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IM-109-00-011 Rev B Installation Manual

1. SPEED E H Ul ONTROL SWITCH DRAWING S SE E NE L n9 1Ug SERIE IF S102B14 IFSI0ZCTIA IF S106 B20 SWITCH SSURE IRING DIAGRAM PINK LINES LRAT IHE HIGH ENSER BI ER AT IS ACTIVATE E RESET L AL A 1851021014 15108014 p APT EVAP SPEEI HIGH PRESSURE SWITCH CLOSE GROUP IF S101C14 14 HANDSHAKE 3X IF SI03C14 1 SEE 2 5 5350 SH 1 OF 2 WIRE SPEC MIL W 22759 WIRE ND IFS X GROUND GAUGE CONTROL SWITCH IF S101E14 REVISION RECORD DWG 7 APPVD REV REV LTR DATE DESCRIPTION OF CHANGE EVAP AFT FAN MOTOR Lr CONDENSER BLOWER LOW PRESSURE MPR SWITCH
2. 2 LLL sss C 5 j _ Date 09 24 09 Rev B Section 1 Kit Inventory Page 6 of 16 Integrated Flight Systems KIT INVENTORY LIST A109 00 011 Air Conditioning KI T INVENTORY LIST STEP PART NAME PART Chk d Verf d By m 1 3 dE sss ws A 3 sss wsum 3 _ NN NN NN NN n mE ZEE 2 ve Wemaepsa 8 _ mE n ___ 93984 AFT CABIN DUCT ASSEMBLY 1 _ _ s ALTERNATE DELRON ru w 504SE1032 06 02 saw AN 3 _ l LC LOL LC SCREW WASHER as LOL WASHER 2 Date 09 24 09 Rev B Section 1 Kit Inventory Page of 16 2 n m Oo Co Integrated Flight Systems KIT INVENTORY LIST A109 00 011 Air Conditioning KI T INVENTORY LIST a __ y 8 _ wm easi 6 _ mor Aem 23 WS ema _ p UL 3 _ ia com our ase meme a _ ERE NN NE 1 _ esw xos oen 2 oa
3. 5 5 _ 5 5 4 oa 4 Mende 8 _ 8 _ Dur ALT vezor azao 4 _ OOS arewa soxassemary s a COMPRESSOR 010001 3 O EMEN BOLT AN6 H10A 8 8 WASHER NAS1149F0663P WASHER NAS1149F0632P Date 09 24 09 Rev B Section 1 Kit Inventory Page 8 of 16 Integrated Flight Systems KIT INVENTORY LIST A109 00 011 Air Conditioning KI T INVENTORY LIST QTY Verf d 00 PART NAME PART SHIM CALIPER 261012 1 2 8 12 SHIM CALIPER 261013 1 2 SHIM CALIPER 261014 1 2 STRUT BRACE 300330 1 8 13 BOLT ANAH11A 2 WASHER NAS1149F0463P 1 FITTING 90 AN833 4D NUT AN924 4D 1 1 gt 3E TI AJ BOLT AN3H11A NAS1149F0363P NUT MS21044 N3 SPACER 3 16 I D X 5 SPACER 3 16 I D X 7 2 Co Ul 2 2 MEE NEN mE NEN NEN p NEN NEN NEN NEN _ NEE EN wa MN MEE NEN NEN NEN BOLT AN3 3A NAS1149F0363P MS21919WDG 10 AN365 1032A 17 14 3 3 ADEL CLAMP U Co Z gt gt zE m m 2 2 FIREWALL ANGLE 300337 1 8 17 BOLT AN3 3A NAS1149F0363P MS20615 3M3 RIVET 12 Date 09 24 09 Rev B Section 1 Kit Inventory Page 9 of 16 Integrated Fl
4. LEFT SIDE DETAIL COND SUPPORT MUST CLEAR ALL CONTROLS COND SUPPORI MUST CLEAR TRANSMISSION SUPPORTS INTEGRATED CONDENSER MUST CLEARALL HYDRAULIC Flight Systems OIL TUBING BY 10 MIN AGUSTA 109 TITLE CONDENSER INSTALL OUTBOARD RIGHT A109A A109A A109C A109K2 DRAWN BY DATE REV SCALE SHEET A109A A109A IT A109C A109K2 7 A109 DOUBLER P N260867 5 DRILL 4 EA 10 HOLES ATTACH WITH 4 AN3 4A BOLTS 8 960 10 WASHERS 4 MS21044 N3 NUTS RIGHT AFT CONDENSER SUPPORT FOOT LOCATION INSTALL AN3 13A BOLT THRU ROOF BLOWER SUPPORT TUBE ENSURE 5 CLEARANCE BLOWER HOUSING BOTTOM TO CONTROL TUBE EBENE EE HOUSING L H SHOWN R H OPPOSITE ENSURE 1 CLEARANCE TO TRANSMISSION mi AIT VIEW LOOKING AFT COWLINC REMOVED CONDENSER ASSY CONDENSER LEG SUPPORT ASSEMBLY PN 510227 1 SUPPORT TUBES TYP BOTH SIDES RIGHT AFT CONDENSER SUPPORT FOOT LOCATION INSTALL 3 13A AGUSTA TRANSMISSION OIL TUBE SUPPORT REVISION RECORD rev DESCRIPTION OF CHANGE IR FS BY CONVERTED TO AUTOCAD OLD PHOTOS ADDED A109A MODEL TO APPLICATION BLOCK ae REVISED TITLE BLOCK iii VIEW B B l CONDENSER LEG AFT CONDENSER LEG SUPT ASSY DELETED FOR CLARITY FOOT AN3S 13A BOLT S N 7414 ONLY AN4 13A ALL OTHERS R x nent wen TYP 2 PL N N V CABIN
5. Fi il mui FORWARD FWD FAN GROUND WIRE CONNECTED TO AN3 5A BOLT 1 59 FILL W A 4 METAL SET TYP 4 RIGHT SIDE LOOKING IN SEE DETAIL A MOUNT FAN SUPPORT INTO SHURLOK SL601 3 3A ALT DELRON PN 504SE1052 06 02 WITH 1 EA 5 BOLT amp 1 EA AN960 10 WASHER MOUNT INTO FAN HOUSING WITH 1 EA ANS 4A BOLT amp 1 EA AN960 10 WASHER POSITION EVAP 2 EXISTING FRESH AIR FORWARD OF TUBES OPENING ENLARGE FROM 2 5 TO 3 5 INSTALL 3 4 NIPPLE P N 250279 SEAL UNDER amp AROUND NIPPLE W PRC 890 B X WASHERS 12 6 POSITION EVAP INBOARD TO CLEAR DUCT ON BLEED AIR LINE SEE DETAIL B SIX SHURLOK INSERTS POTTED INTO UPPER DECK P N SL601 3 3A ALT DELRON INSERT PN 5045 1052 06 02 SEE DETAIL A FORWARD HOSE NIPPLE PN 250279 AT DEC DOUBLERS PN 261510 DRILL 10 HOLE THRU AN960 10 WASHER 15 BOLT AIRCRAFT SKIN DETAIL C MATCH DRILL SKIN TO DOUBLER RIVET WITH CR3243 4 2 RIVETS 24 PLC S TOP AND BOTTOM AFT AIR DUCT DOUBLER PN 261510 DETAIL B UT BACK AND FILL WITH ETAL SET SHURLOK INSERT PN SL601 35 3A ALT DELRON INSERT PN 504SE1032 06 02 A C RESISTOR OMITTED OIL LINES FOR CLARITY TT _ OIL TANK CONTROL ROD BLOWER MOTOR MUST CLEAR CONTROL CYLINDER TOP VIEW FORWARD DRILL 3 EA 10 8 EQ S
6. INTEGRATED FLIGHT TITLE WIRE W ROUTING AIR CONDITIONER DRAWN BY DATE REV SCALE SHEET A109A 109 A109C A109K2 2 1 A109 REVISION RECORD e INSTALL INSTRUCTIONS CONNECTION OF AIR CONDITIONING POWER WIRE BEFORE CONNECTING THE 8 MAIN AIR CONDITIONING POWER LEAD A C MASTER TO THE AIRCRAFT BUSS REFER 50 AMP C B TO THE AGUSTA MAINTENANCE MANUAL LOCATION FOR THE SERIAL NUMBER OF THE AIRCRAFT INVOLVED 8 A C WIRE TO A C 50 AMP C B IN AUX ELECTRICAL PANEL CHECK LOAD OF A C AND USE BUSS NO 1 OR NO 2 WHICH EVER HAS LEAST AMP LOAD AIR CONDITIONING MASTER 50 AMP CIRCUIT BREAKER LOCATION ABOVE PILOTS HEAD USE 2 EA MS20659 INSULATED RING TERMINALS AT C B PN 050012 9 8 SCREW HOLE 8 WIRE AIR CONDITIONING MASTER CONTROL PANEL ABOVE AND LEFT OF PILOTS HEAD ELECTRICAL PANEL ALTERNATE LOCATION FOR AFT EVAPORATOR FAN SWITCH LOOKING AFT INTEGRATED Systems TITLE ELECTRICAL ROUTING AGUSTA A109E DRAWN BY DATE REV SCALE SHEET POWER APPLICATION DWG No NO 1 BUSS OR ND 2 BUSS DO NOT INSTALL ON ESSENTIAL BUSS OS500 PN 540045 1 CP 100 20 JUMPER NOTE 50 AMP C B PN 050019 9 USE 2 EA MS20659 No 8 INSULATED RING TERMINAL x No 8 WIRE 10 14 Ad 0150 RESET RELAY CP101 ELEC PANEL ASSY P N 540028 3 A109E POWER WIRING DIAGRAM AFT SPEED CONTROL SWITCH A
7. 6 HOSE ASSY CONDENSER TO REC DRIER PN 570053 O HIGH PRESSURE SWITCH PN 090004 FORWARD EVAPORATOR ASSEMBLY PN 560043 O 10 RETURN HOSE 8 HIGH PRESSURE HOSE 6 HIGH PRESSURE HOSE NOTE 1995 AND ON mn M LI ll SWITCHES MOVED FROM COMPRESSOR FORWARD OLDER UNITS MAYBE RETROFITTED TO THIS CONFIGURATION 48 HOSE ASSY COMPRESSOR TO CONDENSER PN 570058 1 0 P COMPRESSOR PN 010001 3 O CONDENSER ASSEMBLY PN 550022 O a m LOW PRESSURE EN AGUSTA A109E POWER 10 HOSE ASSY EVAPORATOR TO COMPRESSOR PN 570029 1 0 P T E G R A T E D Systems TITLE PLUMBING DIAGRAM DRAWN BY DATE REV SCALE SHEET APPLICATION DWG No AGUSTA A109E 3 1 A109P SPIRAL WRAP LINE AND SECURE CHECK CONTROL ROD CLEARANCES oTi DULL AS AFT FIREWALL DELETED FOR 8 AND 10 CLARITY FREON LINES RUNNING TO COMPRESSOR 8 HIGH PRESSURE CONNECTION TO COMPRESSOR 522 10 LOW PRESSURE CS CONNECTION TO COMPRESSOR Vy HIGH PRESSURE SERVICE PORT SIGHT GLASS LOW PRESSURE SERVICE PORT DRIER BOTTLE REVISION RECORD Ww DESCRIPTION OF CHANGE SCREW MS35207 265 ADEL CLAMP MS21919WDG32 ADEL CLAMP MS21919WDG16 WASHER AN960 10 mn ADEL CLAMP NUT MS21919WDG14 AN365 1032A 22 22 DETAIL A MS21919WDG14 SIZE BY INSTALLER AS REQUIRED 99 2
8. MPRESSO N IF S104C14 m 1 FOR WIRE SPLICE LUC FORWARD SPEED CUNTROL SWITCH DRAWN BY i REV SCALE SHEET J 08 01 07 NIS 11 LIF 1 APPLICATION DWG NO AGUSTA 109 SERIES DIAGRAM 3
9. Phone 1 817 624 6600 E Mail info rotorcraftservices com Fax 1 817 624 6601 Integrated Flight Systems REQUIRED TOOLS CONSUMABLES A109 Air Conditioning Tools and Consumables Required to Complete the Job P Assorted Drill Bits 40 30 10 14 amp 21 NEN Standard Sockets to 3 4 cap Ratchet amp Extensions DIT NN Torque Wrench For Pulley 200 in Ibs REN i Torque Bite For Belly Pan Pan American Tool 170 10 amp 170 8 Power Torque ri Integrated Flight Systems REQUIRED TOOLS CONSUMABLES A109 Air Conditioning Ball peen Hammer for Removing Rivets Assorted Bucking Bars Safety Wire 032 Steel Ruler Adjustable Wrench Cap 1 1 2 Gauge Manifold O to 500 psi Nitrogen 400 psi available R 134A Ibs Blocks for Supporting Forward Engine Vacuum Cleaner Rivnut Puller REVISION RECORD REV DESCRIPTION OF CHANGE REV 1 BY ADDED A109A MODEL TO APPLICATION BLOCK n REVISED TITLE BLOCK CIRCUIT BREAKER LOCATION FOR MASTER AIR CONDITIONING 50 AMP CIRCUIT BREAKER PN 050012 9 AFT OF PILOTS HEAD AND PLACARD PN 120009 2 NEW WEMACS SHOWN PILOTS CONDENSER COMPRESSOR LOCATED AFT OF TRANSMISSION Z 4 EVAPORATOR 2 ASSEMBLY SN NS MASTER A C lt gt ASSEMBLY MASTER ELECTRICAL CONTROL BOX NEW COCKPIT YALSVW O V AIR DUCT ASSEMBLY POSITION PLACARD r DUM E uy UPSIDE DOWN AS
10. 4 Manzger Cabin safet chanical amp Environmental Branch Los Angeles Certification Pie Anp aeuum of hu ur af cnm PLSS or coda 3 warn er ferm dibo Ri35 i mary feted accion weit AW 2 47 Sinia Aourim Department of rinspartutien Aviation Abministration Supplemental Type Certificate Qontinustion Sheet SRODOSDDE aa l FAA Approved Rotorcraft Mamani Supplement dated October 14 1993 or later FAA Approved revision is required with this insrallarkan 2 The installation should met be incorporated im any aircraft unless it is determined that the interrelatianship between this Installation amd any previously approved configuration will not Intros any adversa effect upon the airworthiness of the aircraft The approval of this modification applies to the above noted airplane model series only If the holder agrees to permai another person to us thes exrtificabe to alter the product the bolder shall give the other person writien evidence of that permission 1 A copy of this Certificate and FAA Approved Rotorcraft Flight Mansal Supplement RFMS A 1059 00 01 1 dated October 14 1994 or later Approved revision mart be mamismed ns part af the permanent records for the
11. EVAPORATOR HOUSING ASSEMLBY PN 560043 O COCKPIT AIR DUCT ASSEMBLY PN 520062 alm 150 RIGHT SIDE REF MOUNT W 6 EA AN3 5A BOLTS amp 6 EA AN960 10 WASHERS nr FAN OMITTED FOR T CLARITY FORWARD TOP VIEW elk 2 x RETURN AIR DUCT DELETED FOR _ LEFT SIDE STA 2000 VIEW A A VIEW LOOKING DOWN REVISION RECORD DESCRIPTION OF CHANGE CONDENSER LEG SUPPORT ASSEMBLY PN 510227 1 NOTE DRAIN LINES RUN UNDER DRAIN LINE DETAIL EVAPORATOR ASS Y OUTLINE OF EVAPORATOR EVAPORATOR ASSY Y PN 100181 HOSE DRAINS ON DECK DRAIN LINES PN 090018 1 AGUSTA A109E POWER INTEGRATED Systems TITLE EVAPORATOR INSTALL DRAWN BY DATE REV SCALE SHEET K A 08 01 07 IR NONE 1 OF 2 APPLICATION DWG No AGUSTA A109E 4 1 A109P OPTIONAL MODIFICATION IF NO AIR SYSTEM IS INSTALLED FOR CABIN STA 2000 HOSE NIPPLE PN 250279 MS21044 N3 NUT AN970 35 WASHER DOUBLERS 3 PN 261510 1 65 DRILL 10 HOLE Pm AN960 10 WASHER ZUM mi FORWARD h AIRCRAFT SKIN FWD FAN GROUND WIRE CONNECTED TO 5 55 BOLT DETAIL C B BOLT MATCH DRILL SKIN TO DOUBLER RIVET WITH CR3243 4 2 RIVETS 24 PLC S TOP AND SEE DETAIL MOUNT FAN SUPPORT INTO SHURLOK SL601 3 3A ALT DELRON PN 504SE1032 06 02 WITH 1 EA ANS 5A
12. In on the receiver drier The other condition that might give you a cloudy glass on a full system 15 a restriction in the liquid line from the condenser to the receiver drier On some new receiver driers the filter screen could be pushed up so the bottom of the screen is blocking the liquid pickup tube You will have to cut open the receiver drier to confirm your diagnosis You should test next for a system that 15 overcharged If the sight glass 15 clear but the high and low pressure gauge readings are high 300 or more on the high side 50 or more on the low side disconnect the compressor clutch Note that on HFC 134A systems milky is the normal look for a correctly charge system The refrigerant should foam and then settle away from the glass in less than forty five seconds If the sight glass remains clear foe more that forty five seconds you have an overcharged condition and will have to remove Freon MM 109 00 01 1 3 Agusta 109 Series Trouble Shooting Guide INTEGRATED Flight Systems Trouble Excessive moisture in the system Symptoms Insufficient cooling during hottest part of the day or during extended flying Low side pressure normal though it may be too low or even a vacuum High side pressure normal though it may be low at the same time low side 15 low Receiver drier sight glass may show tiny bubbles Note This could be a tough call with HFC 134A since the sight glass is always milky Air in the ducts
13. LOW PRESSURE SERVICE PORT AIRCRAFT SKIN OR AN3 XA BOLT OR AN525 10RX FIREWALL LENGTH AS REQUIRED AN960 10 WASHER MS20364 1032C OR SIGHT GLASS MS21044 N3 NUT DRIER BOTTLE TIE BLOCK ZZCR4HM HIGH PRESSURE SERVICE PORT DETAIL C TIE WRAPS TY524M AGUSTA 109 USED TO TIE REFRIGERANT HOSES TOGETHER AGUSTA 109 A A109A A109A II A109C A109K2 INTEGRATED Systems TITLE PLUMBING ROUTING MGV 08 01 07 A NONE 3 OF 3 A109A A109A II 109 A109K2 3 1 A109 2 ge NEW LOCATION OF ROTOR BRAKE VIEW B B RIGHT SIDE VIEW LOW PRESSURE SWITCH P N 050107 ANGLE AN960 10 WASHER AN365 1032 NUT w 4 AN3 4A BOLT ADEL CLAMP REVISION RECORD DESCRIPTION OF CHANGE 8 HOSE MS21919WDG4 10 HOSE MS21914WDG16 8 HOSE ASS Y 10 HOSE ASS Y P N 5700059 O P HIGH PRESSURE SWITCH P N 090004 VIEW D D LEFT SIDE VIEW P N 570058 O P 6 HOSE ASS Y P N 570053 O E em EXPANSION VALVE KLAN P N 090002 O 6 HOSE ASS Y P N 570052 O REC DRIER VIEW A A BOTTLE LEFT SIDE FWD OF FWD ENGINE FIREWALL AGUSTA A109E POWER INTEGRATED Systems TITLE PLUMBING DIAGRAM DRAWN BY DATE REV SCALE SHEET NONE APPLICATION DWG No AGUSTA A109E 3 1 A109P 6 HOSE ASSY REC DRIER TO EVAPORATOR PN 570052 O EXPANSION VALVE PN 090002 O FORWARD BOTTLE RECEIVER DRIER PN 090016 5
14. Los Angeles Transport Aircrnft a 4 ero FAA Approved Date June 18 1009 Page 2 of Flzzhi Systems RFM Supplement to the Agusta 1900 Flightline Drive Suijs 3 amp ADE Flight Manual Lincoln CA 95643 Flight Systems Ai Conditioner Supplement RFIMS A 109 00 0 1 STC SRIMMIGUDE TABLE OF CONTENTS LOG OF REVISIONS TABLE OF CONTENTS SECTION Operating Limitations SECTION I Normal Procedures Ground Operation One Engine 1 Required One Generator Ground and Flight Operations SECTION III Emergency Procedures DC Generator Failure Excessive Temperature Fire Smoke SECTION IV Performance SECTION V Weight and Balance SECTIOM V Manufacturer s Information Systems amp Description Electrical Loading d Zh 5 LA Lh LA de j RETE FAA Approved Date June 18 Page 3 of Integrated Flight Supplement bo dhe Agusta Hodel A 196060 FIrzhiline Drive Suite 3 AMA A109F82 amp AE Flight Manal Lincoln CA 9564B aara Flight Systems Air Conditioner Supplement Ho 5 1089 00 01 1 STE SROODGODE SECTION I OPERATING LIMITATIONS The air conditioner system must be turned OFF during engine start Operation of the air conditioner system is prohibited on one generator if the total electrical load will exceed 115 amps except mod
15. i E 6 HOSE ASSY CONDENSER TO REC DRIER PN 570053 i HIGH PRESSURE ni SWITCH 090004 D 6 HOSE ASSY REC DRIER TO EVAPORATOR PN 5 0052 0 FORWARD EVAPORATOR ASSEMBLY EXPANSION PN 560043 O VALVE PN 090002 O FORWARD It 10 RETURN HOSE 8 HIGH PRESSURE HOSE 6 HIGH PRESSURE HOSE REVISION RECORD HIGH AND LOW PRESSURE COMPRESSOR FORWARD OLDER UNITS MAYBE RETROFITTED TO THIS CONFIGURATION 8 HOSE ASSY COMPRESSOR TO CONDENSER PN 570058 1 0 COMPRESSOR PN 010001 3 O CONDENSER ASSEMBLY PN 550022 O J 7 TT LOW PRESSURE AGUSTA 109 A A109A A109A A109C A109K2 PN 050107 10 HOSE ASSY EVAPORATOR TO COMPRESSOR PN 570059 1 0 INTEGRATED Systems TITLE PLUMBING DIAGRAM SCALE DRAWN BY DATE JTYE A NONE 2 A APPLICATION DWG No A109A A109A II A109C A109K2 3 1 A109 REVISION RECORD REV DATE DESCRIPTION OF CHANGE Ur TEM ADDED A109A MODEL TO APPLICATION BLOCK P REVISED TITLE BLOCK HOSE ROUTING SECURING RIGHT SIDE TRANSMISSION SCREW MS35207 265 ADEL CLAMP LOW PRESSURE SWITCH MS21919WDG32 ADEL CLAMP MS21919WDG16 AFT FIREWALL DELETED FOR CLARITY VIEW B B WASHER AN960 10 a n ADEL CLAMP NUT MS21919WDG14 AN365 1032A DETAIL A ADEL CLAMP TYP MS21919WDG16 MS21919WDG14 SIZE BY INSTALLER AS REQUIRED 32 22 DETAIL B
