ASSY (USBL on S/N 1 - 6) 1 EA. 4 AN3-3A BOLT 4 EA 5 MS20364-1032 NUT 4 EA 6 MS20470AD4-5 RIVET 10 EA 7 MS20470AD4-6 RIVET 2 EA 8 NAS1149D0332J WASHER 4 EA

9 ES00140-3 GROMMET(USBL on S/N 7, Subs.) 8 IN. 10 ES49008-2 ELBOW(USBL on S/N 7, Subs.) 1 EA. 11 CT4B TYRAP(USBL on S/N 7, Subs.) 10 EA. 12 MS35489-14 GROMMET(USBL on S/N 7, Subs.) 1 EA. 13 NSF-51-3/8 X1/2 HOSE(USBL on S/N 7, Subs.) 17 FT. 14 MS35207-268 SCREW(USBL on S/N 7, Subs.) 1 EA. 15 ES39450-1 HOSE CLAMP(USBL on S/N 7, Subs.) 1 EA. 16 NAS1149F0332P WASHER(USBL on S/N 7, Subs.) 2 EA.

PR-407AC-120M Rev. 7, 08/01/2006


Parts list for Figure 5, Sheet 2 ITEM NO PN DESCRIPTION QTY TYP 1 CAT-24 DUCT 6 IN 2 CT4B TYRAP 3 EA 3 CT6B TYRAP 3 EA 4 ES39450-1 HOSE CLAMP 3 EA 5 ES49008-2 ELBOW 1 EA 6 MS21042L3 NUT 3 EA 7 MS35207-264 SCREW 3 EA 8 MS35489-14 GROMMET 1 EA 9 NAS1149F0332P WASHER 3 EA 10 NSF-51-3/8 X 1/2 HOSE 36 IN 11 ES49008-3 TEE(USBL on S/N 7, Subs.) 1 EA.

PR-407AC-120M

REV. 6, 11/30/2005


Parts list for Figure 5, Sheet 3 ITEM NO PN DESCRIPTION QTY TYP 1 1624-0411 RIVET 4 EA 2 206AC-4510-1 FRAME 1 EA 3 206AC-4510-2 FRAME 1 EA 4 206AC-4510-3 SCREEN 1 EA 5 206AC-4510-4 FILTER 1 EA 6 206AC-4550-1 DUCT ADAPTER 2 EA 7 206AC-4550-3 DUCT ADAPTER 1 EA 8 MS20364-1032 NUT 12 EA 9 AN525-10R8 SCREW 12 EA 10 ES6100-2-1 HOOK TAPE 30 IN 11 ES6100-2-2 LOOP TAPE 30 IN 12 NAS1149D0332J WASHER 12 EA

PR-407AC-120M REV. 6, 11/30/2005


Parts list for Figure 5, Sheet 4 ITEM NO PN DESCRIPTION QTY TYP 1 1624-0411 RIVET 8 EA 2 206AC-4620-2 PLENUM 1 EA 3 CAT 10 DUCT 52 IN 4 CAT 12 DUCT 10 IN 5 CT11B TYRAP 6 EA 6 ES72140-1 DUCT ADAPTER 2 EA 7 MS21919WDG-40 CLAMP 1 EA 8 MS27039-1-15 SCREW 1 EA 9 NAS44DD3-32 SPACER 1 EA

PR-407AC-120M

REV. 6, 11/30/2005

Figure 6: Plumbing Installation (Sheet 1 of 12)

PR-407AC-120M Rev. 8, 02/02/2009


Parts list for Figure 6, Sheet 2 ITEM NO PN DESCRIPTION QTY TYP 1 407AC-5017-1 TUBE ASSEMBLY (S/N: 53000 - 53754) 1 EA 407AC-5017-1A TUBE ASSEMBLY (S/N: 53755 & SUBS) 1 EA 2 407AC-5200-2 HOSE ASSEMBLY 1 EA 3 407AC-5200-4 HOSE ASSEMBLY 1 EA 4 407AC-5300-1 FITTING 1 EA 5 407AC-5510-1 STIFFENER 1 EA 6 407AC-5510-2 STIFFENER 1 EA 7 AN832-8D BULKHEAD FITTING 1 EA 8 AN924-12D NUT 1 EA

9 AN924-8D NUT 1 EA

PR-407AC-120M

Rev. 6, 11/30/2005


Parts list for Figure 6, Sheet 3 ITEM NO PN DESCRIPTION QTY TYP 1 AN815-6D UNION 1 EA 2 AN815-8D UNION 1 EA 3 AN832-8D FITTING 1 EA 4 AN924-8D NUT 1 EA 5 MS21042L3 NUT 1 EA 6 MS21919WDG-11 NUT 1 EA 7 MS21919WDG-13 CLAMP 2 EA 8 MS35207-264 SCREW 2 EA 9 NAS1149F0363P WASHER 3 EA 10 NAS43DD3-16 CLAMP 1 EA

