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New system plumbing installation
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Component replacement in the plumbing system
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Line or hose rupture
3.5.2.1
Remove, if required, all panels, doors, shrouds, etc, to gain access to system/component being leak checked (refer to aircraft maintenance manual).
3.5.2.2
Remove, if required, any enclosures or access doors to expose all tubing, hoses, fittings, etc. to the system components.
3.5.2.3
Verify all plumbing connections are tight.
3.5.2.4
Verify that power is removed from aircraft. If it is not practical to remove aircraft power, technician must pull and collar applicable circuit breakers.
CAUTION: HIGH PRESSURE HOSE (RED) IS CONNECTED TO PORT MARKED “D” AND THE LOW PRESSURE HOSE (BLUE) IS CONNECTED TO THE SERVICE PORT MARKED “S”. INCORRECT CONNECTION COULD RESULT IN MANIFOLD DAMAGE AND/OR INCORRECT PRESSURE READINGS.
3.5.2.5
Remove service port caps from the A/C system. The high pressure service port is located on the receiver-dryer and low pressure service port is located on the compressor suction header.
3.5.2.6
Close all manifold gauge valves and verify hose connections are tight.
Component Maintenance Manual
12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
http://www.enviro-ok.com
EFFECTIVITY: ALL 21-00-09
Page 1005
FEBRUARY 16, 2010
3.5.2.7
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 and pull to remove quick-connect fittings.
3.5.2.8
Connect yellow charging hose to a regulated dry nitrogen source
NOTE: An adapter is required to connect yellow charging hose to the nitrogen source.
CAUTION: DO NOT EXCEED 200 PSIG NITROGEN PRESSURE DURING PROCEDURE OR DAMAGE TO EXPANSION VALVE WILL RESULT.
3.5.2.9
Regulate nitrogen source to a pressure of 200 PSIG maximum.
3.5.2.10
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: DO NOT USE ANY LEAK DYE IN R-134a SYSTEM OR DAMAGE TO SYSTEM MAY RESULT.
CAUTION: DO NOT OVER TIGHTEN PLUMBING CONNECTIONS. STRIPPED THREADS OR CRACKED FLARES MAY RESULT.
3.5.2.11
Apply soapy leak check fluid to each fitting connection. If leaks are detected, attempt to tighten fitting without over tightening. If leak cannot be corrected with tightening, system must be evacuated (refer to Servicing, Section 13) and then fitting must be disconnected and new thread sealant and loctite primer applied.
3.5.2.12
Using a wire brush and cleaning solvent, completely remove old thread sealant. Apply a thin layer of thread sealant primer to fitting threads.
CAUTION: WHEN APPLYING THREAD SEALANT, TAKE EXTREME CARE TO KEEP SEALANT OFF FIRST 2 OR 3 THREADS.
3.5.2.13
Apply thread sealant on all male fitting threads sparingly.
CAUTION: WHEN APPLYING R-134a OIL TO FLARE AND O-RING, TAKE EXTREME CARE TO KEEP OIL AWAY FROM FITTING THREADS
3.5.2.14
Apply a light coating of R-134a refrigerant oil to flare and/or o-ring to prevent metal galling or o-ring damage.
3.5.2.15
Tighten joints as required to stop leaks (refer to Table 1, Section 1.3 for torque values).
CAUTION: VENT SYSTEM PRESSURE VERY SLOWLY TO ASSURE COMPRESSOR OIL IS NOT VENTED WITH THE NITROGEN. DO NOT LET AIR ENTER THE SYSTEM.
Component Maintenance Manual
12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
http://www.enviro-ok.com
EFFECTIVITY: ALL 21-00-09
Page 1006
FEBRUARY 16, 2010
3.5.2.16
After leak check is finished and system integrity is sound, turn off nitrogen source, disconnect yellow charging hose from nitrogen source and slowly release nitrogen pressure to zero.
3.5.2.17
Close manifold valve.
3.5.2.18
System is now ready for charging (refer to Servicing, Section 13).
SUBTASK 21-00-09-81-001
3.6
Fault Isolation (trouble shooting):
3.6.1
The following list of system/component failures and/or abnormal operation and possible solutions is only a partial listing of what may occur. The more informed service personnel are in the operation of the system and its various components, the less time will be required to diagnose failures. Use this trouble shooting list as well as all information contained in this manual, to aid in diagnosing system faults. Contact Enviro Systems customer service for any items not listed in this trouble shooting list.
NOTE: Refer to Refrigerant Flow (Figure 2) and Electrical Schematic (Figure 3), Section 4.
　
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