16. 1 _ RFMS A109 00 011 RevA 511 1 MASTERPARTSLIST 51311 WARRANTY CLAIMSFORM 1 Date 09 24 09 Rev B Section 1 Kit Inventory Page 15 of 16 Integrated Flight Systems KIT INVENTORY LIST A109 00 011 Air Conditioning MAJ OR COMPONENTS SERI AL NUMBERS Condenser Blower S N Condenser Blower S N Date 09 24 09 Rev B Section 1 Kit Inventory Page 16 of 16 Page 1 7 THIS INFORMATION PERTAINS TO IPS PN 070003 TOUCH UP Material Safety Data Sheet IPS PN 070003 1 TOUCH UP PAINT GREY acc to ISO DIS 11014 Printing date 07 28 2005 Reviewed on 02 07 2005 I Identification of substance Product detail Trade name 61003 Multi Coat Blank Aerosol Article number 61007 Manufacturer Supplier SEM Products Inc 651 Michael Wylie Dr Charlotte NC 25217 USA 704 522 1006 Information department HHR EMERGENCY CHEMTREC 800 424 9300 2 Composition Data on components Chemical characterization Description Mixture of the substances listed below with nonazardow additions Dangerous components ace lore 74 95 0 propane 78 93 3 firtanone 3 Hazards identification Hazard description Irritant Extremely flammable Information pertaining to particular dangers for man and environment The product has to be labelled due to the calculation procedure of international guidelines Warning Pressurized comainer Has a narcotizing effect Extremely
17. FORWARD COMPRESSOR BRACKET ASSY PN 510255 EXISTING HARD HYDROLIC LINE ROTOR BRAKE EXISTING ADEL CLAMPS BELT DELETED FOR CLARITY PN 060030 OR 060031 ROTATE EXISTING ADEL CLAMPS 180 STAND OFF WITH 3 16 I D X 5 7 SPACERS AN3 11A BOLTS 2 NAS1149F0363P WASHERS 4 MS21044N3 NUTS 2 ENSURE ALIGNMENT OF C L OF BOTH BELT GROOVES WITHIN 10 ROTOR BRAKE DRIVE PULLEY PN 3003 FIREWALL ANGLE PN 300337 DRIVE PULLEY INSTALLATION INSTRUCTIONS DISASSEMBLE THE TAIL ROTOR DRIVE SHAFT AT THE THOMAS COUPLING PRIOR TO REMOVING ROTOR BRAKE CALIPER AND DISC ROTATE DISC INSPECT FOR TRUE RUNNING DISC AND ANY FOR AFT END PLAY AT INPUT QUILL RECORD END PLAY INSPECT CLEARANCE FROM DISC TO PUCKS ON BOTH SIDES RELOCATE CALIPER AFT IF NECESSARY BY THE USE OF IFS SHIMS PN 261012 020 PN 261013 032 OR PN 261014 040 FINAL CLEARANCE SHOULD BE AS EQUAL AS POSSIBLE FROM EACH PUCK TO THE DISC IN NO CASE SHALL DLEARANCE BE LESS THAN 005 AFTER TAKING INTO ACCOUNT INPUT QUILL MAXIMUM MOVEMENT END PLAY REVISION RECORD REV DESCRIPTION OF CHANGE REV ADDED A109A MODEL TO APPLICATION BLOCK B pense REVISED TITLE BLOCK WHILE TAIL ROTOR SHAFT IS REMOVED ATTACH SPARE BELT PN 060030 OR 060031 TO FWD SIDE OF FIREWALL USING 2 EA MS21919WDG 10 ADEL CLAMPS ATTACH TO OUTBOARD BOLT LOCATIONS AT FIREWALL BOX ASSY JTYE LOCATE THIRD ADEL CLAMP
18. 1 Service system to a clear sight glass R12 Note On 134a systems the sight glass appears milky when properly charged though there should be no bubbles in the sight glass 2 Service system by measuring temperature from evaporator Add Freon while watching the temperature As long as temperature keeps falling add Freon Once temperature stops dropping holds or starts to rise stop 3 Service system by weight If you have a service service station or scale you can add the proper amount by weight 4 Service according to a standard pressure temperature chart 82 F or higher service with 1 8 lbs max Freon Below 82 F service with 2 0 lbs max Freon 8 One evaporator is not cooling A Expansion valve may be blocked form contamination B Hose may be crimped kinked or have a fitting bent over blocking flow C NOTE The recommended fix is to pump down system Change expansion valves and dryer bottle Make sure to mount sensing bulb on suction side of coil and when possible at 9 or 3 o clock position on tube Re service system MM 109 00 01 1 Agusta 109 Series Trouble Shooting Guide INTEGRATED 9 Compressor clutch failure A Low Freon in system This causes the system to low pressure out through the low pressure switch It will cycle the clutch on and off until it heats up causing the coil to overheat and fail or heat up the bearing to the point the grease will liquefy and run out This will add to the heat and help
19. 4 DRILL 10 DIA HOLES OUT TO 250 DIA DOUBLER 554 MS20470AD4 X RIVET CCR264 SS3 3 TYP VIEW LOOKING DOWN amp FORWARD D P N 260889 260890 ALTERNATE MS20426A3 3 EXISTING COVER STA 2000 STRUCTURE DRILL 4 EA 30 HOLES POSITION WEMAC SUPPORT P N 250276 AS SHOWN IN amp B NUTPLATE MS21059 L3 TYP gt INSTALL NUTPLATES ON INSIDE ALTERNATE MS21060 3 22 4 REF OF STRUCTURE PER NOTE NOTE IF UNABLE TO FIT NUTPLATE A RIVNUT P N A10K80 IS OPTIONAL NOTE POSITION HOLES BETWEEN EXISTING RIVETS 25R TYP a BOTTOM ROW RIVETS AG U SIA 1 09 FLUSH MS20426AD4 4 ABA 4 4 4 PLS OR MS20470AD4 X P N 250275 A109A A109A A109C A109K2 DOUBLER P N 260889 1 8 DETAIL L H CO PILOTS SIDE TYP PILOTS OPPOSITE INTEGRATED OCKPIT OVERHEAD AIR DUCT INSTALL USE NUTPLATES ON INSIDE RIVET LEGEND FORWARD gt 4 4 MS20426AD4 4 3 TITLE AIR DISTRIBUTION O MS20470AD4 4 3 DRAWN BY DATE REV SCALE SHEET CCR264 SS3 3 NONE APPLICATION DWG No A109A A109A II A109C A109K2 5 A109 Systems REVISION RECORD PITOT TUBES DELETED DESCRIPTION OF CHANGE FOR CLARITY CONVERTED TO AUTOCAD ADDED PHOTO CHANGED TITLE BLOCK ADDED E SHEET 4 OF 4 COCKPIT AIR DUCT ASSY ADDED A109A MODEL TO APPLICATION BLOCK OUTBOARD RIGHT FWD um 3 N 260916 AN525 1
20. 5 1 A109P Sheet 3 of 4 Remove all shavings or debris Now that the duct is temporarily in place position the Evaporator Housing Assembly P N 560043 O and align with duct 5 See drawing 4 A109 Sheet 1 of 2 For A109 E Installation utilize drawing 4 1 A109P Sheet of 2 DO NOT drill any holes at this time Date 09 24 09 Rev A Section 5 Installation of Evaporators Page 2 of 10 Integrated Flight Systems INSTALLATION OF EVAPORATORS A109 Air Conditioning STEP PROCEDURE MECH INSP Now position the Condenser Leg Support Assy P N 510227 1 as shown in drawing 7 A109 Sheet 1 of 2 and 7 A109 Sheet 2 of 2 For A109 E Installation utilize drawings 7 1 A109P Sheets and 2 of 2 Warning Check all flight controls Move the cyclic collective and anti torque pedals Reposition evaporator condenser and condenser mount as necessary to maintain 15 clearance of flight controls Align Fwd Evap Fan with cockpit air duct Mark or drill all mount holes to deck Then scribe condenser nut plate holes to mount bracket Back drill 4 each 10 holes in condenser lower mount to evaporator upper support See View Looking Aft Cowling Removed Dwg 7 A109 Sheet 2 of 2 For A109 E Installation utilize drawing 7 1 A109P Sheet 2 of 2 Remove all shavings or debris Remove evaporator condenser and condenser support mount Drill out and pot holes for evaporator and install Shurlock s or Delron inserts Per Dwg 4 A109 Sheet 2 of 2 For
21. A109A 1 A109C A109K2 NAS1149F0363P WASHERS 18 PLC S INTEGRATED 5 CUT LATERAL FWD FIREWALL TO MATCH SIZE amp SHAPE OF FIREWALL BOX ASSY PN 530089 Flight Systems NOTE TORQUE ALL BOLTS AND FASTENERS TITLE COMPRESSOR IAW AC 43 13 OR APPLICABLE AIRCRAFT SERVICE MANUALS INSTALLATION DRAWN BY DATE REV SCALE SHEET AFT VIEW OF FWD FIREWALL APPLICATION DWG No A109A A109A II A109C A109K2 6 1 A109 D gt SEQUENCE FOR BELT TIGHTENING A LEAVE THE COMPRESSOR ANCHORING BOLTS LOOSE LEAVE THE ANCHOR BOLT TYP BOTH ENDS FOR P N 530088 LOOSE UNTIL BELT TENSION IS SET NAS1149F0863P WASHER MS21044N8 NUT 2 PLC S AN6 H10A BOLT 2 15 BELT BRACKET ASSY B ADJUST BELT TENSION BY ADJUSTING BY Z PN 510263 P ADJUSTING THE NUTS ON P N 530088 BELT ADJUSTMENT ASSY UNTIL A MIN OF 5 TO A MAX OF 75 DEFLECTION IS ACHIEVED AT 10 Ibs PRESSURE AT MID SPAN OF THE BELT LOCK BELT BRACKET ASSY P N 510263 P IN PLACE 4 gt I BELT ADJUSTMENT ASSY PN 530088 C TIGHTEN AND SAFETY THE COMPRESSOR TO BELT BRACKET ASSEMBLY BOLTS D TIGHTEN AND SAFETY THE COMPRESSOR TO COMPRESSOR BRACKET ASSEMBLY BOLTS TIGHTEN ANCHOR BOLT ON P N 530088 BELT PN 060031 1 E AFTER INSTALLATION OF BOLTS INTO SELF LOCKING HELI COILS SAFETY WIRE 032 MIN TO EACH OTHER FAR SIDE Sc AN6H10A BOLT 2 NAS1149F0663P OR NAS1149F0632P WASHER 2 TYP B
22. B Systems TITLE COWLING MODIFICATION MS20426AD 5 4 AGUSTA A109E APPLICATION DWG No FS Date 08 01 07 Section 7 Not used Integrated Flight Systems NOT USED A109 Air Conditioning Step 7 This Step is not Utilized in this Installation Page of 1 Integrated Flight Systems INSTALLATION OF COMPRESSOR A109 Air Conditioning Step 8 Installation of Compressor Date 07 06 09 Rev A Section 8 Installation of Compressor Page 1 of 3 Integrated Flight Systems INSTALLATION OF COMPRESSOR A109 Air Conditioning NOTE ALL REMOVAL AND RE ATTACHMENT OF EQUIPMENT SHOULD BE DONE IN ACCORDANCE WITH APPLICABLE AGUSTA SERVICE MANUALS TORQUE ALL FASTENERS IN ACCORDANCE WITH AC43 13 OR APPLICABLE AGUSTA SERVICE MANUALS E Remove right hand engine air inlet and screen assembly Caution Tape over Turbine Intakes pa Unbolt rotor brake disc Disconnect tail rotor drive shaft per Agusta Service Manual Install compressor mount bracket P N 510255 in place See drawing 6 1 A109 Sheets 1 2 and 3 of 3 Make sure bracket fits flush with rotor brake mount points Adjust bracket to fit flush by removing metal from bracket Remove bracket Install compressor mount bracket P N 510255 P in place See drawing 6 1 109 Sheets 1 2 and 3 of 2 Make sure bracket fits flush with rotor brake mount points Adjust bracket to fit flush by removing metal from bracket Remove bracke
23. CAMLOCK A EXISTING CAMLOCK AIRCRAFT FLANGE INTEGRATED DZUS SUPPORT ASSY P N 510300 DETAIL A Systems AU DETAIL B TITLE COWLING MODIFICATION EE A109A A109C A1t amp tor amp RIVET TYP 4 PL A109A A109A A109C A109K2 K A 11 20 52 B NONE 10F1 e 08 RAO _ A109A 109 II 109 A109K2 8 A109 REVISION RECORD NEW OVERHEAD DUCT P N 520062 co FORWARD AN 525 1088 SCREWS 12 PL H FORWARD a y TOP VIEW OF COWLINC CUT W REMOVED PORTION 4 1 Z FORWARD NOTE THIS VIEW IS INSIDE wenn es LOOKING OUT is TO COWLING CARE TOP COWEL eS Sohn ADD NEW CAMLOCK WAY kay EACH SIDE OF 6 0 MODIFICATION Big Ae re CUT OUT AS SHOWN 50 052 5 MALE EXISTING CAMLOCK 7 EXISTING CAMLOCK E YI 2000 4 AIRCRAFT ALL VIEWS INSIDE COWLING NOTE AFTER MODIFICATION FIT COWLING TO A C MARK LOCATION FOR NEW FEMALE CAMLOCKS ON A C MATCHING NEWLY INSTALLED MALE CAMLOCKS MATCHIN T ON AIRCRAFT aS Es INSTALL 2 EACH P N 50 052 1 FEMALE CAMLOCKS EXISTING CAMLOCK prs NS EXISTING CAMLOCK NN 4 2 FLANGE MODIFICATION AIRCRAFT FLANGE INTEGRATED P N 510300 AU DETAIL B Systems TITLE COWLING MODIFICATION MS20426AD 5 4 AGUSTA A109E APPLICATION DWG
24. ON THE SAME SIDE BELOW THE SHAFT BOLT IN PLACE WITH AN3 5A ADEL CLAMP MS21919WDG 10 TYP 3 PLC S SPARE BELT PN 060030 OR PN 060031 COMPRESSOR ALIGNMENT NOTE COMPRESSOR PORTS SHOULD CLOCK TO THE RIGHT OUTBOARD SIDE OF THE AIRCRAFT COMPRESSOR PN 010001 3 0 33 2 x FIREWALL VF ao AGUSTA 109 FIREWALL BOX ASSY 109 A109A Il A109C A109K2 PN 530089 INTEGRATED Systems TITLE COMPRESSOR INSTALLATION DRAWN BY DATE REV SCALE SHEET e 203 looa n _ A109A A109A II A109C A109K2 6 1 A109 NOTE TORQUE ALL BOLTS AND FASTENERS IAW AC 43 13 OR APPLICABLE AIRCRAFT SERVICE MANUALS C ENGINE COMPARTMENT F Uca REVISED TITLE BLOCK 3 60 NOTE THESE 4 NUTPLATES LOCATED ON INSTALLATION 4 00 REFERENCE EXISTING HOLES ON AIRCRAFT 1 00 2 BACK DRILL Ps DIVIDER TO FIREWALL ANGLE PN 300337 1 CUT DIVIDER USING FIREWALL ii BOX ASSEMBLY 3 SECURE ANGLE PN 530089 AS TO RIGHT OUTBOARD A TEMPLATE SIDE OF DIVIDER HOR W MS20615 3M3 12 10 RIVETS 10 PLC S 9 50 FIREWALL BOX ASSEMBLY PN 530089 OUTBOARD RIGHT VIEW LOOKING INBOARD 1 00 VIEW LOOKING AFT 4 TRIAL FIT DIVIDER OUTBOARD CENTERLINE OF AIRCRAFT OUTBOARD FIT FIREWALL BOX ASSY EFT AGUSTA 109 AND BOLT IN PLACE WITH Ee AN3 3A BOLTS AND A109A
25. Trim deflectors as necessary to clear inner fairing and new duct Rivet in place with CR3243 4 4 Remove all shavings or debris Rev A Page 5 of 10 Integrated Flight Systems INSTALLATION OF EVAPORATORS A109 Air Conditioning STEP PROCEDURE Fit and trim as necessary air ducts P N 250275 in place as shown in drawing 5 A109 Sheet 2 of 4 Re 5 30 position lines and wires as necessary Rivet in place For A109 E Installation utilize drawings 5 1 A109P Sheet 2 of 4 Remove all shavings or debris 5 31 Reserved 5 32 Secure seal air ducts all the way around with ProSeal 890 B2 or B 1 2 After sealing install Cockpit Air Duct PN 520062 per drawing 5 A109 Sheet 3 of 4 For A109 E Installation utilize drawings 5 1 A109P Sheet 3 of 4 Seal with ProSeal 890 B2 or B 1 2 all around duct Strip inner wire from Air Duct PN 060007 then install from Evaporator blower to Cockpit Upper Air Duct as shown in 5 A109 Sheet 1 of 4 using 2 each 6 Band clamps PN 060035 Wrap with foam insulation tape and aluminum foil tape Install Wemac Support Panels overhead per drawing 5 A109 sheet 2 of 4 attach with AN525 10R58 screws For A109 E Installation utilize drawings 5 1 A109P Sheet 2 of 4 Position Co Pilots Bulkhead Doubler P N 260866 5 36 as shown in drawing 5 A109 Sheet 1 of 4 Mark around outside and inside edge of doubler 5 36 Position Co Pilots Bulkhead Doubler P N 260866 P A109 E as shown in drawing
26. m Co Date 09 24 09 Rev B Section 1 Kit Inventory Page 11 of 16 Integrated Flight Systems KIT INVENTORY LIST A109 00 011 Air Conditioning KI T INVENTORY LIST STEP PART NAME PART HOSE ASSY 6 TO DRIER 570052 0 ADEL CLAMP MS21919WDG 10 SCREW AN525 10R7 10 3 WASHER AN960 10 By d e e UJ UJ CORK INSULATION TAPE PT1 FOAM INSULATION TAPE K501 Alt K502 PROSEAL 890 890 B2 OR B1 2 1 Pint NENNEN 1 o rrr a 1 CORK INSULATION TAPE Pu 2 100 20 20 10 100 25 Qt e UJ Date 09 24 09 Rev B Section 1 Kit Inventory Page 12 of 16 Integrated Flight Systems KIT INVENTORY LIST A109 00 011 Air Conditioning DRAWI NG LIST CONDITIONING overview Ice do amp 1 ECINCALROUTNG amp 1 A 1 2 t ato aor3 A 1 PLUMBING DIAGRAM armoa amp 1 UMBNGDIAGRAM armoo A 1 PLUMBING ROUTING A 1 EVAPORATOR INSTALL evaporator INSTALL 9 1 _ mros 1 _ 8 1 AIR DISTRIBUTION 5 A109 3 of 4 3 AIR DISTRIBUTION 5 A109 4 of 4 a COMPRESSOR INSTALLATION 6 1 A109 1 of 3 COMPRESSOR INSTALLATION 6 1 A109 2 of 3 COMPRESSO
27. uv SHOWN QUEM Y XY COMPRESSOR RETURN AIR AGUSTA 109 y NEW WEMACS A109A 109 A109C A109K2 CO PILOTS INTEGRATED MASTER AIR CONDITIONING CONTROLS amp FORWARD FAN SPEED CONTROL SWITCHES OVER PILOTS HEAD TO RIGHT OF THROTTLE Systems TITLE AIR CONDITIONING RETURN AIR SCREEN PN 080036 OVERVIEW ABOVE AND BEHIND CO PILOTS HEAD DATE REV SCALE SHEET NEW CO PILOTS WEMACS a P 08 01 07 NONE fori OF 1 O PILOTS OPPOSITE REVISION RECORD DESCRIPTION OF CHANGE COMPRESSOR LOCATED AFT OF TRANSMISSION Z EVAPORATOR ASSEMBLY NEW WEMACS PILOTS gt lt gt CONDENSER lt 57 ASSEMBLY d lt NEW COCKPIT M MASTER ELECTRICAL AIR DUCT ASSEMBLY Z LOCATION FOR MASTER AIR CONDITIONING CONTROLS amp FWD FAN SPEED CONTROL 50 AMP CIRCUIT BREAKER PN 050012 9 ABOVE PILOTS HEAD AND RIGHT OF THROTTLE PLACARD PN 120009 2 SHOWN POSITION PLACARD IF AS REQUIRED Z j CONTROL BOX A C MASTER RETURN AIR COMPRESSOR NEW WEMACS CO PILOTS NEW WEMACS AGUSTA A109E CO PILOTS J POWER INTEGRATED Systems g 3 229 TITLE AIR CONDITIONING 2 Ree RETURN AIR SCREEN PN 080036 P OVERVIEW ABOVE AND BEHIND CO PILOTS HEAD DRAWN BY DATE REV SCALE SHEET NEW CO PILOTS WEMACS JTYE NONE APPLICATION DWG No PILOTS OPPOSITE AGUSTA A109E 1 1 A109P Integrated Flight Syst
28. A WITH 2X CR3243 4 4 RIVETS COCKPIT AIR DUCT ASSY EACH SIDE LOOKING UPSIDE DOWN NOTE CUT DUCT FLANGE TO FIT PITOT BASE INTEGRATED BOTH SIDES INSPECT UNDER ROOF PRIOR TO DRILLING USE STOP DRILL WHEN DRILLING ALL BUILD UP FOAM TAPE i ol basen TITLE AIR DISTRIBUTION er M E AN 2 AGUSTA A1 O9E DRAWN BY DATE REV SCALE SHEET TAPE SEAL TO SKIN WITH 12000 DL LU 08 01 07 NONE 30F4 FOAM TAPE POWER APPLICATION DWG No AGUSTA A109E 5 1 A109P Systems REVISION RECORD DESCRIPTION OF CHANGE 9107 1 INSERT 10 CLIP NUT P N 521 4972 10 02 FOAM AROUND DRILL _ a IE m um HOSE NIPPLE 25 HOLE V E CEILING P N 250509 VIEW B B PLACARD P N 120071 AFT CABIN DUCT ASSY TYP 2 1 OPPOSITE P N 520066 NOTES 35 5 IN DECK HOLE 2 EA AN3 14A BOLTS UPPER DECK 2 EA AN9 0 4 WASHERS 2 IF ELECTRICALLY ACTUATED EXISTING SIGNS PLACARDS BY AGUSTA ARE IN AIRCRAFT INSTALL IFS P N 120071 TO DUCT IF ELECTRICALLY ACTUATED SIGNS PLACARDS BY AGUSTA ARE IN AIRCRAFT REMOVE amp INSTALL ON ASSY P N 520066 1 REMOVE AFT CABIN DUCT AND HEADLINER AS REQUIRED 9 INSULATION 3 DRILL 2 EA HOLES THROUGH DECK INTO DECK ASS Y AT EACH END THEN INSTALL 2 EA CLIP NUTS AS SHOWN CEILING PANEL 4 POSITION UNDER 3 5 HOLE UNDER DECK CENTER ON INTERNAL DUCT MARK HOLE IO DUCT REMOVE DUCI ASSEMBLY CUT HOLE RIVET HOSE NIPPLE P N 250509 TO DUC