PR-407AC-120M Rev. 6, 11/30/2005



ITEM NO PN DESCRIPTION QTY TYP 1 407AC-5019-1 TUBE ASSEMBLY 1 EA 2 407AC-5019-2 TUBE ASSEMBLY 1 EA 3 461-537 ELBOW 1 EA 4 AN743-12 ANGLE 1 EA 5 AN824-6D TEE 1 EA 6 AN833-6D BULKHEAD 90º ELBOW 1 EA 7 AN924-6D NUT 1 EA 8 ES43050-2 DRIER BOTTLE 1 EA 9 MS21042L3 NUT 6 EA 10 MS21919WDG11 CLAMP 3 EA 11 MS21919WDG4 CLAMP 2 EA 12 MS21919WDG40 CLAMP 2 EA 13 MS35207-262 SCREW 2 EA 14 MS35207-263 SCREW 2 EA 15 MS35207-266 SCREW 2 EA 16 NAS1149F0363P WASHER 12 EA 17 NAS43DD3-16 SPACER 2 EA

PR-407AC-120M

Rev. 6, 11/30/2005



ITEM NO PN DESCRIPTION QTY TYP

1 0603-12-8S REDUCER ASSEMBLY 1 EA 2 407AC-5020-1 TUBE ASSEMBLY 1 EA 3 AN821-8D ELBOW 1 EA 4 AN824-12D TEE 1 EA

PR-407AC-120M Rev. 6, 11/30/2005




1 AN815-6D UNION 1 EA 2 MS21042L3 NUT 2 EA 3 MS21919WDG11 CLAMP 2 EA 4 MS21919WDG12 CLAMP 1 EA 5 MS35207-263 SCREW 3 EA 6 NAS1149F0363P WASHER 3 EA

PR-407AC-120M

Rev. 6, 11/30/2005



1 407AC-5017-2 TUBE ASSEMBLY 1 EA 2 407AC-5017-3 TUBE ASSEMBLY 1 EA 3 AN815-12D UNION 2 EA 4 MS21042L3 NUT 2 EA 5 MS21919WDG11 CLAMP 3 EA 6 MS21919WDG13 CLAMP 3 EA 7 MS35207-264 SCREW 3 EA 8 MS35207-265 SCREW 2 EA 9 NAS1149F0363P WASHER 5 EA 10 NAS43DD3-23 SPACER 2 EA

PR-407AC-120M Rev. 6, 11/30/2005



ITEM NO PN DESCRIPTION QTY TYP 1 0603-6-4 REDUCER 2 EA 2 20621-6-6 3/8” FEMALE SWIVEL 2 EA 3 285-6 5/16” HOSE 78 IN 4 AN821-6D 90º ELBOW 2 EA 5 AN824-6D TEE 1 EA 6 MS21042L3 NUT 1 EA 7 MS21919WDG10 CLAMP 1 EA 8 MS21919WDG16 CLAMP 1 EA 9 MS35207-265 SCREW 1 EA 10 NAS1149F0332P WASHER 2 EA 11 NAS43DD3-16 SPACER 1 EA

PR-407AC-120M

Rev. 6, 11/30/2005




1 20621-12-12 ¾” FEMALE SWIVEL 2 EA 2 285-12 5/8” HOSE 78 IN 3 407AC-5300-3 FITTING 1 EA 4 AN743-12 ANGLE 1 EA 5 MS21042L3 NUT 1 EA 6 MS21919WDG14 CLAMP 1 EA 7 MS21919WDG16 CLAMP 2 EA 8 MS35207-265 SCREW 2 EA 9 NAS1149F0332P WASHER 2 EA 10 NAS1149F0363P WASHER 1 EA 11 NAS43DD3-16 SPACER 1 EA

PR-407AC-120M Rev. 6, 11/30/2005



1 AN743-12 ANGLE 1 EA 2 AN815-12D UNION 1 EA 3 CT7B TYRAP 2 EA 4 GM-32 CATERPILLAR GROMMET 4 IN 5 MS21042L3 NUT 4 EA 6 MS21919WDG10 CLAMP 2 EA 7 MS21919WDG13 CLAMP 1 EA 8 MS21919WDG16 CLAMP 2 EA 9 MS35207-264 SCREW 1 EA 10 MS35207-265 SCREW 2 EA 11 NAS1149F0332P WASHER 5 EA 12 NAS43DD3-16 SPACER 2 EA

