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

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PR-407AC-120M
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PR-407AC-120M
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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LIST OF EFFECTIVE PAGES

PAGE NO. REVISION DATE PAGE NO. REVISION DATE

COVER 8 02/02/2009 24 6 11/30/2005
COVER 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
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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
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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
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PR-407AC-120M
Rev. 8, 02/02/2009

AIRWORTHINESS 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
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1.0 SYSTEM DESCRIPTION

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
forced through them by the fan. The refrigerant is then returned to the compressor.
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
rpm for the forward and aft evaporators.
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.
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2.1 Safety Precautions

The refrigerant used in the air conditioner system is HFC-134a. Other refrigerants,
such as R-12, must not be introduced into the system.
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
present when using refrigerant.
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.
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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.
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TABLE I
TROUBLESHOOTING PROCEDURES

INDICATION PROBABLE CAUSE POSSIBLE SOLUTION

A. No system power 1. Gnd power not connected 1. Plug in gnd power cart
2. Aircraft power switch off 2. Energize power switch
B. Power on but system will not 1. Air cond. Circ.Brkr. off 1. Energize aircond. Circ.Brkr.
operate 2. Air cond. Circ.Brkr. failed 2. Replace
3. Aircond. mode SW failed 3. Replace
4. Vented system 4. Press. Check, evacuate and
charge system
C. System operates but does not 1. Low refrig. Charge 1. Charge as required
cool. 2. Overcharged system cutout (Hi- 2. Reclaim refrig. As required
Low Switch) 3. Replace
3. Failed compressor 4. Replace
4. Broken belt 5. Replace
5. Failed expansion valve(s) 6. Replace
6. Evap. blower switch(s) failed 7. Replace
7. Evap. blower(s) motor failed 8. Replace
8. Evap. blower(s) fuses blown 9. Remove debris
9. Evap. module air inlet clogged 10. Remove debris
10. Ex. valve inlet clogged 11. Replace rec-dryer assy
11. Excessive moisture in system 12. Drain excessive oil
12. Excessive oil in system
D. Evaporator noisy 1. Blower Wheel hitting scroll 1. Replace
2. Defective blower motor bearing 2. Replace motor
3. Air inlet clogged 3. Remove debris
E. No low evap. fan speed (hi 1. Failed switch 1. Replace
speed ok) 2. Failed resistor 2. Replace
F. No evaporator(s) air flow 1. Circ.Brkr. off 1. Turn on
2. Circ.Brkr. failed 2. Replace
3. Mode SW failed 3. Replace
4. Fan speed SW failed 4. Replace
5. Seized motor(s) 5. Replace
6. Blower wheel failed 6. Replace
7. Blocked air outlet duct 7. Remove debris
8. Blocked air inlet duct 8. Remove debris
9. Aircraft power not on 9. Turn on
10. Ground power not on 10. Turn on

(CONTINUED, NEXT PAGE)

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PR-407AC-120M
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TABLE I (Cont’d)
TROUBLESHOOTING PROCEDURES

INDICATION PROBABLE CAUSE POSSIBLE SOLUTION

G. Evap. module coil freezing 1. Expansion valve failed or 1. Remove debris or replace
clogged 2. Reset to obtain 26-30 suction
2. Expansion valve setting low pressure
H. Pressure switch cycles (high 1. System over charged 1. Reclaim refrig. As required
press. Cutout) 2. Cond. coil inlet air extremely 2. Normal condition
hot 3. Remove debris
3. Cond. inlet clogged 4. Replace hose
4. Discharge line clogged or 5. Normal condition
kinked
5. Excessively high ambient
temperature
I. Compressor will not operate 1. Circ.Brkr. failed on off 1. Turn on or replace
2. Hi-Lo pressure switch failed 2. Replace Hi-Lo switch
3. Broken clutch power wire 3. Replace wire
4. Low refrigerant charge 4. Re-charge system
5. Loose belt tension or broken 5. Tighten or replace belt
belt 6. Replace compressor
6. Clutch failure
J. Drive Belt Failure 1. Worn or deteriorated belt 1. Replace
2. Improper belt tension 2. Follow correct belt tension
3. Poor belt alignment procedure
4. System over charge 3. Re-align compressor
5. Compressor failure 4. Recharge system
5. Replace
K. Condensor Fan will not run 1. No power to condenser 1. Turn on system power or
2. Fan motor failed Circ.Brkr.
3. Poor ground 2. Replace fan assembly
4. Broken power wire 3. Properly ground fan
4. Replace wire
L. Condenser Fan Noisy 1. Retainer clip broken 1. Replace clip and damaged
2. Exhaust screen bent or loose components
2. Replace or straighten screen
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PR-407AC-120M
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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 13.2 15.5 0.40 13.2 15.50 0.40

EVAPORATORS

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

FASTENERS

* 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.
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PR-407AC-120M
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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
REPLACED IN THE SYSTEM PRIOR TO RECHARGING.
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.
Reinstall and tighten clamps and attaching hardware.
NOTE: Apply a light film of refrigerant oil to the mating surfaces of
flare fittings before assembly. Tighten fittings according to the
following chart.
Tube O.D. Torque
( in.) (ft-lb)
1/4 11-15
3/8 18-25
1/2 36-45
3/4 71-97
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PR-407AC-120M
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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
of operation.
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
fan shaft.
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.
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(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.
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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
Paravion Technology, Inc.
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.
Page 12
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.
 Page 13
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.
Page 14
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.
 Page 15
PR-407AC-120M
Rev. 6, 11/30/2005