29. A109 E 520061 Seal duct to wall with ProSeal M 890 B 2 or 1 2 Attach Screen P N 080036 to bulkead and duct using 3 each AN525 10R10 Screws 3 each AN970 3 Washers Position Return Air Duct Lower P N 250286 as 4 shown in drawing 5 A109 Sheet 1 of 4 Trim as necessary For A109 E Disregard this step Caution Check all flight controls move cyclic 5 44 collective and anti torque pedals be sure duct clears control tubes by 15 For A109 E Disregard this step Position duct supports P N s 510230 and 510231 as shown in drawing 5 A109 Sheet 1 of 4 Drill and Cleco in place to deck Remove all shavings or debris For A109 E Disregard this step Date 09 24 09 Rev A Section 5 Installation of Evaporators Page 7 of 10 Integrated Flight Systems INSTALLATION OF EVAPORATORS A109 Air Conditioning STEP PROCEDURE MECH INSP 5 5 5 5 5 5 5 5 53 A109 E 46 AT A8 49 50 51 52 54 Install Plate Assembly P N 510232 with ABA4 4 rivets to Return Air Duct Lower P N 250286 Install Duct Mount PN 260912 1 to outboard plate assembly as shown in drawing 5 A109 Sheet of 4 For A109 E Disregard this step Mark inside of lower duct using Return Air Duct Assembly PN 520061 lower aft lip as guide For A109 E Disregard this step Next fit Return Air Duct Upper P N 250285 in place Trim as necessary to fit Drill and Cleco in place around duct every 2 For A109 E Disregard this step Un Cleco duc
30. A109 E Installation utilize drawing 4 1 A109P Sheet 2 of 2 Allow Metalset to cure per manufacturers instructions Remove all shavings or debris Drill out and pot holes for Condenser Leg Support Assembly PN 510227 1 Allow Metalset to fully cure Re drill holes for Condenser Leg Support after potting dries See View B B 7 A109 Sheet 2 of 2 For A109 E Installation utilize drawing 7 1 A109P Sheet 2 of 2 View B B Remove all shavings or debris Connect drain lines PN 090018 1 to two 2 90 drain nipples under evaporator and connect to drain Ys PN 100181 Just aft of the evaporator under resistor See drawing 4 A109 Sheet 1 of 2 Drain Line Detail For A109 E Installation utilize drawing 4 1 A109P Sheet 1 of 2 Drain Line Detail Date 09 24 09 Rev A Section 5 Installation of Evaporators Page 3 of 10 Integrated Flight Systems INSTALLATION OF EVAPORATORS A109 Air Conditioning STEP PROCEDURE MECH INSP Install evaporator with hardware called out in drawing 4 A109 Sheet 2 of 2 For A109 E Installation utilize drawing 4 1 A109P Sheet 2 of 2 Connect drain line to evaporator blower and connect to drain Y with other drain line from 5 16 evaporator Remove duct P N 5200062 Install upper transmission cowling and mark duct as required to cut out cowling Remove cowling Begin a small cut out on cowling as shown in drawing 8 A109 Sheet of See step 5 19 Save Camloc For A109
31. AIRCRAFT ON WHICH OTHER PREVIOUSLY FAA APPROVED MODIFICATIONS ARE INCORPORATED UNLESS IT IS DETERMINED BY THE INSTALLER THAT THE INTERRELATIONSHIP BETWEEN THIS CHANGE AND ANY OF THOSE OTHER PREVIOUSLY APPROVED MODIFICATIONS WILL PRODUCE NO ADVERSE EFFECT UPON THE AIRWORTHINESS OF THE AIRCRAFT Date 09 24 09 Rev A Section 2 Aircraft Pre Inspection Page 2 of 4 Integrated Flight Systems AIRCRAFT PRE INSPECTION A109 Air Conditioning General Safety Instructions PROCEDURE WARNING Always handle the refrigerant fluids carefully WARNING Do not mix other refrigerant fluids with the R134a Do not use refrigerant canned for pressure operated accessories such as boat air horns This refrigerant is not pure and will cause malfunctions in the system WARNING When the system must be opened to do maintenance before you do the work you must drain the air conditioning system WARNING When you open the system you must collect the refrigerant in accordance with Federal and Local regulations WARNING When the R134a 15 used in normal conditions it is not flammable Do not use it near a source of heat to prevent the risk of separation of the vapors WARNING Avoid skin and eye contact with R 134a The liquid R 134a at normal atmospheric temperatures evaporates so quickly that it will freeze anything is comes in contact with WARNING Wear safety goggles when servicing any part of the refrigerant system WARNING Never he
32. DETAIL B AIRCRAFT SKIN OR AN3 XA BOLT OR AN525 10RX FIREWALL LENGTH AS REQUIRED AN960 10 WASHER MS20364 1032C OR MS21044 N3 NUT TIE BLOCK ZZCR4HM DETAIL TIE WRAPS TY524M USED TO TIE REFRIGERANT HOSES TOGETHER AGUSTA A109E POWER INTEGRATED Systems TITLE PLUMBING ROUTING DRAWN BY DATE REV SCALE SHEET MGV 08 01 07 IR NONE 3 OF 3 APPLICATION DWG No AGUSTA A109E 3 1 A109P Date 09 24 09 Section 11 Paperwork Integrated Flight Systems PAPERWORK A109 Air Conditioning Step 11 Paperwork Rev A Page 1 of 2 Integrated Flight Systems PAPERWORK A109 Air Conditioning DETAILED WEIGHT AND BALANCE DATA FOR INTEGRATED FLI GHT SYSTEMS FREON AIR CONDI TI ONI NG UNIT INSTALLED IN A TYPICAL HELICOPTER MODEL A109A A109A II A109C A109E and 109 2 PERTAINS KIT A109 00 011 Weights and Moments I TEM WEI GHT ARM MOMENT Evaporator Condenser 38 00 128 8 4894 0 Assembly Compressor Assembly 13 00 144 3 1875 9 Compressor Mounting Bracket 2 00 142 0 284 0 Freon Hose Assembly 6 00 138 0 828 0 Hardware Ducts and Electric 10 0 120 0 1200 0 69 0 131 62 9082 3 Air Conditioner Date 09 24 09 Rev A Section 11 Paperwork Page 2 of 2 Integrated Flight Systems 900 Flighalinc Drive Sae 3 Linkin CA Supplement RFMS A 109 0 FAA APPROVED ROTORCRAFT FLIGHT MANUAL SUPPLEMENT TO THE AGUSTA 5 MODEL A109C A109K2 amp ATUSE Agusta
33. DEVELOP IN ACCORDANCE WITH MANUFACTURER S RECOMMENDATIONS Systems TITLE EVAPORATOR INSTALL AGUSTA A109E AGUSTA A109E 4 1 A109P REVISION RECORD DESCRIPTION OF CHANGE d INTEGRATED REPOSITION AS SHOWN RETURN AIR DUCT P N 520061 109 LOCATION OF HEATER TEMPERATURE CONTROL BEFORE RELOCATION NEW LOCATION OF BUS BAR BURNISH AREA UNDERNEATH BAR MATCH DRILL AND ATTACH WITH 7X CCR3245 4 2 RIVETS RETURN AIR DUCT AFT OF CO PILOTS BULKHEAD WIRE BUSS AFTER REMOVAL FOR RE LOCATION REMOVE MOUNTING ANGLE DISCARD AFTER REMOVAL OF ANGLE RIVETS ABA 4 6 2 EA PER AIR DUCT P N250275 RIVETS MS20470AD 4 X REVISION RECORD REV DATE DESCRIPTION OF CHANGE CONVERTED TO AUTOCAD OLD PHOTOS A 08 01 07 REPLACED CHANGED TITLE BLOCK ADDED MGV SHEET 4 OF 4 P N 520061 IS NOW 520061 109 ADDED A109A 09 24 09 MODEL TO APPLICATION BLOCK REVISED TITLE IFS JTYE BLOCK TYP 4 PL AN525 10R10 SCREW AND970 3 WASHER RM52LHA4972 10 02 CLIP NUT RETURN AIR DOUBLER P N 260866 RETURN AIR SCREEN P N 080036 TOUCH UP PAINT ON DOUBLER RIVETS AND SCREWS AFTER COMPLETION FORWARD SIDE CO PILOTS BULKHEAD AFTER INSTALLATION COVER R A DUCTS W Y 370 INSULATION OR 125 FOAM INSULATION TAPE SEAL W FOIL TAPE SUPPORT P N 510230 PLATE ASSEMBLY P N 510232 TYP 2 PL AN3 4A BOLT 1 AN960 10 WASHER 1 SUPPORT P N 5102
34. FASTENERS X IAW 43 13 OR APPLICABLE AIRCRAFT SERVICE MANUALS COMPRESSOR BRACKET ASSY PN 510255 P OR SECURE CALIPER W NAS1304 5H BOLT amp NAS1149F0463P OR ORIGINAL ROTOR BRAKE LOCATION SECURE CALIPER W BOLT 4 NAS1149F0432P WASHER 4 NAS1149F0432P SAFETY WIRE 032 MIN WASHER 4 SETS REQUIRED SECURE W SAFETY WIRE 032 MIN ROTOR BRAKE RELOCATED TO THIS AREA REMOVE STORE EXISTING AN815 4D FITTING INSTALL 90 AN833 4D FITTING BULKHEAD AND JAM NUT PN AN924 4D INTEGRATED BETWEEN CALIPER AND COMPRESSOR Systems PN 261012 1 261013 1 OR PN 261014 1 AS REQUIRED TITLE COMPRESSOR INSTALLATION AGUSTA 109 MS AGUSTA A109E 6 1 A109P NOTE REVISION RECORD SD505 COMPRESSOR WHILE TAIL ROTOR SHAFT IS DESCRIPTION OF CHANGE PN 010001 3 O REMOVED ATTACH SPARE BELT PN 060031 1 TO FWD SIDE OF FIREWALL USING 2 EA MS21919WDG 10 ADEL CLAMPS ATTACH TO OUTBOARD BOLT LOCATIONS AT FIREWALL BOX ASSY EXISTING HARD HYDROLIC LINE ROTOR BRAKE NOTE ENSURE THAT HEAD BOLTS LOCATE THIRD ADEL CLAMP ON THE SAME SIDE BELOW THE SHAFT BOLT IN PLACE WITH AN3 5A ON COMPRESSOR DO NOT PROTRUDE MORE THAN AB EXISTING ADEL CLAMPS AN6 H10A BOLT 2 PLC S ADEL CLAMP MS21919WDG 10 TYP 3 PLC S WIRE TOGETHER 032 INTO SELF LOCKING BELT DELETED FOR CLARITY HELI COILS SAFETY PN 060031 1 MINIM
35. FOR MASTER AIR CONDITIONING ELECTRICAL CONTROL BOX INSERT INSTALLATION INSTRUCTIONS 1 MATCH DRILL COMPONENTS UNDER DETAIL A AND B TO HELICOPTER CABIN ROOF USING 10 HOLES 2 SPOT FACE UPPER FACE SKIN TO 9 16 DIAMETER AT EACH 10 HOLE 5 USING A 90 ANGLE TOOL REMOVE CORE OF CABIN ROOF TO A DIAMETER OF 1 5 FROM UNDERSIDE OF UPPER SKIN TO UPPER SIDE OF LOWER SKIN VACUUM OUT ALL CORE MATERIALS REMOVED TRAIL FIT SUR LOK INSERT P N SL601 3 3A ALT DELRON INSERT PN 5045 1032 06 02 ENSURE THAT INSERT WILL FIT FLUSH WITH UPPER SKIN SURFACE 6 OBTAIN METALSET A 4 AND MIX ACCORDING TO MANUFACTURER S DIRECTIONS 7 FILL EACH CAVITY WITH METALSET A 4 AND INSTALL SUR LOK INSERT INTO THE METALSET ENSURE THAT INSERT IS TOTALLY ENCAPSULATED 8 ENSURE THAT INSERT CENTER THREAD OPENING DOES NOT BECOME CLOGGED WITH METAL SET ALLOW METAL SET TO FULLY CURE BEFORE INSTALLING EVAPORATOR TO ASSEMBLY OR MASTER A C ELECTRICAL PANEL 9 RETAIN A SAMPLE OF THE METALSET A 4 USED IN THIS INSTALLATION FOR A PERIOD OF 24 HOURS ENSURE THAT CURING AND BONDING PROPERTIES DEVELOP IN ACCORDANCE WITH MANUFACTURER S RECOMMENDATIONS db INTEGRATED Systems TITLE EVAPORATOR INSTALL none 20F2 K A 11 20 92 B NONE 2 OF 2 S Mioa aoan aoc aooe _ A109A A109A II A109C A109K2 4 A109 L H SIDE VIEW CONDENSER ASSEMLBY PN 550022 0 RETURN AIR ADAPTER PN 110100 P
36. INSTALL SIGN OFF This Form Must be received from the Owner of the Aircraft for the warranty to be active Warranty period extends from Date of Purchase for a period of one year or 1000 hours Subject to the limitations identified in the attached Warranty Terms effective 22 February 2007 PLEASE REVIEW THE ATTACHED WARRANTY POLICY PRIOR TO SUBMITTING THIS REGISTRATION FORM RSG Products Form 33 41 Rev 09 19 2011 PRODUCTS INC WARRANTY CLAIM FORM DATE RMA CUSTOMER NAME ADDRESS CITY STATE ZIP PHONE NUMBER FAX NUMBER COMPONENT NAME PARI NUMBER SERIAL NUMBER TYPE AIRCRAFT N S N AIR CONDITIONING INSTALLATION DATE AIR CON INSTALLATION COMPANY DATE INSTALLED T T AT INSTALLATION DATE REMOVED T T AT REMOVAL REASON FOR RETURNING COMPONENT For Company use only Date Received Warranty Accepted _ YES NO Disposition of component Comments RSG Products Form 33 41 Rev 09 19 2011 Integrated Flight Systems Trouble Shooting Guide A109 Air Conditioning Step 15 Trouble Shooting Guide Date 08 01 07 Section 15 TROUBLE SHOOTING GUIDE INTEGRATED Flight o Systems 3900 Falcon Way West Hanger 16S Ft Worth Texas 76106 servicing and Trouble Shooting Guide Agusta 109 Series Air Conditioning System MM 109 00 011 Agusta 109 Series Trouble Shooting Guide INTEGRATED TROUBLESHOOTING YOUR AIR CONDITIONING SYSTEM The following consists
37. N 540028 C 3 TYP BOTH ENDS OF ELECTRICAL BOX SHURLOK INSERT SL601 35 3A FILL W A 4 ALT DELRON PN 504SE 1032 06 02 METAL SET TYP 4 A C SPEED CONTROL RESISTOR PN 050024 2 COMPRESSOR WIRE RUNS AFT WITH FREON LINES TO COMPRESSOR ASSY S CONNECTED HARNESS ASSEMBLY MASTER ELECTRICAL BOX ASSY P N 540028 ABOVE AIR CONDITIONER BOX W HARNESS PN 540028 C 3 PN 540059 1 HARNESS ASSEMBLY PN 540045 1 5 OUTBOARD LOOKING 3 IN AT A C MASTER OPTIONAL DUCT IF ELECTRICAL BOX VENTILATION SYSTEM IS INSTALLATION FW D NOT PRE INSTALLED R H CONDENSER WIRES 1 REVISION RECORD ER ex or conver AE AN3 4A BOLT WITH AN960 10 WASHER INTO SHURLOCK PN SL601 3 3A POTTED FITTING TYP 4 PY JD anl 3 E maf IB nal PE X B PEP OVE X b A C CLUTCH WIRE IN LINE WITH HIGH PRESSURE AND AFT CABIN A C SPEED LOW PRESSURE SWITCHES CONTROL SWITCH ASS Y PN 540061 INTEGRATED FLIGHT L AIR CONDITIONER m INTEGRATED ALTERNATE LOCATION TRIM PLACARD AS NECESSARY Systems INTEGRATED FLIGHT L AIR CONDITIONER TITLE WIRE ROUTING DRAWN BY DATE REV SCALE SHEET JTYE 08 01 07 IR NONE 30 3 APPLICATION DWG No AGUSTA 109E 2 1 A109P L H SIDE VIEW CONDENSER ASSEMLBY PN 550022 O EVAPORATOR HOUSING ASSEMLBY CONDENSER LEG SUPPORT ASSEMBLY PN 560043
38. No AGUSTA A109E 4 1 A109P OPTIONAL MODIFICATION IF NO AIR SYSTEM IS INSTALLED FOR CABIN STA 2000 HOSE NIPPLE PN 250279 MS21044 N3 NUT AN970 35 WASHER DOUBLERS 3 PN 261510 1 65 DRILL 10 HOLE Pm AN960 10 WASHER ZUM mi FORWARD h AIRCRAFT SKIN FWD FAN GROUND WIRE CONNECTED TO 5 55 BOLT DETAIL C B BOLT MATCH DRILL SKIN TO DOUBLER RIVET WITH CR3243 4 2 RIVETS 24 PLC S TOP AND SEE DETAIL MOUNT FAN SUPPORT INTO SHURLOK SL601 3 3A ALT DELRON PN 504SE1032 06 02 WITH 1 EA ANS 5A BOLT amp 1 EA AN960 10 WASHER MOUNT INTO FAN HOUSING WITH 1 EA ANS 4A BOLT amp 1 EA AN960 10 WASHER RIGHT SIDE LOOKING IN WIRE HARNESS GROUND LEADS GROUND AT THIS LOCATION AFT AIR DUCT DOUBLER DETAIL B PN 261510 UT BACK 1 AND FILL WITH METAL SET A C RESISTOR OMITTED FOR CLARITY OUTBOARD RIGHT MOUNT EVAP 6 EA AN3 5A BOLTS amp 6 EA AN960 10 WASHERS REMOVE THIS INNER PART POSITION EVAP INBOARD TO CLEAR DUCT ON BLEED AIR LINE 12 6 id p FORWARD SIX SHURLOK INSERTS POTTED INTO UPPER DECK P N SL601 3 3A ALT DELRON INSERT PN 5045 1032 06 02 SEE DETAIL A SHURLOK INSERT PN SL601 3 3A ALT DELRON INSERT PN 504SE1032 06 02 15 AN3J 4A BOLTS REF AN960 10 WASHERS TYP 6 PLS INTERCHANGABILITY BETWEEN MS20470AD MS20426AD RIVETS AN
39. Very slow leaks will usually only vent refrigerant and not oil but a fast leak like a ruptured hose or a very lose fitting will leak the refrigerant so fast that the oil 1s carried out of the system as well If your system has suffered a major leak be sure to check the oil level in the compressor before refilling the system MM 109 00 01 1 2 Agusta 109 Series Trouble Shooting Guide INTEG RATEI TED Flight Systems Troubleshooting Trouble Low or partial refrigerant charge Symptoms Insufficient cooling Low side pressure too low High side pressure too low Receiver drier sight glass shows a stream of bubbles Air in ducts only slightly cool Cause The system is low on refrigerant probably cause by a leak Correction Find and fix the leak If there was a loss of oil be sure to check the compressor oil level Evacuate and recharge A System Full of Refrigerant First you should double check all the obvious things 1 6 the compressor clutch the belt tension and the operation of the evaporator blower Next establish some baseline conditions for your testing run aircraft high blower and coldest thermostat setting doors and windows closed ambient temperature of 70 F or above Situations do occur where the system 15 full of refrigerant yet the sight glass remains cloudy The first thing to consider 15 whether the receiver drier 1s install backwards Be sure the line from the condenser goes to the port marked
40. authorization from RSG Products Inc For the Equipment the warranty period is 12 months or 1 000 hours whichever comes first from the date of sale In the case of new spare parts this warranty is further limited to a period of six 6 months from the date of sale In the case of overhauled products this warranty is further limited to a period of three 3 months from the date of sale In the case of repaired products this warranty is further limited to a period of thirty 30 days from the date of sale and applies only to the parts used for the repair Any claims under this warranty shall be made to RSG Products Inc 3900 Falcon Way West Hanger 16S Fort Worth Texas 76106 USA Warranty is not valid unless the enclosed Registration Card 15 completed and returned to RSG Products Inc prior to any claim The Warranty Claim Form must be completed and returned with the Equipment All claims shall be handled according to standard warranty repair procedures Limitations amp Exclusions This warranty shall not apply to any Equipment repaired or altered outside the Rotorcraft Services Inc Service Department unless express prior written authorization is granted nor shall this warranty apply to any Equipment that has been subjected to misuse or accident as determined solely by Rotorcraft Services Inc The sole responsibility and liability of RSG Products Inc and your exclusive remedy under any claim arising out of connected with or resulting from this