PR-407AC-120M

Rev. 6, 11/30/2005



1 4-C6X-S 90° ELBOW 1 EA 2 AN821-8D 90° ELBOW 1 EA

PR-407AC-120M Rev. 6, 11/30/2005



ITEM NO PN DESCRIPTION QTY TYP 1 0.250 X 0.035 WALL 1/4” DIA. TUBE, 5052-0 AL TUBING 3 FT 2 0.375 X 0.035 WALL 3/8” DIA. TUBE, 5052-0 AL TUBING 25 FT 3 0.500 X 0.035 WALL 1/2” DIA. TUBE, 5052-0 AL TUBING 9 FT 4 AN818-4D NUT 2 EA 5 AN818-6D NUT 2 EA 6 AN818-8D NUT 2 EA 7 AN819-4D SLEEVE 2 EA 8 AN819-6D SLEEVE 2 EA 9 AN819-8D SLEEVE 2 EA 10 BH-7 FIRESLEEVE (3/8” DIA.) 25 FT 11 BH-9 FIRESLEEVE (1/2” DIA.) 6 FT 12 ES39500-1 FERRULE NONE N/A 13 ES39501-1 FERRULE 2 EA

PR-407AC-120M

Rev. 7, 08/01/2006

Figure 7: Electrical Installation (Sheet 1 of 3)

PR-407AC-120M Rev. 7, 08/01/2006

Figure 7: Electrical Installation (Sheet 2 of 3)

PR-407AC-120M

Rev. 7, 08/01/2006 Parts list for Figure 7


1 206AC-6120-1 PLACARD 1 EA 2 3 4 407AC-6110-2 JUMPER 2 EA 5 407AC-6110-1 JUMPER 2 EA 6 407AC-6112-1 FUSE HOLDER ASSY 3 EA 7 407AC-6114-1 WIRE BUNDLE ASSY 1 EA 8 407AC-6114-2 WIRE BUNDLE ASSY 1 EA 9 407AC-6116-1 WIRE ASSY 1 EA 10 407AC-6117-1 WIRE BUNDLE ASSY 1 EA 11 407AC-6118-1 DIODE ASSY 1 EA 12 407AC-6119-1 WIRE ASSY 1 EA 13 5A446 CONNECTOR, KNIFE 2 EA 14 AGC-10 FUSE (10 AMP) 1 EA 15 CT4B TYRAP 3 EA 16 ES50240-1 FEMALE TERMINAL 9 EA 17 ES50240-2 MALE TERMINAL 9 EA 18 ES50243-1 FEMALE MOLEX CONNECTOR 3 EA 19 ES50530-2 SWITCH (DPDT) 1 EA 20 KTN 50 CONNECTOR, PUSH-ON 2 EA 21 MS14105-35 BREAKER 1 EA 22 MS21042L08 NUT 5 EA 23 MS24523-23 SWITCH (SPDT) 2 EA 24 MS25036-107 TERMINAL 2 EA 26 MS25036-149 TERMINAL 2 EA 27 MS25036-153 TERMINAL 3 EA 28 MS25036-156 TERMINAL 2 EA 29 MS35206-245 SCREW 5 EA 30 MS35489-4 GROMMET 1 EA 31 MS50243-2 MALE MOLEX CONNECTOR 3 EA 32 NAS1149FN832P WASHER 5 EA 33 SFE-20 FUSE (20 AMP) 1 EA 34 M7928/5-4 BLUE-WINDOW SPLICE 1 EA. 35 VT-4 TUBE, INSULATION 3 IN 36 AGC-10 FUSE, 10-amp (Condenser Assy S/N 1 - 17) 1 EA AGC-15 FUSE, 15-amp (Condenser Assy S/N 18, Subs.) 1 EA

PR-407AC-120M REV. 6, 11/30/2005

Figure 8: Placards

Parts list for Figure 8 ITEM NO PN DESCRIPTION QTY TYP

1 206AC-3610-1 PLACARD 1 EA. 2 206AC-6120-1 PLACARD 1 EA.

PR-407AC-120M

Rev. 6, 11/30/2005

APPENDIX A

STANDARD TORQUE VALUE CHART

These charts removed

Torque all loose and/or replaced fasteners and fittings per standardized torque values as shown in AC43-13.1, as revised.

PR-407AC-120M Rev. 6, 11/30/2005

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PR-407AC-120M

Rev. 6, 11/30/2005

APPENDIX B

ANNUAL/300HR INSPECTION CHECKLIST

Annual/300 Hour Inspection Checklist

INSPECTION COMMENTS INITIALS 1. Check all electrical wires and

connections for chafing and security.

2. Check electrical operation of the entire system.

3. Check all fittings, fasteners, and components for security. If necessary, torque per appropriate section, Appendix A or Section 3.3.

4. Check compressor drive belt for wear and tension.

5. Check system operating temperatures. It is generally not necessary to inspect for system leakage, or to adjust the refrigerant volume if the evaporators produce a temperature drop of 25°F or greater.

6. Verify placard installation and condition.

* Refer to Table I (Troubleshooting) if any system malfunctions occur.

PR-407AC-120M Rev. 6, 11/30/2005

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