7.0 FIGURES
Page 16
PR-407AC-120M
Rev. 6, 11/30/2005

THIS PAGE INTENTIONALLY BLANK

 Page 17
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
Page 18
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
 Page 19
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
Page 20
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
 Page 21
PR-407AC-120M
Rev. 6, 11/30/2005

Figure 3: Compressor Installation (Sheet 2 of 6)

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
Page 22
PR-407AC-120M
Rev. 6, 11/30/2005

Figure 3: Compressor Installation (Sheet 3 of 6)

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
 Page 23
PR-407AC-120M
Rev. 6, 11/30/2005

Figure 3: Compressor Installation (Sheet 4 of 6)

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
Page 24
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
 Page 25
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
Page 26
PR-407AC-120M
Rev. 6, 11/30/2005

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

CONFIGURATION
(Right-Hand Side Installation, opposite)
 Page 27
PR-407AC-120M
Rev. 6, 11/30/2005

Figure 4: Forward Evaporators Installation (Sheet 2 of 3)

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
Page 28
PR-407AC-120M
Rev. 8, 02/02/2009

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

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

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
 Page 29
PR-407AC-120M
Rev. 7, 08/01/2006

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

Parts list for Figure 5, Sheet 1

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.
 Page 30
PR-407AC-120M
Rev. 7, 08/01/2006

Figure 5: Aft Evaporator Installation (Sheet 2 of 4)

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.
 Page 31
PR-407AC-120M
REV. 6, 11/30/2005

Figure 5: Aft Evaporator Installation (Sheet 3 of 4)

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
Page 32
PR-407AC-120M
REV. 6, 11/30/2005

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

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
 Page 33
PR-407AC-120M
REV. 6, 11/30/2005

Figure 6: Plumbing Installation (Sheet 1 of 12)

Page 34
PR-407AC-120M
Rev. 8, 02/02/2009

Figure 6: Plumbing Installation (Sheet 2 of 12)

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
 Page 35
PR-407AC-120M
Rev. 6, 11/30/2005

Figure 6: Plumbing Installation (Sheet 3 of 12)

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
Page 36
PR-407AC-120M
Rev. 6, 11/30/2005

Figure 6: Plumbing Installation (Sheet 4 of 12)

Parts list for Figure 6, Sheet 4

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
 Page 37
PR-407AC-120M
Rev. 6, 11/30/2005

Figure 6: Plumbing Installation (Sheet 5 of 12)

Parts list for Figure 6, Sheet 5

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
Page 38
PR-407AC-120M
Rev. 6, 11/30/2005

Figure 6: Plumbing Installation (Sheet 6 of 12)

Parts list for Figure 6, Sheet 6

ITEM NO PN DESCRIPTION QTY TYP
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
 Page 39
PR-407AC-120M
Rev. 6, 11/30/2005

Figure 6: Plumbing Installation (Sheet 7 of 12)

Parts list for Figure 6, Sheet 7

ITEM NO PN DESCRIPTION QTY TYP
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
Page 40
PR-407AC-120M
Rev. 6, 11/30/2005

Figure 6: Plumbing Installation (Sheet 8 of 12)

Parts list for Figure 6, Sheet 8

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
 Page 41
PR-407AC-120M
Rev. 6, 11/30/2005

Figure 6: Plumbing Installation (Sheet 9 of 12)

Parts list for Figure 6, Sheet 9

ITEM NO PN DESCRIPTION QTY TYP
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
Page 42
PR-407AC-120M
Rev. 6, 11/30/2005

Figure 6: Plumbing Installation (Sheet 10 of 12)

Parts list for Figure 6, Sheet 10

ITEM NO PN DESCRIPTION QTY TYP
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
 Page 43
PR-407AC-120M
Rev. 6, 11/30/2005

Figure 6: Plumbing Installation (Sheet 11 of 12)

Parts list for Figure 6, Sheet 11

ITEM NO PN DESCRIPTION QTY TYP
1 4-C6X-S 90° ELBOW 1 EA
2 AN821-8D 90° ELBOW 1 EA
Page 44
PR-407AC-120M
Rev. 6, 11/30/2005

Figure 6: Plumbing Installation (Sheet 12 of 12)

Parts list for Figure 6, Sheet 12

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
 Page 45
PR-407AC-120M
Rev. 7, 08/01/2006

Figure 7: Electrical Installation (Sheet 1 of 3)

Page 46
PR-407AC-120M
Rev. 7, 08/01/2006

Figure 7: Electrical Installation (Sheet 2 of 3)

 Page 47
PR-407AC-120M
Rev. 7, 08/01/2006
Parts list for Figure 7
ITEM NO PN DESCRIPTION QTY TYP
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
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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.
 Page 49
PR-407AC-120M
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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.
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PR-407AC-120M
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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.
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