41. cylinder to equalize through the system until at least 50 PSI is noted Utilizing an electronic leak detector check all fittings on the system to determine the point of leakage Any fitting indicating an oily or dirty condition 18 a prime suspect Service the system in accordance with the procedures outlined in the IFS Maintenance Manual Document Number MM 109 00 011 5 Maintenance Instructions An Integrated Flight Systems unit is designed to be as maintenance free as possible It incorporates design components that have proven themselves to be highly reliable It is suggested that at each periodic inspection Whether at 50 or 100 hour intervals at least a visual inspection be accomplished to the following ttems to fulfill with inspection criteria per Appendix D Far 43 Para A Para B 2 Para C 1 7 Para D 2 7 9 and Para F G 2 3 J ommo Compressor Compressor Clutch Bearing Compressor Mount Refrigerant Hose and Fittings Evaporator Fan and Mounting Condenser Blower and Mounting Condense Evaporator Coils Compressor 1 111 1V In addition to the above inspection the compressor should be inspected for atrue turning and free clutch One mechanic should turn the main rotor blade while another observes the belt and clutch faceplate Turn svstem to A C and check magnetic operation of clutch plate An independent 14 wire may be necessary from the compressor to an airframe ground in order to ensure that the clu
42. fail coil or bearing B Air gap on clutch may have changed C Coil may have weakened D Bearing may have failed causing clutch to slip and fail coil NOTE If ongoing maintenance is not maintained on compressor clutch bearing as prescribed in IFS maintenance manual bearing may fail 10 Compressor failed A Loss of oil or insufficient oil B Low Freon in system causing insufficient flow of oil lubricant C Contamination in system D Compressor bearing failed E Over servicing of system to the point of liquid lock NOTE This has happened 11 Compressor belt failure A Low Freon in system Cause low pressure switch to cycle the clutch on and off excessively B Insufficient belt tension C Clutch bearing dragging of failing This causes excessive belt slipping D Over service of system E Air gap excessive causes clutch to slip heating pulley This will stretch belt making it slip 12 Air conditioner runs but pops amp circuit breaker A Check condenser fan or fans for operation B Check blockage of air flow in and out of condenser C Check coil to see if fins are clean or rolled over D Check for over service of Freon E Put gauges on and run system 1 Is system popping 1 amp circuit breaker at 350 or higher a If not change high pressure switch F Check expansion valves and make sure sensing bulbs are mounted to suction lines 1 Measure Delta of both evaporators a If Delta 1s over 32 F expansi
43. flammable Irritating to eyes respiratory system and skin Vapours cause drowsiness and dizziness Pressurized container protect from sunlight and do not expose to temperatures exceeding 50 i e electric lights Do not pierce or burn even after use 100 0 hy mass of the contents are flammabie Keep out of the reach of children Classification system The classification was made according to the latest editions of international substances lists and expanded upon from company and literature data NFPA ratings scale 0 4 Health 2 Fire 4 Reactivity 7 0 Contd on page 2 USA Page 2 7 THIS INFORMATION PERTAINS TO IPs PN ov0003 TOUCH UP paint Tea Material Safety Data Sheet IPS PN 070005 1 TOUCH UP FAINT GREY to ISO DIS 11014 Printing date 07 28 2005 Reviewed on 02 07 2005 Trade mame 61003 Multi Coat Blank Aerosol Comd of page 1 HMIS ratings scale 0 4 1 Health 2 REACTIVITY Reactivity 0 First aid measures After inhalation In case of unconsciousness place patient stably in side position for transportation After skin contact Immediately wash with water and soap and rinse thoroughly After eve contact Rinse opened eye for several minutes under noming water If symptoms persist consult a doctor After swallowing If symptoms persist consult doctor Fire fighting measures Suitable extinguishing agents CO2 sand extinguishing powder Do not use water For safe
44. foam tape Lay a layer of foam tape over the top to seal to the aircraft skin This will keep air from running to end of duct and direct it into the holes DO NOT install duct yet Locate doublers P N 260889 and 260890 in position as shown in drawing 5 A109 Sheet 2 of 4 These holes should line up with holes cut out in upper skin Relocate heater control as necessary to provide for doubler installation Locate doublers P N 260889 P and 260890 P in position as shown in drawing 5 1 A109P Sheet 2 of 4 These holes should line up with holes cut out in upper skin Mark around doubler Drill out rivets inside marking DO NOT drill wires and lines inside overhead panel Back drill other holes Remove all shavings or debris Maintain 2X diameter edge distance Cut out holes and rivet doublers in place Use flush rivets on lower row per Dwg 5 A109 Sheet 2 of 4 Remove all shavings or debris Maintain 2X diameter edge distance Cut out holes and rivet doublers in place per Dwg 5 1 A109P Sheet 2 of 4 Remove all shavings or debris Maintain 2X diameter edge distance Fit Wemac Support P N 250276 Drill mounting holes Install MS21059 L3 Nutplates per Dwg 5 A109 Sheet 2 of 4 For A109 E Installation utilize drawings 5 1 A109P Sheet 2 of 4 DO NOT INSTALL SUPPORT Remove all shavings or debris Date 09 24 09 Section 5 Installation of Evaporators Install air deflectors P N s 260916 and 260917 as shown in drawing 5 A109 Sheet 3 of 4
45. modified aircraft 4 This approval nequires the inspections and overhwel schedules ta be performed zs mandated by Insezraied Flight Systems Inc Instructicas for Comtinued Airworthiness ICA A TJS 00 01 1 Revin IR dated Movember B 200B or later FAA mccepied vison m Rm m EHD affection ef pair pov of egia 08 or cece not gd 3 ar FETTET O FAM rertyizair map refered m accidere nm 21 47 Step 12 Instructions for Continued Airworthiness Integrated Flight Systems Air Conditioning System Instructions for Continued Airworthiness For Agusta S p A AT109A 109 109 2 109 Document No ICA A109 00 0 1 Rev IR Date November 1 2008 Page 2 of 10 RECORD OF REVISIONS Initial Release 11 01 08 LIST OF EFFECTIVE PAGES PAGE REVISION DATE IR 11 01 08 2 R 11 08 3 3 110108 4 110108 5 j R 6 R L7 R 108 _ 8 R 1100 9 R 1008 Document No ICA A 109 00 0 Rev IR Date November 1 2008 Page 3 of 10 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS FOR INTEGRATED FLIGHT SYSTEMS AGUSTA S p A AIO09A II AIO9C AIO9K2 AND AIO9E AIR CONDITIONING SYSTEM Aircraft Make Agusta S p A Aircraft Model A109A IL 109 A109K2 AIO9E 1 Introduction Kit 109 00 011 is applicable to the specified models of the Agusta A109 series helicop
46. of a belt drrven vapor cycle R1344 air conditioning system The system as supplied may be used without any heater installed The Agusta Bleed Air Heater Casey Shroud Heater or other FAA Approved heaters may be utilized The Air Conditioning System provides for cabin comfort during all operations both on the ground and in flight During ground operations when only the 1 engine is running cooling may be provided Controls for the Air Conditioning System are over the pilots head Two switches are provided The Master Control Selector consists of a toggle type switch labeled OFF and FAN Selecting the A C position turns on the system s evaporator fans condenser blowers and belt driven compressor clutch The second toggle switch pravides far HIGH LOW and MED evaporator fan speed selection for the cockpit A rocker switch in the aft cabin provides blower speed control for passengers A high pressure safety switch disengages the compressor and stops operation of the refrigeration cycle in the event of excessive refrigerant pressure This can occur due to a failure of the condenser blowers or restricted condenser intake A low pressure switch of similar design protects the system due to loss of refrigerant Both switches will automatically reset and the system will cycle an again when the pressures are again at preset point The evaporator fan system may be used any time air circulation is desired This is accompli
47. provisions limitations and exclusions set forth herein Such term provisions limitations and exclusions shall not be modified deleted or supplemented In a case where the purchaser has negotiated warranty terms by express written agreement with RSG Products Inc as to certain equipment the terms of that agreement shall supersede the warranty RSG Products Form 33 39 Rev 09 19 2011 1 PRODUCTS INC Standard Terms and Conditions of Sale 1 Terms of Payment Unless prior arrangements are made to establish credit terms RSG Products Inc all sales are prepaid in full prior to shipment Payment may be made via cash check or electronic transfer to RSG Products Inc prior to delivery 2 Buyer s Deposit A 50 deposit is required to process an order for an air conditioning kit The deposit is non refundable and will be applied to the final price of the kit 3 Taxes Other Charges Prices of the specified products are exclusive of all city state federal and international taxes duties levies or charges of any kind including without limitation taxes on manufacture sales receipts gross income occupation use and similar taxes or other charges Whenever applicable any taxes or other charges shall be added to the invoice as a separate charge to be paid by Buyer 4 Shipment and Packaging All products will be suitably packed marked and shipped F O B RSG Products Inc Fort Worth Texas in accordance with standard packaging procedu
48. without notice In no event shall RSG Products be held liable for indirect or consequential damages or any damages resulting from the use of information from this Site The information on this Site 15 at the recipient s own risk Links This site contains links to other Sites on the World Wide Web RSG Products Inc provides such links for your convenience only and is not responsible for the content of any Site linked to or from this Site Links from this Site to any other Site does not mean that RSG Products Inc approves of endorses or recommends that Site Rights of Use Any person is hereby authorized to view copy print and distribute any document published by Integrated Flight Systems Corp provided that it is for personal use for information purposes and reference must be made to RSG Products Inc when the document is used Information Collected When you visit this site RSG Products Inc may collect information in two ways through information automatically gathered from your computer or through information you voluntarily provide As to automatically gathered information RSG Products collects navigational information about where visitors go on our Site how many visits are made to the Site when the Site is visited and other non personally identifiable information for example this can include domain type browser version service provider IP address The navigational information that is automatically gathered when you visit integ
49. 0 70 gem Solubility in Miscibility with Water Not miscible or difficult to mix Solvent content Organic solvents content 1070 Stability and reactivity Thermal decompasition conditions to be avoided No decomposition If used according to specifications Dangerous reactions No dangerous reactions Known Dangerous products of decomposition No dangerous decomposition products known 1 Toxicological information Acute taxicity 50 values that are relevant for classification 6 64 1 acetone Oral 5800 Dermal 1 050 20000 mg kg rabbit Contd om page 5 USA Page 3 7 THIS INFORMATION PERTAINS TO ws PN 070003 TOUCH UP Material Safety Data Sheet IFS PN 070003 1 TOUCH UP PAINT GRE Y ace to ISO DIS 11014 Printing date 07 28 2005 Reviewed on 02 07 2005 Trade name 6 1003 Multi Coat Blank Aerosol Cont d of page 4 Primary irritant effect the skin irritant to skin am mucous membranes on the eve Irritating effect Sensitization No sensitizing effects known Additional taxicalagical information Ihe product shows the following dangers according to internally approved calculation methods for preparations Irritant 12 Ecological information General notes Water hazard class 3 Selfzissessment extremely hazardous for water Do not allow product to reach ground water water course or sewage system even in
50. 0R8 SCREWS AN960 10L WASHERS MS21059L3 NUPLATES ALT A10K80 RIVNUTS LEFT SIDE LOOKING IN DETAIL A 3 3 2 6 AIR DEFLECTOR caua RIVET TYP 2 4 OUTBOARD O UPPER AND INNER DUCT Lo sS o xU x s ij i NOTE CUT DUCT FLANGE NIME NUN TO FIT PITOT BASE INTEGRATED P N 260917 BOTH SIDES INSPECT UNDER ROOF PRIOR TO DRILLING Svstems BUILD UP FOAM TAPE FROM INSIDE USE STOP DRILL WHEN DRILLING ALL y DUCT TO TOP OF AIRCRAFT HOLES THRU ROOF COVER WITH ALUMINUM TITLE AIR DISTRIBUTION TAPE SEAL TO SKIN WITH STA FOAM TAPE 2000 AGUSTA 109 5 A109A A109A II A109C A109K2 5 A109 REVISION RECORD DATE DESCRIPTION OF CHANGE CONVERTED TO AUTOCAD CHANGED TITLE pus BLOCK REPLACED OLD PHOTOS ADDED SHEET 4 OF 4 FOAM TAPE AROUND ooj4 oo ADDED P N 520066 CABIN DUCT FOR A109A rec NIPPLE TO FORM iy NIPPLE ATTACHMENT BRACKET P N 261009 AIR SEAL TO CABIN P N 250509 A CEILING AFT CABIN DUCT ASSY B P N 520066 FOR A109A USE P N 520066 A PLACARD P N 120071 2 T OPPOSITE NOIES 3 5 IN DECK HOLE _ UPPER DECK 1 REMOVE AFT CABIN DUCT AND HEADLINER AS REQUIRED EXISTING NUTPLATES HAT SECTION SHOWN MAY 2 IF ELECTRICALLY ACTUATED EXISTING SIGNS PLACARDS BY AGUSTA ARE BE ROTATED 90 IN Z N NOT IN AIRCRAFT INSTALL IFS P N 120071 TO DUCT SOME AIRCRAFT IF ELECTRICALLY ACTUATED SIGNS PLACARDS BY AGUS
51. 2 6 POSITION EVAP INBOARD TO CLEAR DUCT ON BLEED AIR LINE SEE DETAIL B SIX SHURLOK INSERTS POTTED INTO UPPER DECK P N SL601 3 3A ALT DELRON INSERT PN 5045 1052 06 02 SEE DETAIL A FORWARD HOSE NIPPLE PN 250279 AT DEC DOUBLERS PN 261510 DRILL 10 HOLE THRU AN960 10 WASHER 15 BOLT AIRCRAFT SKIN DETAIL C MATCH DRILL SKIN TO DOUBLER RIVET WITH CR3243 4 2 RIVETS 24 PLC S TOP AND BOTTOM AFT AIR DUCT DOUBLER PN 261510 DETAIL B UT BACK AND FILL WITH ETAL SET SHURLOK INSERT PN SL601 35 3A ALT DELRON INSERT PN 504SE1032 06 02 A C RESISTOR OMITTED OIL LINES FOR CLARITY TT _ OIL TANK CONTROL ROD BLOWER MOTOR MUST CLEAR CONTROL CYLINDER TOP VIEW FORWARD DRILL 3 EA 10 8 EQ SP CENTER ON FLANGE ATTACH WITH AN3 13A BOLTS 3 EA MS21044 N3 NUTS 3 EA AN970 3 WASHER 3 EA AN960 10 WASHER 3 EA HOSE NIPPLE P N 250279 PER DETAIL C IFS MASTER AIR CONDITIONING ELECTRICAL CONTROL BOX P N 540028 0 5 HARNESS ASSY P N 540059 HARNESS ASSY P N 540045 1 TWO EACH CONTROL RODS AND MIXER OMITTED FOR CLARITY STA 2000 AGUSTA 109 A109A A109A II A109C A109K2 REVISION RECORD wv pars DESCRIPTION OF CHANGE CONVERTED TO AUTOCAD OLD PHOTOS ADDED A109A MODEL TO APPLICATION BLOCK REVISED TITLE BLOCK MGV JTYE MOUNTING AREA
52. 20470AD4 4 WEMAC SUPPORT 250276 NUTPLATE MS21059 L3 RIVET CCR264 SS3 3 AIR DUCT 250275 RIVET ABA4 4 d Verf d STEP A109 E A109 E Ul Ul N N UJ Ul N CO NJ lt Date 09 24 09 Rev B Section 1 Kit Inventory Page 4 of 16 Integrated Flight Systems KIT INVENTORY LIST A109 00 011 Air Conditioning KI T INVENTORY LIST O STEP PART NAME PART pa d SCREW AN525 10R8 DUCT 7 060007 erin WEMAC 030012 SCREW AN525 10R8 MS21044N3 SCREW AN525 10R8 CO PILOTS BULKEAD DOUBLER 260866 CO PILOTS BULKEAD DOUBLER 260866 P RIVET MS20470AD4 3 RIVET RIVET RIVET RETURN AIR DUCT ASSEMBLY SCREEN 9 8 x 7 4 RETURN AIR a I Ul Date 09 24 09 Rev B Section 1 Kit Inventory Page 5 of 16 Integrated Flight Systems KIT INVENTORY LIST A109 00 011 Air Conditioning KI T INVENTORY LIST RETURN AIR DUCT ASSEMBLY 520061 P 1 SCREEN 9 8 x 7 4 RETURN AIR 08036 1 WASHER aos 43 RETURN AIR DUCT LOWER 25086 1 __ _ 0 Ul Ul 510231 B VERTICAL SUPPORT ASSEMBLY n m B VERTICAL SUPPORT ASSEMBLY 510230 Hc o RP RIVET ABA 8 DUCTMOUNT 2009121 1 RIVET o 12 m _ NN J NE AMA 49 _ x E I pi d Ul N Bawa
53. 31 PLATE ASSEMBLY P N 510232 DUCT MOUNT PN 260912 1 RETURN AIR DUCT LOWER PN 250286 SUPPORT P N 510230 2 PLG S DRILL AS REQUIRED TO MAINTAIN 15 CLEARANCE ATTACH WITH RETURN AIR DUCT 2 CR35245 4 4 RIVET INTEGRATED PN 520061 109 Systems STRIP WIRE FROM DUCT PN 060007 AND INSTALL WITH 2 EACH RELOCATE RELAY FORWARD TO 6 IN BAND CLAMPS TITLE AIR DISTRIBUTION NEW LOCATION AS SHOWN TuS A109A A109A II A109C A109K2 5 A109 REVISION RECORD NOTE TORQUE ALL FASTENERS IN ACCORDANCE WITH APPLICABLE AGUSTA AIRCRAFT SERVICE 5 CONVERTED TO AUTOCAD OLD PHOTOS A 08 01 07 REPLACED CHANGED TITLE BLOCK ADDED MGV A HEAT SYSTEM SHEET 4 OF 4 e k BLOCK REVISED TITLE BLOCK FORWARD mb c CO PILOTS SIDE AIR DUCT TM ovr SE DOUBLER P N 260889 P N 250275 Ku FITTED a DRLLED DOUBLER P N 260890 _ INSTALLED WEMAC SUPPORT P N 250276 amp INTERCHANGABILITY BETWEEN MS20470AD MS20426AD RIVETS AND CR3243 CR3242 RIVETS ALLOWABLE GRIP LENGTH OF RIVET TO BE s DETERMINED BY INSTALLER INSTALL IN ACCORDANCE WITH 43 13 1A CHAPTER 2 SECTION 3 99 RIVETING a b c d FIGURE 2 19 USE ANS25 10R8 SCREWS TYP 4 NOTE CHAPTER 5 SECTION 1 232 TYPE OF RIVETS a e f DATED 1972 PL gt 1 DRILL 10 DIA TYP 15 2 DRILL RIVET HOLES WITH NUTPLATE FIXTURE 3 COUNTERSINK RIVET HOLES
54. 4 1 0 0 5 0 1 mm shims 3 Align keyway in armature assembly to shaft key Using driver and a hammer or arbor press drive the armature assembly down over the shaft until it bottoms on the shims A distinct sound change will be noted if driving with a hammer 4 Replace retaining nut and torque to specification 1 2 20 20 25 ftelb 27 34 Nem 270 350 kgecm 8 11 15 510 15 21Nem 150 210kgf cm MM 109 00 011 Agusta 109 Series Trouble Shooting Guide SERVICE OPERATIONS CLUTCH INTEGRATED Systems Note Over torque of SD508 5H14 dust cover bolts will cause air gap to become out of spec MM 109 00 01 1 Check air gap with a feeler gauge Specification 15 0 011 0 019 0 3 0 5mm If gap is not even around the clutch gently tap down at the high spots If the overall gap is out of spec remove the armature assembly and change shims as necessary Replace armature dust cover if used and torque 3 or 6 bolts to specification below 3 1 4 20 bolts 50 5 2 4 ftelb 2 5 Nem 25 50 kgf cm 6 5 bolts SD 7 5 8 ftelb 7 11 Nem 70 110 kgf cm 15 LOW PRESSURE BIG LINE 10 INLET EXPANSION VALVE LOW PRESSURE SWITCH BLUE LEADS 22 PSI CLOSES 7 PSI OPENS CAP TUBE W f SENSING TUBE HIGH PRESSURE SMALL LINE 8 HIGH PRESSURE SMALL LINE 6 HIGH PRESSURE SWITCH BLACK LEADS 350 PSI OPENS 250 PSI CLOS
55. 5 1 CP 100 20 JUMPER NOTE 90 AMP C B PN 050012 9 USE 6 EA MSe0659 No 8 INSULATED RING TERMINAL x No 8 WIRE AFT SPEED CONTROL SWITCH ASSY PN 540061 HANDSHAKE 3X IF S101C14 RESISTOR ASSY PN 540020 IF S101C14 lt ea e e L 10 A 14 ES IF S102B14 48 IF S107C14 IF S103C14 IF S104B14 HIGH PRESSURE SWITCH IF S108B20 RESET RELAY IFS108D20 CP101 NOTE EVAP AFT FAN MOTOR MOTOR PN 050143 IF 5101314 IFS107B14 fo 9 9 IF S107N14 IFS103B14 fo 9 IF S103N14 1 SEE 2 5 5350 SH 1 OF 1 FOR WIRE SPLICE LOC WIRE SPEC MIL W 22759 16 WIRE NO IFS XXX X XX GROUP SEQUENCE INDICATES GROUND WIRING DIAGRAM A109 ELEC PANEL ASSY P N 540028 3 DUAL CUNDENSER FAN GAUGE EVAP FWD FAN MOTOR CONDENSER FAN MOTOR PN 050143 HANDSHAKE CONDENSER FAN MOTOR PN 050143 IF S104C14 IF S105B20 IF S106B20 IF S105N20 REVISION RECORD ADDED A109A MODEL TO APPLICATION BLOCK REVISED TITLE BLOCK TIERE FWD SWITCH ASSY PN 540060 CP 103 SWITCH PN 050093 IFS102D14 EN w Fa LOW PRESSURE SWITCH CP 102 HANDSHAKE BUTT SPLICE COMPRESSOR CLUTCH CP 102 IF 5104 14 OR OPTIONAL TEMP CONTROL FWD SWITCH ASSY PN 540060 SWITCH PN 050091 IF 105C20 AGUSTA 109 A A109A A109A II A109C A109K2 INTEGRATED S
56. 5 1 A109 Sheet 1 of 4 Mark around outside and inside edge of doubler Remove ground buss from upper deck as shown in 3 37 drawing 5 109 Sheet of 4 Move existing wire from forward bulkhead For A109 E Installation Disregard this Step Next drill out rivets inside marked area Step 5 36 Remove all shavings or debris Date 09 24 09 Section 5 Installation of Evaporators Rev A Page 6 of 10 Integrated Flight Systems INSTALLATION OF EVAPORATORS A109 Air Conditioning Installation of Aft Evaporator STEP PROCEDURE MECH INSP Back drill existing holes in doubler to aircraft back drill holes in aircraft to doubler Maintain 1 5X edge distance Remove all shavings or debris Cut out return air hole Remove all shavings or debris Rivet doubler in place per drawing 5 A109 2 41 Sheet 1 of 4 For 109 E Installation utilize drawings 5 1 A109P Sheet 1 of 4 Position return air duct P N 520061 Trim as necessary to fit Drill 4 each 10 mount holes See drawing 5 A109 Sheet 1 of 4 for hole location Install 4 RM52LHA4972 10 02 Nutclips on P N 520061 Seal duct to wall with ProSeal M 890 B 2 or B1 2 Attach Screen P N 080036 to bulkead and duct using 4 each AN525 10R10 Screws 4 each AN970 3 Washers Position return air duct P N 520061 Trim as necessary to fit Drill 3 each 10 mount holes See drawing 5 A109 Sheet of 4 for hole location 5 42 Install 3 RM52LHA4972 10 02 Nutclips on P N
57. 7 set at 7 PSI out 22 PSI in is utilized The switch will automatically reset to the closed position as soon as pressure 1s applied in PSI greater than the cut in point Document No ICA A109 00 011 Rev IR Date November 1 2008 Page 9 of 10 High Pressure Switch A High pressure switch is identified under P N 090004 It is also located in the engine compartment near the compressor It 1s a normally closed switch which opens on a rise in pressure that exceeds the switches upper limit Once the pressure has been reduced below the switches upper design point it will again close automatically System Operation Limitations A Below 60 degrees Fahrenheit it may be found that the air conditioning compressor will not come on line and remain in operation This is due to that fact that coolness of the air available across the condenser does not allow the refrigerant system to maintain sufficient low side pressure to keep the safety low pressure switch from tripping the compressor off line The system should not be operated in temperatures below 66 F except for re circulation of air only 7 Removal and Replacement Information The Integrated Flight Systems Air Conditioning Kit Part Number A109 00 011 is installed and removed in accordance with Installation Instructions Document Number IM A109 00 01 1 8 Diagram COMPRESSOR LOCATED AFT OF TRANSMISSION EE EVAPORATOR ASSEMBLY PILOTS A NEW WEMAC
58. A109P Center caliper to disc with shims P N s 261012 1 261013 1 261014 1 as necessary Mark and Drill strut brace P N 300330 to existing nutplates on bracket P N 510255 as shown in 6 1 A109 For AIO9E use 6 1 A109P Bolt to transmission case and bracket as shown in drawing Remove all shavings or debris Replace straight fitting on caliper with 90 fitting AN833 4D and nut AN924 4D as shown on drawing 6 1 A109 Sheet 1 of 3 For A109 E Installation utilize drawings 6 1 A109P Sheet 1 of 3 Connect brake line to new fitting per drawing 6 1 A109 sheets 1 and 2 of 3 For A109 E Installation utilize drawings 6 1 A109P Sheets 1 and 2 of 3 Rotate existing adel clamps 15 180 standoff with 3 16 LD x 5 7 spacers Attach with 2 AN3HILA bolts 4 NAS1149F0363P washers and 2 MS21044 N3 nuts Safety wire 032 min Re service system 1f necessary and check operation of brake IAW Agusta Service Manual Back drill in place and install firewall box P N 530089 Using AN3 3A bolts and NAS1149F0363P washers Secure spare belt P N 060031 P N 530089 P and 060031 1 for A109E Remove all shavings or debris Modify center firewall per drawing 6 1 A109 Sheet 3 of 3 and install Install firewall angle P N 300337 Rivet in place Back drill and install with AN3H3A bolts and AN960 10 washers For 109 disregard this step Install compressor P N 010001 3 0 and Belt Adjustment Assy P N 530088 and Belt Bracket Assy P N 510263 per drawin
59. AIDED POSITIVE LEAD DOES NOT CONTACT HOUSING CAUSING SHORT The fins of the condenser coil as well as the evaporator coil should be checked for cleanliness and that they are straight If damage has occurred to the fins a fin comb should be utilized put them in like new condition 6 Troubleshooting Information General A Should the system not perform as expected either because of unreasonably erratic pressure readings total lack of cooling or reduced cooling it will be necessary to use the trouble shooting procedures outlined in the IFS Maintenance Manual Document Number MM 109 00 011 The high and low pressure switches should be checked if electrical power is lost to the compressor clutch These are in series and they should be checked from their electrical source which is the 50 amp condenser blower circuit breaker Always check system R 134a pressure first as leaking unit may have caused the low pressure switch to open This switch is set to open at 8 PSI and close at 22 PSI Document No ICA A 109 00 01 1 Rev IR Date November 1 2008 Page 7 of 10 D Failure of the condenser blower or coil blockage could result 1n high side pressure switch opening Both switches are designed to reset automatically NOTE Internal blockage of the high pressure side of the refrigerant system can cause a very low pressure reading at the low side service gage and may also cause a low pressure reading at the high side servic
60. Air Conditioning Step 5 Installation of Evaporators Date 09 24 09 Rev A Section 5 Installation of Evaporators Page 1 of 10 Integrated Flight Systems INSTALLATION OF EVAPORATORS A109 Air Conditioning Warning The minimum clearance of the flight controls is 15 inches The clearance must maintained throughout installation of evaporator and condenser Caution After any step that requires drilling Care must be taken to remove any shavings from the area Torque all fasteners with applicable Agusta service manuals or utilize AC 43 13 STEP PROCEDURE MECH INSP For proper installation of evaporator condenser and condenser mount the following steps should be followed in order Position Cockpit Air Duct Assembly P N 520062 using drawings 8 A109 Sheet 1 of 1 and 5 A109 Sheet 3 of 4 For A109 E Installation utilize drawings 8 1 A109P Sheet 1 of 1 and 5 1 A109P Sheet 3 of 4 Using the Cockpit air Duct Assembly P N 520062 mark each side of the flange where it will be cut Remove Duct 5 1 5 2 5 3 5 5 5 6 7 Cut off flange from aircraft as shown in drawing 8 A109 Sheet 1 of 1 Duct sides should clear 10 Save Camloc from removed flange For A109 E Installation utilize drawing 8 1 A109P Sheet 1 of 1 Temporarily install and align duct Lay out and drill mounting holes through duct and top of helicopter as shown in drawing 5 A109 Sheet 3 of 4 Cleco in place For A109 E Installation utilize drawing
61. Approved Rotorcratt Flight Manual when equipped with Integrated Flight Systems Inc Air Conditioning System Registration Serial This supplement must be attached to the Agusta Approved Rotorcraft Flight Manual when the rotorcraft is modified by the installation of Integrated Flight Systems Inc Air Conditioning System in accordance with STC No SR00060DE The information contained herein supplements or supersedes the basic manual only in those areas listed herein For limitations procedures and performance information not contained in this supplement consult the basic Rotorcraft Flight Manual FAA Approved _ 27 aere A Manager Flight Test Brafich AMM 160L Federal Aviation Administration Los Angeles Acra Certification Office Transport Aircraft Directorate FAA Approved Date Ppt JE feel Original issue date October 14 1993 Pope curated Systenis Supplement to the Ageia Model 1900 Flighiline Drive Suite 3 AIRS AIK amp Flight Manual Lincaln CA 95648 Imegrated Flight Systems Air Conditicesr Supplement No RFMS ALOS 00 0 1 STC No SRIKKIAUDE RECORD OF REVISIONS PAA Approval Initial Release Ehad E Jenmings Manager Denver NM Region Date 161454 company address added AIE Model added RPMS Number removed density allitede chart from section 4 Br ANM
62. BOLT amp 1 EA AN960 10 WASHER MOUNT INTO FAN HOUSING WITH 1 EA ANS 4A BOLT amp 1 EA AN960 10 WASHER RIGHT SIDE LOOKING IN WIRE HARNESS GROUND LEADS GROUND AT THIS LOCATION AFT AIR DUCT DOUBLER DETAIL B PN 261510 UT BACK 1 AND FILL WITH METAL SET A C RESISTOR OMITTED FOR CLARITY OUTBOARD RIGHT MOUNT EVAP 6 EA AN3 5A BOLTS amp 6 EA AN960 10 WASHERS REMOVE THIS INNER PART POSITION EVAP INBOARD TO CLEAR DUCT ON BLEED AIR LINE 12 6 id p FORWARD SIX SHURLOK INSERTS POTTED INTO UPPER DECK P N SL601 3 3A ALT DELRON INSERT PN 5045 1032 06 02 SEE DETAIL A SHURLOK INSERT PN SL601 3 3A ALT DELRON INSERT PN 504SE1032 06 02 15 AN3J 4A BOLTS REF AN960 10 WASHERS TYP 6 PLS INTERCHANGABILITY BETWEEN MS20470AD MS20426AD RIVETS AND m CR3243 CR3242 RIVETS ALLOWABLE GRIP LENGTH OF RIVET TO BE 1 56 DETERMINED BY INSTALLER INSTALL IN ACCORDANCE WITH AC 43 13 1A CHAPTER 2 SECTION 3 99 RIVETING a b c d FIGURE 2 19 CHAPTER 5 SECTION 1 232 TYPE OF RIVETS a e f DATED 1972 FILL W A 4 BLOWER MOTOR MUST METAL SET CLEAR CONTROL CYLINDER TYP 4 DETAIL A FORWARD TOP VIEW INSTALL RETURN AIR ADAPTER P N 110100 DRILL AND ATTACH WITH ABA4 4 RIVETS AS REQUIRED FOAM AND FOIL TAPE SECURE RETURN AIR DUCTING PN 060012 WITH 6 BAND CLAMP PN 060055 DRILL 3 EA 10 9 EQ SP CENTER ON F
63. CONDITIONING 4 CONTROLS amp FWD FAN SPEED CONTROL 50 AMP CIRCUIT BREAKER PN 050012 9 ABOVE PILOTS HEAD AND RIGHT OF THROTTLE PLACARD PN 120009 2 SHOWN 4 eT POSITION PLACARD IF AS REQUIRED j A C MASTER RETURN AIR COMPRESSOR NEW WEMACS CO PILOTS CONDENSER ASSEMBLY MASTER ELECTRICAL CONTROL BOX NEW WEMACS AGUSTA A109E CO PILOTS POWER INTEGRATED Systems o o o o o TITLE AIR CONDITIONING RETURN AIR SCREEN PN 080036 P OVERVIEW ABOVE AND BEHIND CO PILOTS HEAD DRAWN BY DATE REV SCALE SHEET NEW CO PILOTS WEMACS ITYE NONE APPLICATION DWG No PILOTS OPPOSITE AGUSTA A109E 1 1 A109P L H SIDE VIEW CONDENSER ASSEMLBY PN 550022 O EVAPORATOR HOUSING ASSEMLBY CONDENSER LEG SUPPORT ASSEMBLY PN 560043 O COCKPIT AIR DUCT ASSEMBLY STA 2000 fo PN 520062 O O O O O 000 DRAIN LINE DETAIL OUTLINE OF EVAPORATOR EVAPORATOR ASSY a A RIGHT SIDE n CE VIEW LOOKING DOWN wl 5 v Passy ort 5 2 E FAN OMITTED FOR T T me aii CLARITY EA g 3 IN FORWARD lt TOP VIEW MS II v d O BOE RETURN AIR DUCT dd DELETED FOR Tu CLARITY ZEN e L 8 LEFT SIDE VIEW A A STA 2000 REVISION RECORD DESCRIPTION OF CHANGE REV DATE APPV A 08 01 07 CONVERTED TO AUTOCA
64. D ADDED A109A MODEL TO APPLICATION BLOCK REVISED TITLE BLOCK REV Y PN 100181 DRAIN LINES PN 090018 1 AGUSTA 109 A109A A109A A109C A109K2 INTEGRATED Systems TITLE EVAPORATOR INSTALL K A 11 20 92 B NONE 1 OF 2 A109A A109A II A109C A109K2 4 A109 WIRE HARNESS GROUND LEADS GROUND AT THIS LOCATION OUTBOARD 15 RIGHT MS21044 N3 NUT AN970 3 WASHER INTERCHANGABILITY BETWEEN MS20470AD MS20426AD RIVETS AND CR3243 CR3242 RIVETS ALLOWABLE GRIP LENGTH OF RIVET TO BE DETERMINED BY INSTALLER INSTALL IN ACCORDANCE WITH AC 45 15 1A CHAPTER 2 SECTION 3 99 RIVETING a b c d FIGURE 2 19 CHAPTER 5 SECTION 1 232 TYPE OF RIVETS a e f DATED 1972 DETAIL A AN3J 4A BOLTS AN960 10 WASHERS TYP 6 PLS 4 a Fi il mui FORWARD FWD FAN GROUND WIRE CONNECTED TO AN3 5A BOLT 1 59 FILL W A 4 METAL SET TYP 4 RIGHT SIDE LOOKING IN SEE DETAIL A MOUNT FAN SUPPORT INTO SHURLOK SL601 3 3A ALT DELRON PN 504SE1052 06 02 WITH 1 EA 5 BOLT amp 1 EA AN960 10 WASHER MOUNT INTO FAN HOUSING WITH 1 EA ANS 4A BOLT amp 1 EA AN960 10 WASHER POSITION EVAP 2 EXISTING FRESH AIR FORWARD OF TUBES OPENING ENLARGE FROM 2 5 TO 3 5 INSTALL 3 4 NIPPLE P N 250279 SEAL UNDER amp AROUND NIPPLE W PRC 890 B X WASHERS 1
65. D m CR3243 CR3242 RIVETS ALLOWABLE GRIP LENGTH OF RIVET TO BE 1 56 DETERMINED BY INSTALLER INSTALL IN ACCORDANCE WITH AC 43 13 1A CHAPTER 2 SECTION 3 99 RIVETING a b c d FIGURE 2 19 CHAPTER 5 SECTION 1 232 TYPE OF RIVETS a e f DATED 1972 FILL W A 4 BLOWER MOTOR MUST METAL SET CLEAR CONTROL CYLINDER TYP 4 DETAIL A FORWARD TOP VIEW INSTALL RETURN AIR ADAPTER P N 110100 DRILL AND ATTACH WITH ABA4 4 RIVETS AS REQUIRED FOAM AND FOIL TAPE SECURE RETURN AIR DUCTING PN 060012 WITH 6 BAND CLAMP PN 060055 DRILL 3 EA 10 9 EQ SP CENTER ON FLANGE ATTACH WITH AN3 13A BOLTS 3 EA MS21044 N3 NUTS 3 EA AN970 3 WASHER 3 EA AN960 10 WASHER 3 EA HOSE NIPPLE P N 250279 P IFS MASTER AIR CONDITIONING ELECTRICAL CONTROL BOX P N 540028 C 3 HARNESS ASSY P N 540059 1 HARNESS ASSY P N 540045 1 TWO EACH CONTROL RODS AND MIXER OMITTED FOR CLARITY STA 2000 POWER AWAY 7 INSTALL 3 4 NIPPLE P N 250279 P INSERT INSTALLATION INSTRUCTIONS MATCH DRILL COMPONENTS UNDER DETAIL A AND B TO HELICOPTER CABIN ROOF USING 10 HOLES SPOT FACE UPPER FACE SKIN TO 9 16 DIAMETER AT EACH 10 HOLE USING A 90 ANGLE TOOL REMOVE CORE OF CABIN ROOF TO A DIAMETER OF 1 5 FROM UNDERSIDE OF UPPER SKIN TO UPPER SIDE OF LOWER SKIN VACUUM OUT ALL CORE MATERIALS REMOVED TRAIL FIT SUR LOK INSERT P N SL601 3 34A ALT DEL
66. DOES NOT BECOME CLOGGED WITH METAL SET ALLOW METAL SET TO FULLY CURE BEFORE INSTALLING EVAPORATOR TO ASSEMBLY OR MASTER A C ELECTRICAL PANEL 9 RETAIN A SAMPLE OF THE METALSET A 4 USED IN THIS INSTALLATION FOR A PERIOD OF 24 HOURS ENSURE THAT CURING AND BONDING PROPERTIES DEVELOP IN ACCORDANCE WITH MANUFACTURER S RECOMMENDATIONS db INTEGRATED Systems TITLE EVAPORATOR INSTALL none 20F2 K A 11 20 92 B NONE 2 OF 2 S Mioa aoan aoc aooe _ A109A A109A II A109C A109K2 4 A109 L H SIDE VIEW CONDENSER ASSEMLBY PN 550022 0 RETURN AIR ADAPTER PN 110100 P EVAPORATOR HOUSING ASSEMLBY PN 560043 O COCKPIT AIR DUCT ASSEMBLY PN 520062 alm 150 RIGHT SIDE REF MOUNT W 6 EA AN3 5A BOLTS amp 6 EA AN960 10 WASHERS nr FAN OMITTED FOR T CLARITY FORWARD TOP VIEW elk 2 x RETURN AIR DUCT DELETED FOR _ LEFT SIDE STA 2000 VIEW A A VIEW LOOKING DOWN REVISION RECORD DESCRIPTION OF CHANGE CONDENSER LEG SUPPORT ASSEMBLY PN 510227 1 NOTE DRAIN LINES RUN UNDER DRAIN LINE DETAIL EVAPORATOR ASS Y OUTLINE OF EVAPORATOR EVAPORATOR ASSY Y PN 100181 HOSE DRAINS ON DECK DRAIN LINES PN 090018 1 AGUSTA A109E POWER INTEGRATED Systems TITLE EVAPORATOR INSTALL DRAWN BY DATE REV SCALE SHEET K A 08 01 07 IR NONE 1 OF 2 APPLICATION DWG
67. E REV DATE A 07 07 09 09 24 09 APPV BY REV BY DRAWING REVISED PER ECO 0192 JTYE ADDED A109A MODEL TO APPLICATION BLOCK REVISED TITLE BLOCK STALLATION INSTRUCTIONS IN ds UJ AN833 4D FITTING BULKHEAD IT IS IMPERATIVE THAT BEFORE ANY ATTEMPT IS MADE TO INSTALL THE SUBJECT AIR CONDITIONING KIT THAT AGUSTA MANDATORY SERVICE BULLETIN 109 82 OR LATER REVISIONS BE COMPLIED WITH NO ATTEMPT SHOULD BE MADE TO INSTALL THE COMPRESSOR OR IT S SUPPORTING BRACKET UNTIL THE ABOVE AGUSTA SERVICE BULLETIN HAS BEEN ACCOMPLISHED TORQUE ALL BOLTS AND FASTENERS IAW AC 43 13 OR APPLICABLE AIRCRAFT SERVICE MANUALS p 2465 AGUSTA 109 A109A A109A II A109C A109K2 VIEW FROM AFT LOOKING FORWARD INTEGRATED Systems TITLE COMPRESSOR INSTALLATION DRAWN BY DATE REV SCALE SHEET ALTE 08 01 07 B NONE APPLICATION DWG No A109A A109A II A109C A109K2 6 1 A109 90505 COMPRESSOR PN 010001 3 O NOTE ENSURE THAT HEAD BOLTS ON COMPRESSOR DO NOT PROTRUDE MORE THAN 10 AN6 H10A BOLT 2 PLC S INTO SELF LOCKING HELI COILS SAFETY WIRE TOGETHER O32 MINIMUM er LEE Uu i FASTEN DRIVE PULLEY WITH NAS 1304 4H BOLT AND NAS1149F0463P AND OR NAS1149F0432P WASHER AS REQUIRED 5 SETS REQ D SECURE W SAFETY WIRE 032 MIN OUTBOARD LOOKING INBOARD FROM LEFT SIDE OF AIRCRAFT ROTOR BRAKE DISK EXISTING STA 3884
68. E Installation utilize drawings 8 1 A109P Sheet 1 of 1 Re install duct P N 520062 temporarily s Start a small cut out remove material as necessary to fit around duct Repeat step 5 18 as necessary to achieve proper fit View on drawing 8 A109 Sheet 5 19 1 of 1 is inside looking up The curve cut out runs to the right side of aircraft For A109 E Installation utilize drawings 8 1 A109P Sheet 1 of 1 With duct in place fit cowl leaving 10 clearance around duct Remove duct Install MS21059 L3 nutplates when possible or use A10K80 Rivnuts for final installation of duct Attach with 12 each AN525 10R8 screws Kemove all shavings or debris Cut out holes as shown in drawing 5 A109 Sheet 2 of 4 For A109 E Installation utilize drawings 5 1 A109P Sheet 2 of 4 For air supply to cockpit Remove all shavings or debris Date 09 24 09 Rev A Section 5 Installation of Evaporators Page 4 of 10 STEP eo A109 E 2 23 5 26 A109 E 5 28 A109 E QN gt 5 29 Integrated Flight Systems INSTALLATION OFEVAPORATORS A109 Air Conditioning Install air deflectors P N s 260916 P and 260917 P as shown in drawing 5 1 A109P Sheet 3 of 4 Rivet to Air Duct as shown in drawing Remove all shavings or debris Block inside of duct just forward of forward hole with foam tape Build up a dam with foam tape P N 070078 cover with aluminum tape P N 070076 over the
69. E PER NOTE 23A O DOUBLER RIVET CCR264 SS3 3 TYP VIEW A e O P N 260889 260890 ALTERNATE MS20426A3 3 e 9 Or IF UNABLE TO FIT NUTPLATE RIVNUT P N A10K80 STRUCTURE e ej IS OPTIONAL Le NUTPLATE MS21059 L3 TYP ALTERNATE 521060 3 8 NOTE O WEMAC DOUBLER B POSITION HOLES BETWEEN P N 260889 J EXISTING RIVETS O 19 7 15 9 REF E RIVETS 4 4 4 PLS OR MS20470AD4 X P N 250275 AGUSTA 1 O9E POWER d L H CO PILOIS SIDE TYP PILOTS 5 INTEGRATED RIVET LEGEND Systems ABA4 4 TITLE AIR DISTRIBUTION O MS20470AD4 4 3 DRAWN BY DATE REV SCALE SHEET CCR264 SS3 3 ML NONE APPLICATION DWG No AGUSTA A109E 5 1 A109P REVISION RECORD PITOT TUBES DELETED DWG DATE DESCRIPTION OF CHANGE APPYD REV TUBES EACS LEFT SIDE LOOKING IN ALIGN DEFLECTORS BETWEEN HOLES DRILL AND ATTACH PER VIEW A A LEFT SIDE SHOWN RIGHT SIDE OPPOSITE AFT HOLE COCKPIT AIR DUCT ASSY P N 520062 FWD ium BUILD UP FOAM TAPE AIR DAM JUST FOWARD OF MOST FORWARD HOLES COVER WITH ALUMINUM TAPE SEAL WITH STRIP OF FOAM TAPE FWD HOLE 3 3 7 0 3 3 5 0 70 AIR DEFLECTOR R H SIDE SHOWN P N 260916 P AIR DEFLECTOR L H SIDE SHOWN P N 260917 P MATCH DRILL AIR DUCT TO DEFLECTORS ATTACH VIEW A
70. ECURE W SAFETY WIRE 032 MIN ROTOR BRAKE DISK EXISTING m ss A NAS1149F0463P WASHER BETWEEN STRUT BRACE AND CASE 6 OV STRUT BRACE STEEL PN 300330 gt NAS1149F0616P WASHER 2 A A AN6H10A BOLT 2 NAS1149F0663P OR NAS1149F0632P OR TYP BOTH ENDS V AN4H7A BOLT 2 PLC S NAS1149F0432P WASHER 2 PLC S SECURE W SAFETY WIRE 032 MIN W NUTPLATES OR AN4H11A BOLT 2 PLC S NAS1149F0463P OR NAS1149F0432P WASHER 4 PLC S MS21044N4 NUT OR MS20364 424C 2 PLC S W O NUTPLATES SECURE W SAFETY WIRE 032 MIN NAS1149F00863P WASHER A MS21044N8 NUT 2 PLC S gt BELT BRACKET ASSY PN 510263 BELT ADJUSTMENT ASSY PN 530088 xev ORIGINAL ROTOR BRAKE LOCATION NAS1149F0863P WASHER 1 N MS21044N8 NUT 1 FAR SIDE COMPRESSOR BRACKET ASSY PN 510255 E uw N SECURE CALIPER W BOLT 4 A NAS1149F0432P WASHER 4 SECURE W SAFETY WIRE OR SECURE CALIPER W NAS1304 5H BOLT amp NAS1149F0463P OR NAS1149F0432P WASHER 4 SETS REQUIRED SECURE W SAFETY WIRE 032 MIN ROTOR BRAKE RELOCATED TO THIS AREA PC ge REMOVE STORE EXISTING AN815 4D FITTING INSTALL 905 AND JAM NUT PN AN924 4D BETWEEN CALIPER AND COMPRESSOR BRACKET ASSEMBLY ADD PN 261012 1 261013 1 OR PN 261014 1 AS REQUIRED REVISION RECORD DESCRIPTION OF CHANG
71. ER BLOWER 050143 14 NYLON BLADE AND HUB ASSY 580000 15 BRUSHES 2 Brush motor 050031 Date 09 24 09 Rev A Section 13 Parts Break Down Page 3 of 4 ITEM 16 I7 15 19 Date 09 24 09 Integrated Flight Systems PARTS BREAK DOWN A109 Air Conditioning DESCRIPTION MISC PARTS RECEIVER DRIER 1991 amp ON O RING TYPE EXPANSION VALVE 1992 amp ON FWD AND AFT EVAP O RING TYPE HIGH PRESSURE SAFETY SWITCH ALL YEARS LOW PRESSURE SAFETY SWITCH 1991 amp ON NON ADJUSTABLE 7 OUT 22 IN Section 13 Parts Break Down PART 090016 5 090002 O 090004 050107 Rev A Page 4 of 4 Integrated Flight Systems Warranty Repair A109 Air Conditioning Step 14 Warranty Repair Date 11 04 09 Rev C Section 14 WARRANTY REPAIR EFFECTIVE DATE 11 04 09 Page 1 of 6 N 4 2 2 2 PRODUCTS INC Warranty Terms RSG Products Inc warrants that each of its Air Conditioning Systems the Equipment shall be free from defects in material and workmanship under normal use and service until one year after its date of sale if and only if installation maintenance and operation of the Equipment is in accordance with the specifications and instructions provided by RSG Products Inc and no substitute parts are installed in accordance with the specifications and instructions provided by RSG Products Inc and no substitute parts are installed in the equipment without the prior written
72. ES RESET REVISION RECORD DWG REV LTR DATE DESCRIPTION OF CHANGE APPVD REV BY BY gt a HIGH PRESSURE SMALL LINE 6 INTEGRATED Flight Systems SCHEMATIC TITLE SIMPLE AIR CONDITIONING DRAWN BY DATE JTYE 08 01 07 REV SCALE NONE SHEET APPLICATION N A DWG No A C SCHEMATIC REVISION RECORD DWG APPVD REV REV DATE DESCRIPTION OF CHANGE EVAP FWD FAN MOTOR N FWD EVAP SPEED CONTROL SWITCH b 1851021014 _ z 2 Ul N f IFS102C14 SPEED CONTROL SWITCH ads J104 FAN MOTOR r 8 IFS101C14 IF S101C14 P N 540045 1 I O F y D e fw 1 O gt T T 1 CO mm M IFS101E14 P _7 CONDENSER BLOWER 14 HANDSHAKE 3X 1 OR 2 BUSS gp T Too 814 IFS107C14 OMP RESSORZ CONDENSER RELAY 5 IF S1I03C14 EN 7 1 IF S104 B14 CONDENSER BLOWER LOW PRESSURE COMPRESSOR SWITCH CLOSED CLUTCH HIGH PR
73. ESSURE SWITCH CLUSE S IF S104C14 IF S108B20 lan Van IF S108D20 FORWARD 2 IF S106 5 O kha SPEED CONTROL SWITCH WITH M SERVICED WITH AGUSTA 109 SERIES eres ELECTRICAL WIRING DIAGRAM j Ad gt o Ll T i E IHE A C FE FAN LX ASELELIEE FAN DUAL CUNDE NSER BLOWER LINES 5 SEQUENCE INDICATES GROUND HE FAN CIRCUIT DRAWN BY i ATE REV SCALE SHEET J 087 J NTS 4 APPLICATION DWG NO les DIAGRAM 1 AGUSTA 109 SER REVISION RECORD DWG APPVD REV REV DATE DESCRIPTION OF CHANGE EVAP FWD FAN MOTOR 188 4 CE 103 E P N 40088 C 3 UN FWD EVAP SPEED CONTROL SVITCH Qum he IFS102D14 A i x 1 e 5 3 B N x IF S102C14 5102 14 EVAR SPEED CONTROL SWITCH 7 J104 y J104 A E
74. INTEGRATED Flight Systems Air Conditioning System Installation Manual For A109 00 011 IM A109 00 011 Rev B 24 September 2009 RECORD REVI SI ONS NC Initial Release 1 August 2007 A Revised Hardware Callouts 7 July 2009 BO Added A109A Warranty 24 Sept 2009 LIST OF EFFECTIVE PAGES sect a Removal ot Factory Components 0 0107 s xa instalation of condenser 06 01 07 La amp s Getting Started The air conditioning system installation instructions are laid out step by step starting with one 1 through ten 9 for installation and eleven 11 through fifteen 15 for care and airworthiness the instructions are designed to be easy to use The example below is designed to give you a basic overview of how the steps work Installation of Aircraft Systems Example When the parts are called out in a step 5 2 locate the part and parts that go with this step 5 2 It is best to organize your parts by step numbers so they can be drawn from as needed Position Cockpit Air Duct Assembly P N 520062 using drawings 8 5 2 A109 Sheet of 1 and 5 A109 Sheet 3 of 4 For A109 E Installation utilize drawings 8 1 A109P Sheet 1 of 1 and 5 1 A109P Sheet 3 of 4 Should you have any questions problems or need technical support do not hesitate to call fax E mail or write us
75. LANGE ATTACH WITH AN3 13A BOLTS 3 EA MS21044 N3 NUTS 3 EA AN970 3 WASHER 3 EA AN960 10 WASHER 3 EA HOSE NIPPLE P N 250279 P IFS MASTER AIR CONDITIONING ELECTRICAL CONTROL BOX P N 540028 C 3 HARNESS ASSY P N 540059 1 HARNESS ASSY P N 540045 1 TWO EACH CONTROL RODS AND MIXER OMITTED FOR CLARITY STA 2000 POWER AWAY 7 INSTALL 3 4 NIPPLE P N 250279 P INSERT INSTALLATION INSTRUCTIONS MATCH DRILL COMPONENTS UNDER DETAIL A AND B TO HELICOPTER CABIN ROOF USING 10 HOLES SPOT FACE UPPER FACE SKIN TO 9 16 DIAMETER AT EACH 10 HOLE USING A 90 ANGLE TOOL REMOVE CORE OF CABIN ROOF TO A DIAMETER OF 1 5 FROM UNDERSIDE OF UPPER SKIN TO UPPER SIDE OF LOWER SKIN VACUUM OUT ALL CORE MATERIALS REMOVED TRAIL FIT SUR LOK INSERT P N SL601 3 34A ALT DELRON INSERT PN 5045 1032 06 02 ENSURE THAT INSERT WILL FIT FLUSH WITH UPPER SKIN SURFACE OBTAIN METALSET A 4 AND MIX ACCORDING TO MANUFACTURER S DIRECTIONS FILL EACH CAVITY WITH METALSET A 4 AND INSTALL SUR LOK INSERT INTO THE METAL SET ENSURE THAT INSERT IS TOTALLY ENCAPSULATED ENSURE THAT INSERT CENTER THREAD OPENING DOES NOT BECOME CLOGGED WITH METAL SET ALLOW METAL SET TO FULLY CURE BEFORE INSTALLING EVAPORATOR TO ASSEMBLY OR MASTER A C ELECTRICAL PANEL RETAIN A SAMPLE OF THE METALSET A 4 USED IN THIS INSTALLATION FOR A PERIOD OF 24 HOURS ENSURE THAT CURING AND BONDING PROPERTIES
76. LOWER HOUSING BOTTOM TO CONTROL TUBE EBENE EE HOUSING L H SHOWN R H OPPOSITE ENSURE 1 CLEARANCE TO TRANSMISSION mi AIT VIEW LOOKING AFT COWLINC REMOVED CONDENSER ASSY CONDENSER LEG SUPPORT ASSEMBLY PN 510227 1 SUPPORT TUBES TYP BOTH SIDES RIGHT AFT CONDENSER SUPPORT FOOT LOCATION INSTALL 3 13A AGUSTA TRANSMISSION OIL TUBE SUPPORT REVISION RECORD rev DESCRIPTION OF CHANGE IR FS BY CONVERTED TO AUTOCAD OLD PHOTOS ADDED A109A MODEL TO APPLICATION BLOCK ae REVISED TITLE BLOCK iii VIEW B B l CONDENSER LEG AFT CONDENSER LEG SUPT ASSY DELETED FOR CLARITY FOOT AN3S 13A BOLT S N 7414 ONLY AN4 13A ALL OTHERS R x nent wen TYP 2 PL N N V CABIN ROOF 2 SEAL W PRC 8908 X 2 0 MS21044 N3 NUT FILL W A 4 METAL SET MS21044 N4 ALL OTHERS TYP NOTE SEAL BOLT HEAD WASHER AND FOOT TO DOUBLER WITH PRC 890 B X SEAL DOUBLER TO CABIN ROOF TYP BOTH SIDES gt TRIM DOUBLER P N 260867 TO FIT AROUND OIL LINE SUPPORT BRACKET INTEGRATED Systems TITLE CONDENSER INSTALL AGUSTA 109 A109A A109A A109C A109K2 O KA iioo none 202 _ K A 11 20 92 B NONE 2 OF 2 D Miamo AG _ A109A A109A II A109C A109K2 7 A109 C C REVISION RECORD SEE DETAIL A dea A gt LT CONDENSER AIR INTAKE IN COWLI
77. NG EXISTING AN3 4A BOLTS AN960 10 WASHERS 4 EA lt J FORWARD CONDENSER LEG SUPPORT ASSEMBLY P N 510227 1 MAKE SURE CONTROL CLEARS SUPPORT STAND COND SUPPORT MUST CLEAR ALL CONTROLS COND SUPPORT MUST CLEAR TRANSMISSION DETAIL A SUPPORTS OUTBOARD LEFT OUTBOARD RIGHT OUTBOARD RIGHT INTEGRATED CONDENSER MUST CLEARALL HYDRAULIC OIL TUBING BY 10 MIN TITLE CONDENSER INSTALL AGUSTA A109E APPLICATION DWG No POWER Systems DOUBLER P N260867 37 DRILL 4 EA 10 HOLES ATTACH WITH 4 4 BOLTS 8 AN960 10 WASHERS 4 MS21044 N3 NUTS RIGHT AFT CONDENSER SUPPORT FOOT LOCATION INSTALL AN3 13A BOLT THRU ROOF BLOWER SUPPORT TUBE HN ENSURE 5 CLEARANCE BLOWER HOUSING BOTTOM TO CONTROL TUBE HOUSING L H SHOWN R H OPPOSITE ENSURE 1 CLEARANCE TO TRANSMISSION J T VIEW LOOKING AFT COWLING REMOVED CONDENSER ASSY P N 550022 0 CONDENSER LEG SUPPORT ASSEMBLY PN 510227 1 AGUSTA TRANSMISSION SUPPORT TUBES TYP BOTH SIDES RIGHT AFT CONDENSER SUPPORT FOOT LOCATION INSTALL AN3 13A OIL TUBE SUPPORT N FIT AROUND OIL LINE SUPPORT BRACKET REVISION RECORD Mte DESCRIPTION OF CHANGE VIEW B B CONDENSER LEG AFT CONDENSER LEG SUPT ASSY DELETED FOR CLARITY FOOT AN3 13A BOLT S N 7414 ONLY AN4 13A ALL OTHERS 70 4 WASHER TYP 2
78. No FS Integrated Flight Systems INSTALLATION OF CONDENSER A109 Air Conditioning Step 6 Installation of Condenser Date 08 01 07 Rev N C Section 6 Installation of Condenser Page 1 of 2 Integrated Flight Systems INSTALLATION OF CONDENSER A109 Air Conditioning Installation of Condenser STEP PROCEDURE MECH INSP Position and bolt in condenser mount to deck P N 510227 1 as shown in drawings 1 and 2 of 7 A109 For A109 E Installation utilize drawings 7 1 A109P Bond in doublers P N 260867 with PROSEAL 890 B 2 or B 1 2 top deck and cabin roof Position condenser assembly in place Install 8 ea AN3 4A bolts in lower and upper condenser flanges See drawings 1 and 2 of 7 109A For A109 E Installation utilize drawings 7 1 A109P Caution Check all flight controls move cyclic collective and anti torque pedals be sure duct clears control tubes by 15 Caution Make sure deck lines clear condenser mount Date 08 01 07 Section 6 Installation of Condenser Page 2 of 2 REVISION RECORD RECORD BY LEFT SIDE LOOKING INBOARD CONVERTED TO AUTOCAD OLD PHOTOS a fas megane b 09 24 09 ADDED A109A MODEL APPLICATION BLOCK IFS JTYE C REVISED TITLE BLOCK b AFT SIDE OF CONDENSER A D p 6 4 BOLTS W assy amp 2 B B 0000020090 AN960 10 WASHERS CONDENSER AIR INTAKE IN COWLING EXISTINC C FORWARD
79. O COCKPIT AIR DUCT ASSEMBLY STA 2000 fo PN 520062 O O O O O 000 DRAIN LINE DETAIL OUTLINE OF EVAPORATOR EVAPORATOR ASSY a A RIGHT SIDE n CE VIEW LOOKING DOWN wl 5 v Passy ort 5 2 E FAN OMITTED FOR T T me aii CLARITY EA g 3 IN FORWARD lt TOP VIEW MS II v d O BOE RETURN AIR DUCT dd DELETED FOR Tu CLARITY ZEN e L 8 LEFT SIDE VIEW A A STA 2000 REVISION RECORD DESCRIPTION OF CHANGE REV DATE APPV A 08 01 07 CONVERTED TO AUTOCAD ADDED A109A MODEL TO APPLICATION BLOCK REVISED TITLE BLOCK REV Y PN 100181 DRAIN LINES PN 090018 1 AGUSTA 109 A109A A109A A109C A109K2 INTEGRATED Systems TITLE EVAPORATOR INSTALL K A 11 20 92 B NONE 1 OF 2 A109A A109A II A109C A109K2 4 A109 WIRE HARNESS GROUND LEADS GROUND AT THIS LOCATION OUTBOARD 15 RIGHT MS21044 N3 NUT AN970 3 WASHER INTERCHANGABILITY BETWEEN MS20470AD MS20426AD RIVETS AND CR3243 CR3242 RIVETS ALLOWABLE GRIP LENGTH OF RIVET TO BE DETERMINED BY INSTALLER INSTALL IN ACCORDANCE WITH AC 45 15 1A CHAPTER 2 SECTION 3 99 RIVETING a b c d FIGURE 2 19 CHAPTER 5 SECTION 1 232 TYPE OF RIVETS a e f DATED 1972 DETAIL A AN3J 4A BOLTS AN960 10 WASHERS TYP 6 PLS 4 a
80. OTH ENDS AN4H7A BOLT 4 NAS1149F0463P WASHERS 4 WITH NUTPLATES OR AN4 10A BOLT 4 PLC S SAFETY WIRE 032 MIN NAS1149F0463P OR A NAS1149F0432P WASHER 8 PLC S MS21044N4 NUT OR MS20364 424C 4 PLC S W O NUTPLATES SAFETY WIRE 032 MIN NAS1149F0463P WASHER BETWEEN STRUT BRACE AND CASE 9 q Oo EN NF I I I I I 9 oI r STRUT BRACE STEEL AN4H7A BOLT 2 PLC S PN 300330 NAS1149F0432P WASHER 2 PLC S W NUTPLATES AFETY WIRE 032 MIN ROTOR BRAKE DISK X EXISTING AN4H11A BOLT 2 PLC S NAS1149F0463P OR NAS1149F0432P 4 PLC S MS21044N4 NUT OR MS20364 424C 2 PLC S W O NUTPLATES SAFETY WIRE 032 MIN NAS1149F0663P OR NAS1149F0632P WASHER 2 A 1 j N NAS1149F0863P WASHER 1 A a MS21044N8 NUT 1 BRACKET ASSEMBLY ADD REVISION RECORD DESCRIPTION OF CHANGE APPVD REV BY BY DWG REV LTR DATE DRAWING REVISED PER ECO 0192 INSTALLATION INSTRUCTIONS IT IS IMPERATIVE THAT BEFORE ANY ATTEMPT IS MADE TO INSTALL THE SUBJECT AIR CONDITIONING KIT THAT AGUSTA MANDATORY SERVICE BULLETIN 109 82 OR LATER REVISIONS BE COMPLIED WITH N NO ATTEMPT SHOULD BE MADE TO INSTALL THE COMPRESSOR OR IT S SUPPORTING BRACKET UNTIL THE ABOVE AGUSTA SERVICE BULLETIN HAS BEEN ACCOMPLISHED NOTE TORQUE ALL BOLTS AND
81. OUNT INPUT QUILL MAXIMUM MOVEMENT AGUSTA A109E p TS END PLAY POWER APPLICATION DWG No AGUSTA A109E 6 1 A109P REVISION RECORD FIREWALL BOX qo ENGINE COMPARTMENT j DIVIDER EXISTING PN 530089 1 TEMPORARILY POSITION COMPRESSOR IN PLACE MARK AROUND PULLEY ON TO FIREWALL 2 REMOVE COMPRESSOR AND CUT FWD FIREWALL SO COMPRESSOR WILL CLEAR FIRE WALL WHEN TEMPORARY INSTALLED 3 CUT FIREWALL USING BOX ASSEMBLY PN 530089 AS A TEMPLATE CUT HOLE FLUSH TO THE TOP OF LOWER STIFFENER ON THE FWD SIDE OF THE FIREWALL VIEW LOOKING AFT OUTBOARD CENTERLINE OF AIRCRAFT OUTBOARD RIGHT LEFT OUTBOARD RIGHT VIEW LOOKING INBOARD REMOVE THIS PANEL AND HOLD FOR REINSTALLATION AFTER FIREWALL BOX INSTALLATION NOTE TORQUE ALL BOLTS AND FASTENERS IAW AC 43 13 OR APPLICABLE AIRCRAFT SERVICE MANUALS INTEGRATED Flight Systems TITLE COMPRESSOR INSTALLATION AGUSTA A109E POWER AGUSTA A109E 6 1 A109P Integrated Flight Systems INSTALLATION OF ELECTRICAL A109 Air Conditioning Step 9 Installation of Electrical Date 08 01 07 Rev N C Section 9 Installation of Electrical Page 1 of 3 Integrated Flight Systems INSTALLATION OF ELECTRICAL A109 Air Conditioning Position master electric control box P N 540028 C 3 as shown in drawing 2 1 A109 Sheet 3 of 3 For A109 E Installation utilize drawings 2 1 A109P Sheet 3 of 3 Mark hole locations on tran
82. OWN JUST BELOW HOLES ON UPPER SKIN COVER DUCT WITH FOAM RETURN AIR DUCT AND ALUMINUM TAPE P N 520061 P RETURN AIR DUCT Toi w GUSTA A109E 4 POWER INTEGRATED POSITION DUCT TO CLEAR CONTROLS AND STRUCTURE RELOCATE RELAY FORWARD TO STRIP WIRE FROM DUCT PN 060007 AND INSTALL WITH 2 EACH 6 IN BAND CLAMPS COVER WITH FOAM AND ALUMINUM TITLE AIR DISTRIBUTION DRAWN BY DATE REV SCALE SHEET KML 08 01 07 IR NONE 1 OF 4 APPLICATION DWG No AGUSTA A109E 5 1 A109P Systems REVISION RECORD DESCRIPTION OF CHANGE d A C SYSTEM FORWARD CO PILOTS SIDE AIR DUCT WEMAC SUPPORT P N 250276 DOUBLER P N 260889 P N 250275 E CN amp FITTED amp DRILLED INSTALLED BEHIND EXHAUST COVER nn USE AN525 10RS SCREWS TYP 4 PL INTERCHANGABILITY BETWEEN MS20470AD MS20426AD RIVETS AND CR3243 CR3242 RIVETS ALLOWABLE GRIP LENGTH OF RIVET TO BE DETERMINED BY INSTALLER INSTALL IN ACCORDANCE WITH AC 43 13 CHAPTER 2 SECTION 3 99 RIVETING a b c d FIGURE 2 19 CHAPTER 5 SECTION 1 252 TYPE OF RIVETS a e f DATED 1972 POSITION WEMAC SUPPORT P N 250276 DRILL 4 EA 30 HOLES 1 DRILL 10 DIA TYP 15 DRILL RIVET HOLES WITH NUTPLATE FIXTURE 520470 04 COUNTERSINK RIVET HOLES gt INSTALL NUTPLATES ON INSIDE TYP DRILL 10 DIA HOLES OUT TO 250 DIA OF STRUCTUR
83. P CENTER ON FLANGE ATTACH WITH AN3 13A BOLTS 3 EA MS21044 N3 NUTS 3 EA AN970 3 WASHER 3 EA AN960 10 WASHER 3 EA HOSE NIPPLE P N 250279 PER DETAIL C IFS MASTER AIR CONDITIONING ELECTRICAL CONTROL BOX P N 540028 0 5 HARNESS ASSY P N 540059 HARNESS ASSY P N 540045 1 TWO EACH CONTROL RODS AND MIXER OMITTED FOR CLARITY STA 2000 AGUSTA 109 A109A A109A II A109C A109K2 REVISION RECORD wv pars DESCRIPTION OF CHANGE CONVERTED TO AUTOCAD OLD PHOTOS ADDED A109A MODEL TO APPLICATION BLOCK REVISED TITLE BLOCK MGV JTYE MOUNTING AREA FOR MASTER AIR CONDITIONING ELECTRICAL CONTROL BOX INSERT INSTALLATION INSTRUCTIONS 1 MATCH DRILL COMPONENTS UNDER DETAIL A AND B TO HELICOPTER CABIN ROOF USING 10 HOLES 2 SPOT FACE UPPER FACE SKIN TO 9 16 DIAMETER AT EACH 10 HOLE 5 USING A 90 ANGLE TOOL REMOVE CORE OF CABIN ROOF TO A DIAMETER OF 1 5 FROM UNDERSIDE OF UPPER SKIN TO UPPER SIDE OF LOWER SKIN VACUUM OUT ALL CORE MATERIALS REMOVED TRAIL FIT SUR LOK INSERT P N SL601 3 3A ALT DELRON INSERT PN 5045 1032 06 02 ENSURE THAT INSERT WILL FIT FLUSH WITH UPPER SKIN SURFACE 6 OBTAIN METALSET A 4 AND MIX ACCORDING TO MANUFACTURER S DIRECTIONS 7 FILL EACH CAVITY WITH METALSET A 4 AND INSTALL SUR LOK INSERT INTO THE METALSET ENSURE THAT INSERT IS TOTALLY ENCAPSULATED 8 ENSURE THAT INSERT CENTER THREAD OPENING
84. PL s WAZ SEAL W PRC 8908 MS20364 1032C OR MS21044 N3 NUT SN 7414 ONLY 2 0 FILL W A 4 METAL SET MS21044 N4_ALL_OTHERS TYP NOTE SEAL BOLT HEAD WASHER AND FOOT TO DOUBLER WITH PRC 890 B X SEAL DOUBLER TO CABIN ROOF TYP BOTH SIDES DOUBLERS 2X P N 260867 CABIN ROOF SEAL TRIM DOUBLER P N 260867 TO INTEGRATED Systems TITLE CONDENSER INSTALL AGUSTA A109E EO REVISION RECORD i RECORD pave pEscumTIONOFCHANGE FS NEW OVERHEAD DUCT P N 520062 BY CONVERTED TO AUTOCAD OLD PHOTOS pe REPLACED ADDED VIEW NOTE ua ADDED A109A MODEL TO APPLICATION BLOCK REVISED TITLE BLOCK 525 10 8 SCREWS 12 PL AIT i uw ER Y FORWARD ALL VIEWS 4 1 TNNT WP t TOP VIEW OF COWLING TOP COWEL CUT W REMOVED PORTION MODIFICATION 7 Z NOTE THIS VIEW IS INSIDE LOOKING OUT A REMOVE THIS TO COWLING AREA ADD NEW CAMLOCK EACH SIDE OF 77 6 0 CUT OUT AS SHOWN EXISTING CAMLOCK P N 50 052 5 1 MALE EXISTING CAMLOCK p 4 20 AIRCRAFT ALL VIEWS INSIDE COWLING NOTE AFTER MODIFICATION FIT COWLING eee TO A C MARK LOCATION FOR NEW 4 2 CUT IS TO BE MADE FROM FEMALE CAMLOCKS ON A C MATCHING NEWLY INSTALLED MALE CAMLOCKS MATCHIN T ON AIRCRAFT iL ak Es INSTALL 2 EACH P N 50 052 1 FEMALE CAMLOCKS SS FLANGE MODIFICATION EXISTING
85. Parts Break Down Page 1 of 4 Date 09 24 09 Integrated Flight Systems PARTS BREAK DOWN A109 Air Conditioning MASTER PARTS LIST IN ALL A109 SERIES FOR KIT 109 00 011 HP with DUAL CONDENSE BLOWER ESTER OIL EQUIPPED COMPRESSOR Model SD 505 Issued 08 01 07 Section 13 Parts Break Down Rev A Page 1 of 4 Integrated Flight Systems PARTS BREAK DOWN A109 Air Conditioning MASTER PARTS LIST A109 SERIES KIT 109 00 011 DUAL CONDENSER BLOWER ITEM DESCRIPTION PART l VEE BELT 060031 Utilized with Oil Cooler Drive System 060030 2 SD 505 COMPRESSOR ASSEMBLY 010001 3 O COMPLETE W 24 VDC COIL FOR USE WITH R 134a ONLY ESTER oil equipped COMPRESSOR PARTS FOR SD 505 W 5 0 CLUTCH BEARING ONLY SD 505 COMPRESSOR W 5 0 CLUTCH 4 24 VDC COIL GREEN WIRE 5 IFS PULLEY 6 PULLEY FACE PLATE 5 0 Date 09 24 09 Rev A Section 13 Parts Break Down Page 2 of 4 Integrated Flight Systems PARTS BREAK DOWN A109 Air Conditioning ITEM DESCRIPTION PART EVAPORATOR BLOWER PARTS 1 S VANE AXIAL BLOWER ASSY 050143 SINGLE FLANGE W NYLON BLADE 8 MOTOR 5 VANE AXIAL BLOWER 050145 9 NYLON BLADE AND HUB ASSY 580000 FITS 5 VANE AXIAL BLOWER 10 BRUSHES 2 EACH MOTOR 050031 11 MOTOR FORWARD EVAPORATOR 050052 1 24 single shaft right hand 12 WHEEL FORWARD EVAPORATOR fan 040004 8 metal CC rotation 5 16 bore CONDENSER BLOWER PARTS 13 CONDENS
86. R INSTALLATION 6 1 A109 3 of 3 CONDENSER INSTALL 7 A109 1 of 2 CONDENSER INSTALL 7 A109 2 of 2 COWLING MODIFICATION 8 A109 1 of 1 Date 09 24 09 Rev B Section 1 Kit Inventory Page 13 of 16 Integrated Flight Systems KIT INVENTORY LIST A109 00 011 Air Conditioning A109E Power DRAWI NG LIST AIR CONDITIONING OVERVIEW rraio aon iR 1 j ECWCALROUING araoa R a FELECTRICALDIAGRAM araeo im 1 ECINCALDAGRUM araeo R 1 Pume araoa _ PLUMBING DIAGRAM araeo im 1 PLUMBING ROUTING im 1 af MEE AIR DISTRIBUTION 5 1 A109P 1 of 4 AIR DISTRIBUTION 5 1 A109P 2 of 4 AIR DISTRIBUTION 5 1 A109P 3 of 4 AIR DISTRIBUTION 5 1 A109P 4 of 4 COMPRESSOR INSTALLATI ON 6 1 A109P 1 of 3 COMPRESSOR INSTALLATI ON 6 1 A109P 2 of 3 COMPRESSOR INSTALLATI ON 6 1 A109P 3 of 3 CONDENSER INSTALL 7 A109P 1 of 2 CONDENSER INSTALL 7 A109P 2 of 2 COWLING MODIFICATION 8 1 A109P 1 of 1 A A 1 1 1 1 1 1 Date 09 24 09 Rev B Section 1 Kit Inventory Page 14 of 16 Integrated Flight Systems KIT INVENTORY LIST A109 00 011 Air Conditioning DOCUMENT LIST DOCUMENT LIST i d Chk d Verf d mum NEN INSTALLATION INSTRUCTIONS Sect 5 10 109 00 011 Rev A Dated 01 26 10 SUPPLEMENTAL TYPE CERTIFICATE SROO060DE
87. RON INSERT PN 5045 1032 06 02 ENSURE THAT INSERT WILL FIT FLUSH WITH UPPER SKIN SURFACE OBTAIN METALSET A 4 AND MIX ACCORDING TO MANUFACTURER S DIRECTIONS FILL EACH CAVITY WITH METALSET A 4 AND INSTALL SUR LOK INSERT INTO THE METAL SET ENSURE THAT INSERT IS TOTALLY ENCAPSULATED ENSURE THAT INSERT CENTER THREAD OPENING DOES NOT BECOME CLOGGED WITH METAL SET ALLOW METAL SET TO FULLY CURE BEFORE INSTALLING EVAPORATOR TO ASSEMBLY OR MASTER A C ELECTRICAL PANEL RETAIN A SAMPLE OF THE METALSET A 4 USED IN THIS INSTALLATION FOR A PERIOD OF 24 HOURS ENSURE THAT CURING AND BONDING PROPERTIES DEVELOP IN ACCORDANCE WITH MANUFACTURER S RECOMMENDATIONS Systems TITLE EVAPORATOR INSTALL AGUSTA A109E AGUSTA A109E 4 1 A109P REVISION RECORD DESCRIPTION OF CHANGE d INTEGRATED Integrated Flight Systems INSTALLATION OF HOSES A109 Air Conditioning Step 10 Installation of Hoses Date 08 01 07 Rev N C Section 10 Installation of Hoses Page 1 of 2 Integrated Flight Systems INSTALLATION OF HOSES A109 Air Conditioning INSTALLATION OF HOSES Drawings required 3 1 A109 Sheets 1 thru 3 For A109E Drawings required 3 1 A109P Sheets 1 thru 3 STEP PROCEDURE MECH INSP Connect hose assembly P N 570053 0 to condenser and run to drier bottle Connect Hi pressure switch P N 090004 to hose assembly Connect hose assembly P N 570058 1 0 to condenser assembly and run to compressor 10 1 Connect hos
88. ROOF 2 SEAL W PRC 8908 X 2 0 MS21044 N3 NUT FILL W A 4 METAL SET MS21044 N4 ALL OTHERS TYP NOTE SEAL BOLT HEAD WASHER AND FOOT TO DOUBLER WITH PRC 890 B X SEAL DOUBLER TO CABIN ROOF TYP BOTH SIDES gt TRIM DOUBLER P N 260867 TO FIT AROUND OIL LINE SUPPORT BRACKET INTEGRATED Systems TITLE CONDENSER INSTALL AGUSTA 109 A109A A109A A109C A109K2 O KA iioo none 202 _ K A 11 20 92 B NONE 2 OF 2 D Miamo AG _ A109A A109A II A109C A109K2 7 A109 REVISION RECORD NEW OVERHEAD DUCT P N 520062 co FORWARD AN 525 1088 SCREWS 12 PL H FORWARD a y TOP VIEW OF COWLINC CUT W REMOVED PORTION 4 1 Z FORWARD NOTE THIS VIEW IS INSIDE wenn es LOOKING OUT is TO COWLING CARE TOP COWEL eS Sohn ADD NEW CAMLOCK WAY kay EACH SIDE OF 6 0 MODIFICATION Big Ae re CUT OUT AS SHOWN 50 052 5 MALE EXISTING CAMLOCK 7 EXISTING CAMLOCK E YI 2000 4 AIRCRAFT ALL VIEWS INSIDE COWLING NOTE AFTER MODIFICATION FIT COWLING TO A C MARK LOCATION FOR NEW FEMALE CAMLOCKS ON A C MATCHING NEWLY INSTALLED MALE CAMLOCKS MATCHIN T ON AIRCRAFT aS Es INSTALL 2 EACH P N 50 052 1 FEMALE CAMLOCKS EXISTING CAMLOCK prs NS EXISTING CAMLOCK NN 4 2 FLANGE MODIFICATION AIRCRAFT FLANGE INTEGRATED P N 510300 AU DETAIL
89. S L Lo A S lt gt eee oe CONDENSER E 22 x ER ASSEMBLY C NEW COCKPIT AIR DUCT ASSEMBLY 2 M MASTER ELECTRICAL j CONTROL BOX RETURN AIR NEW WEMACS CO PILOTS Document No ICA A109 00 011 Rev IR Date November 1 2008 Pase 10 of 10 9 Special Inspection Requirements No special inspections are required for this system 10 Application of Protective Treatments No special treatments are required after inspection and or maintenance 11 Data Torque values for all attachment hardware are listed 1n the Integrated Flight Systems Installation Instructions Document Number IM A109 00 01 1 12 List of Special Tools No special tools are required for inspection or maintenance of this system 13 Recommended Overhaul Periods No additional overhaul time limitations are required for this system 14 Airworthiness Limitation No additional Airworthiness Limitations are required for this system NOTE The Airworthiness Limitations section is FAA Approved and specifies maintenance required under 43 16 and 91 403 of the Federal Aviation Regulations unless an alternative program has been FAA Approved 15 ICA Revision Any revisions to these instructions will be made available at the Production Approval Holders website www integratedflightsys com Integrated Flight Systems PARTS BREAK DOWN A109 Air Conditioning Step 13 Parts Break Down Date 09 24 09 Rev A Section 13
90. SSY PN 540061 HANDSHAKE 3X IF S101C14 RESISTOR ASSY PN 540020 IF S101C14 EVAP AFT FAN MOTOR MOTOR PN 050143 c e IFS101N14 IF S101B14 IF S108 B14 IF S107C14 IF S107B14 6 IFS107N14 IFS103C14 1 5103 14 IFS103N14 IF S104B14 HIGH PRESSURE SWITCH IF S108B20 IF S108D20 NOTE 1 SEE 2 5 5350 SH 1 OF 1 FOR WIRE SPLICE LOC e WIRE SPEC MIL W 22759 16 WIRE NO IFS XXX X XX GROUP SEQUENCE INDICATES GROUND DUAL CUNDENSER FAN GAUGE REVISION RECORD EVAP FWD FAN MOTOR CONDENSER FAN MOTOR PN 050143 HANDSHAKE CONDENSER FAN MOTOR PN 050143 IF S104C14 IF S105B20 IF S106B20 IF S105N20 DWG REV LTR REV BY DATE DESCRIPTION OF CHANGE de FWD SWITCH ASSY PN 540060 SWITCH PN 050093 CP 103 CP 109 IF S108 D14 IF S102C14 IF S102E14 LOW PRESSURE SWITCH HANDSHAKE BUTT SPLICE COMPRESSOR CLUTCH CP 102 IF S104C14 OR OPTIONAL TEMP CONTROL FWD SWITCH ASSY PN 540060 SWITCH PN 050091 IF S105C20 AGUSTA A109E POWER INTEGRATED Systems TE WIRING DIAGRAM DRAWN BY DATE REV SCALE SHEET JTYE 08 01 0 NONE je OF 3 APPLICATION DWG NO AGUSTA A109E 2 1 109 STA 2000 MASTER ELECTRICAL WIRE RUNS ACROSS UNDER BLANKET DETAIL A 4 BOLTS AN960 10 WASHER TYP 4 PLS ELECTRICAL BOX ASSEMBLY P
91. T WITH ABA 4 4 RIVETS HOSE NIPPLE P N 250509 FOAM TAPE 9 ADD FOAM TAPE AROUND HOSE NIPPLE SECTION A A TYPICAL 2 PLACES 6 ATTACH P N 520066 TO A C USING AN3 14A BOLTS INTEGRATED Flight Systems OPTIONAL DUCI INSTALL IF NO CABIN AIR SYSTEM IS INSTALLED TITLE AFT CABIN DUCT INSTALL NE det AGUSTA A109E 410 HOLE emen AGUSTA A109E 5 1 A109P REVISION RECORD RECORD BY LEFT SIDE LOOKING INBOARD CONVERTED TO AUTOCAD OLD PHOTOS a fas megane b 09 24 09 ADDED A109A MODEL APPLICATION BLOCK IFS JTYE C REVISED TITLE BLOCK b AFT SIDE OF CONDENSER A D p 6 4 BOLTS W assy amp 2 B B 0000020090 AN960 10 WASHERS CONDENSER AIR INTAKE IN COWLING EXISTINC C FORWARD LEFT SIDE DETAIL COND SUPPORT MUST CLEAR ALL CONTROLS COND SUPPORI MUST CLEAR TRANSMISSION SUPPORTS INTEGRATED CONDENSER MUST CLEARALL HYDRAULIC Flight Systems OIL TUBING BY 10 MIN AGUSTA 109 TITLE CONDENSER INSTALL OUTBOARD RIGHT A109A A109A A109C A109K2 DRAWN BY DATE REV SCALE SHEET A109A A109A IT A109C A109K2 7 A109 DOUBLER P N260867 5 DRILL 4 EA 10 HOLES ATTACH WITH 4 AN3 4A BOLTS 8 960 10 WASHERS 4 MS21044 N3 NUTS RIGHT AFT CONDENSER SUPPORT FOOT LOCATION INSTALL AN3 13A BOLT THRU ROOF BLOWER SUPPORT TUBE ENSURE 5 CLEARANCE B
92. TA ARE IN AIRCRAFT REMOVE amp INSTALL ON ASSY P N 520066 A 5 USE EXISTING NUTPLATES IN AIRCRAFT WHEN POSSIBLE OR CEILING PANEL ADD NEW SHURLOCK PN SL601 3 3A ALT PN 504SE1032 06 02 INSTALL PER INSTRUCTIONS ON TYP 3 EACH SIDE DRAWING 4 A109 SHEET 2 OF 2 AFT CABIN DUCT lt B HOSE NIPPLE BRACKET P N 261009 4 POSITION UNDER 3 5 HOLE UNDER DECK CENTER ON INTERNAL DUCT P N 250509 SCREW AN525 10R8 MARK HOLE TO DUCT REMOVE DUCT ASSEMBLY CUT HOLE RIVET SECTION WASHER AN960 10 HOSE NIPPLE P N 250509 TO DUCT WITH ABA 4 4 RIVETS er FOAM TAPE UPPER DECK 5 ADD FOAM TAPE AROUND HOSE NIPPLE TYPICAL 3 PLACES PER SIDE EXISTING HAT SECTIONS IN 6 ATTACH P N 520066 TO A C USING AN525 10R8 SCREWS A C LOCATE POSITION OF AFT CABIN DUCT BRACKETS I N T E G R A T E D METALSET A 4 Flight Systems SHURLOK INSERT AGUSTA 109 E NONE APPLICATION DWG No REVISION RECORD Revie pw DESCRIPTION OF CHANGE SECURE RETURN AIR DUCT TO BULKHEAD WITH 3 EA AN525 10R10 SCREWS STA 3 EA AN970 3 WASHERS 2000 3 EA CLIP NUT RETURN AIR DUCT CUT OUT RIVETS AFT OF CO PILOTS BULKHEAD MS20470AD 4 X RETURN AIR DOUBLER P N 260866 P RETURN AIR SCREEN P N 080036 P TOUCH UP PAINT ON DOUBLER RIVETS AND SCREWS AFTER COMPLETION FORWARD SIDE CO PILOTS O BULKHEAD PRC AROUND SCREEEN 0 o 4 TO SECURE IN PLACE POSITION DOUBLER AS SH
93. TENANCE MANUAL FOR THE SERIAL NUMBER OF THE AIRCRAFT INVOLVED DETERMINE FROM THE MANUAL BY SERIAL NUMBER THE DIRECTION OF THE ARROW ON THE ELECTRICAL LOAD SENSING BLOCK A C MASTER 50 AMP C B LOCATION AIR CONDITIONING MASTER 50 AMP CIRCUIT BREAKER IFS PN 050012 9 LOCATION ABOVE AND AFT OF PILOTS HEAD IFS A C POWER LEAD MUST PASS THROUGH THE BLOCK IN THE INDICATED MANNER USE 2 EA MS20659 INSULATED RING TERMINALS AT C B 8 SCREW HOLE AIR CONDITIONING MASTER 8 WIRE CONTROL PANEL ABOVE AND LEFT OF PILOTS HEAD 8 A C WIRE TO A C 50 AMP C B IN AUX ELECTRICAL PANEL 1 BUSS A C WIRE POWER LOCATION ALTERNATE USE 2 BUSS AGUSTA 109 A109A A109A A109C A109K2 A ME MODIFY EXISTING SWITCH S V PANEL PER DETAIL A IF p PANEL IS FULL RELOCATE AIR CONDITIONER SWITCHES TO THE SIDE OF PANEL ABOVE ORIGINAL LOCATION OR IF HEATER IS NOT INSTALLED LOCATE TO THESE HOLES USING IFS PLACARD PN 120205 MASTER AIRCRAFT OVERHEAD ELECTRICAL PANEL LOOKING AFT NOTE IF EXISTING PLACARD I N T E e R A T E D IS BLANK ENGRAVE AS SHOWN IN DETAIL A Systems ENG UVSP je ENG UVSR 1 RESET RESET AIR CONDITIONER TITLE ELECTRICAL ROUTING AM JTYE 08 01 07 A 10F3 DETAIL A A APPLICATION DWG No A109A A109A II A109C A109K2 2 1 A109 NO 1 BUSS DR NO 2 BUSS DO NOT INSTALL ON ESSENTIAL BUSS A O500 PN 54004
94. UM SPARE BELT PLE COMPRESSOR ALIGNMENT NOTE COMPRESSOR PORTS SHOULD CLOCK TO THE RIGHT OUTBOARD SIDE OF THE AIRCRAFT COMPRESSOR BRACKET ASSY PN 510255 P ROTATE EXISTING ADEL CLAMPS 180 ENSURE ALIGNMENT OF ian 5 PN 010001 3 0 C L OF BOTH BELT GROOVES E WITHIN 10 AN3 11A BOLTS 2 NAS1149F0363P WASHERS 4 MS21044N3 NUTS 2 COMPRESSOR BRACKET FASTEN DRIVE PULLEY ASSY PN 510255 WITH NAS 1304 4H BOLT ROTOR BRAKE Ry NAS1149F0463P AND OR NAS1149F0432P i WASHER AS REQUIRED 5 SETS REQ D SECURE W SAFETY WIRE 032 MIN FIREWALL BOX ASSY PN 530089 DRIVE PULLEY INSTALLATION INSTRUCTIONS ROTOR X DISASSEMBLE THE TAIL ROTOR DRIVE SHAFT AT THE THOMAS BERE COUPLING PRIOR TO REMOVING ROTOR BRAKE CALIPER AND DISC ROTATE DISC OUTBOARD RIGHT INSPECT FOR TRUE RUNNING DISC AND ANY FOR AFT END PLAY LOOKING INBOARD AT INPUT QUILL RECORD END PLAY ROTOR BRAKE INSPECT CLEARANCE FROM DISC TO PUCKS ON BOTH SIDES I N E G R E D NOTE DISK EXISTING RELOCATE CALIPER AFT IF NECESSARY BY THE USE OF TORQUE ALL BOLTS AND FASTENERS IAW AC 43 13 OR APPLICABLE AIRCRAFT STA ka 020 PN 261013 032 OR SERVICE MANUALS Systems 3884 FINAL CLEARANCE SHOULD BE AS EQUAL AS POSSIBLE FROM o EACH PUCK TO THE DISC SR TITLE COMPRESSOR os INSTALLATION IN NO CASE SHALL DLEARANCE BE LESS THAN 005 AFTER o FORWARD TAKING INTO ACC
95. VAP AF T FAN MOTOR IFS101C14 IFS101C14 _ E IF S101B14 IF S101E14 Xi C2 CONDENSER BLOWER 414 HANDSHAKE 3X y X 14 IFS107C14 20 Om 1 die NU N P 1 DR 2 BUSS OMPRESSOR CONDENSER RELAY JENSER BLOWER 4 IF S104 B14 CON LUW PRESSURE ex ceil 1 5 OMPRESSOR SWITCH CLOSER CLUTCH LOW PRESSURE SWITCH CLOSE N PM IFS104C14 LE MA 7 E IF S108B20 EN EN S ut IF S108D20 FORWARD EVAP SPEED CONTROL SWITCH 2 IF S106 B20 IF S105Be20 NOTE M 510520 1 DRAWING SHOWN WITH mu AGUSTA 109 SERIES V C ELECTRICAL WIRING DIAGRAM A 5 THIS WILL TURN UN THE KA TUR GR SEE g 3 5 350 SH 1 OF 1 FOR WIRE SPLICE WIRE NO P FANS AND C MPRESS s LLUILH C3LUE NEN d E ae GRAM ENCE INDICATES GROUND ae 08 NTS DWG NO APPLICATION NO AGUSTA 109 S DIAGRAM 2 I m
96. a Sheet IFS PN 070003 1 TOUCH UP PAIND GREY acc to ISO DIS 11014 Printing date 07 28 2005 Reviewed on 02 07 2005 Trade name 61003 Multi Coat Blank Aerosol Cond of page 2 Protect from heat and direct sunlight F LXposure COnras person adi prot PEL 1500 1000 ppm REL 1800 1000 prim TLV 0 4508 mg m 25000 ppm 78 93 3 butanone PEL 0 590 200 ppm REL 0 Short term volue SSS mg m Long term 590 mgm 2 TLV Short term value 555 mem Long term walue 590 m m BEI Additional information The lisis iat were valid during the creation were used as basis Personal protective equipment General protective and hygienic measures Keep away from foodstuffs beverages and feed immediately remove all soiled and contaminated clothing Wash hands before breaks and at the end of work Avoid contact with the eves and skin Breathing equipment In case of brief exposure or low pollution use respiratory filter device In case of intensive or longer exposure use respiratory protective device that ts independent of circulating arr Use suitable respiratory protective device tn case of insufficient ventilation Protection of hands Protective gloves The glove material has to be impermeable and resistant to the product the substance the preparation Due to missing tests no recommendation to the glove material can be given for the product t
97. ace compressor on support stand supported at rear end of compressor If the compressor must be clamped in a vice clamp only on the mounting ears never on the body of the compressor Set rotor squarely over the front housing boss Place the rotor installer ring into the bearing bore Ensure that the edge rests only on the inner race of the bearing not on the seal pulley or outer race of the bearing 13 Agusta 109 Series Trouble Shooting Guide INTEGRATED Flight Systems SERVICE OPERATIONS CLUTCH 4 Place the driver into the ring and drive the rotor down onto the front housing with a hammer or arbor press Drive the rotor against the front housing step A distinct change of sound can be heard when using a hammer to install the rotor 5 Reinstall rotor bearing snap ring if it has been removed with internal snap ring pliers 6 Reinstall rotor retaining snap ring with external snap ring pliers If a bevel is present on the snap ring it should face up away from the body of the compressor a Reinstall rotor bearing dust cover if present by gently tapping it into place 14 6 Armature Assembly Installation l Install shaft key with pliers 2 Install clutch shims NOTE Clutch air gap is determined by shim thickness When installing a clutch on a used compressor try the original shims first When installing a clutch on a compressor that has not had a clutch installed before first try 0 04 0 02 and 0 00
98. at a R 134a supply cylinder to produce additional pressure or attempt to empty the container completely WARNING Insure adequate ventilation when servicing the refrigerant system WARNING If the R 134a and lubrication oil are mixed with water they make hydrochloric acid This will cause corrosion of the system components Date 09 24 09 Rev A Section 2 Aircraft Pre Inspection Page 3 of 4 Integrated Flight Systems AIRCRAFT PRE INSPECTION A109 Air Conditioning General Safety Instructions PROCEDURE WARNING You must replace the filter drier each time you open the system WARNING Comply with the regulations in force in the country where the aircraft is operated when working on the air conditioning system WARNING Only use nitrogen or Alcohol to clean the system components WARNING Always keep the R 134a supply cylinder in an upright position when admitting refrigerant into the system If a cylinder 1s on its side or upside down liquid will enter the R 134a system and cause damage to the compressor Date 09 24 09 Rev A Section 2 Aircraft Pre Inspection Page 4 of 4 Integrated Flight Systems AIRCRAFT PREPERATION A109 Air Conditioning Step 3 Aircraft Preparation Date 08 01 07 Rev N C Section 3 Aircraft Preparation Page 1 of 2 Integrated Flight Systems AIRCRAFT PREPERATION A109 Air Conditioning Aircraft Preparation NOTE Step 3 instructions to be performed in accordance with the appl
99. be overcharged Note Technicians will have to be especially careful to avoid overcharging HFC 134A systems Because the sight glass 15 hard to read and the volume given 15 slightly lower with HFC 134A NOTE Cloudy Sight Glass A cloudy sight glass indicates a system that 15 only partially full of refrigerant with a few exceptions A perfectly clear sight glass use a light to get a good look meaans the system 15 either full or empty Note with HFC 134A the glass appears milky when properly charged though there should be no bubbles in the sight glass MM 109 00 01 1 5 INTEGRATED Agusta 109 Series Trouble Shooting Guide 1 System has no electrical power to air conditioner master control box A Check 50 amp circuit breaker 2 System has power but will not turn on A Check ground lead on cannon plug 102 wire IFS 105320 B Check evaporator fan relay in air conditioner master control box 3 Forward evaporator fan will not turn on but aft fan runs A Check 20 amp circuit breaker in master electrical box B Check ground wire from evaporator motor C Disconnect CP103 and check for power on pin 2 1 If you have power your motor is bad 2 If no power disconnect CP101 cannon plug and check continuity from pin 6 c on CP101 to cannon plug CP103 pin 2 If no power check cannon plugs and switch 4 Aft evaporator fan will not run but forward evaporator runs A Check 20 amp circuit breaker on master electrical
100. box B Check ground wire from fan C Check Brushes D Check for power on wire IFS 101C14 at resistor assembly P N 540020 or resistor P N 050024 2 parts are two way interchangeable 1 If you have power your motor is bad 2 If no power trace through fan switch for power 3 If no power disconnect cannon plug CP101 and check continuity from pin 3 B of CP101 to wire IFS101C14 on resistor with fan switch on Low MM 109 00 01 1 INTEGRATED Agusta 109 Series Trouble Shooting Guide 5 Condenser fan fans do not operate A Check 20 amp circuit breaker B Check 1 amp circuit breaker 1 If popped reset a Check brushes b Check power c Check ground d Check fins for blockage in air condenser assembly 2 Run air conditioning system a Check pressures If pressure 15 running higher than normal then continue with b ect b System may be over serviced c System may be contaminated by improper Freon or a mix of Freon s 3 NOTE This has happened more than once The service carts are great for servicing systems but there 15 a danger in its misuse Untrained operators or an individual who wants to service his car truck motor home or even his room A C can pump down their system into your tank It can have any number of different Freon s It could also be contaminated by a failed compressor dryer bottle wrong oil or any number of things This has happened to a company with brand new equipment just 3 weeks
101. condenser blowers and compressor clutch are energized which requires another 28 amps of electrical system capacity Due to this Delay Feature electrical soft start is provided The maximum electrical requirements of the basic air conditioning system are as follows Condenser Blower 2 each 13 amps 26 amps Compressor each a 2 amps lamps Evaporator Fan Fwd each 13 amps 3 amps Evaporator Fan each 7 amps 7 Total System 48 amps FAA Daie Jime 8 2009 Pape of B tates OM Juearica lepartnsent of Vranspartatinn Federal Abiation Amministratian Supplemental Certificate ca VE Flight 1541 Flighilsme Drive Suite 3 Lincoln California 9564 E basis ie set forth m Type Certificate Data Sheet Hate Agusta SpA m ER IL ATISC 1098 2 yana ina af Tape D agam ote of beli driven Vapor Cycle Air Conditicaing System Kit PYM AL 1009 00 01 0 with dual condenser blower configuration m accordance with FAA approved Integrated Flight Systemes Inc Master Drowing List Report Humber Revision A dated February 25 1995 or later FAA approved revision P aigna rend asma Sheet an Abi d di Fined FM Malesia Vint ma riorem 11 1997 Tiai veiw 22 Yanapana a
102. ct wires per labeling on wiring leads See drawing 2 1 A109 Sheet 2 of 3 For A109 E Installation utilize drawings 2 1 A109P Sheet 2 of 3 Date 08 01 07 Rev N C Section 9 Installation of Electrical Page 2 of 3 Integrated Flight Systems INSTALLATION OF ELECTRICAL A109 Air Conditioning Run 14 wire from low pressure switch to compressor Install 50 Amp circuit breaker P N 050012 9 as shown in drawing 2 1 A109 Sheet 1 of 3 and placard P N 120205 For A109 E Installation utilize drawings 2 1 A109P Sheet 1 of 3 Connect 8 wire from P N 540045 1 to 50 Amp circuit 9 16 breaker Run a 8 wire from 50 Amp circuit breaker P N 050012 9 to master overhead electric panel and connect to aircraft buss as shown in drawing 2 1 A109 Sheet 1 of 3 For A109 E Installation utilize drawings 2 1 A109P Sheet 1 of 3 Connect CP102 from wire harness to master switch assembly P N 540060 as shown in drawing 2 1 A109 Sheet 1 of 3 For A109 E Installation utilize drawings 2 1 A109P Sheet 2 of 3 Connect J104 to aft switch assembly P N540061 Date 08 01 07 Section 9 Installation of Electrical Rev N C Page 3 of 3 REVISION RECORD REV DATE DESCRIPTION OF CHANGE ADDED A109A MODEL TO APPLICATION BLOCK REVISED TITLE BLOCK JTYE INSTALL INSTRUCTIONS CONNECTION OF AIR CONDITIONING POWER WIRE BEFORE CONNECTING THE 8 MAIN AIR CONDITIONING POWER LEAD TO THE AIRCRAFT BUSS REFER TO THE AGUSTA MAIN
103. de screwdriver and hammer Remove shims Use a pointed tool and a small screwdriver to prevent the shims from binding on the shaft 12 Agusta 109 Series Trouble Shooting Guide lt NTEG ATED Flight Systems SERVICE OPERATIONS CLUTCH 14 2 Rotor Assembly Removal l B ow 14 3 Field Coil Assembly Removal b 25 3 4 14 4 Field Coil Assembly Installation 14 5 Rotor Assembly Installation L MM 109 00 011 If bearing dust cover has not been removed remove it now See step 6 of Section 14 1 for Armature Assembly Removal If internal snap ring for bearing is visible above the bearing remove it with internal snap ring pliers Remove rotor snap ring Remove shaft key Remove rotor pulley assembly e Insert the lip of the jaws into the snap ring groove e Place rotor puller shaft protector Puller set over the exposed shaft e Align thumb screws to puller jaws and finger tighten e Turn puller center bolt clockwise using a socket wrench until rotor pulley is free Loosen lead wire clamp screw with 2 Phillips screwdriver until wire s can be slipped out from under clamp Undo any wire connections on the compressor which would prevent removal of the field coil assembly Remove snap ring Remove the field coil assembly Reverse the steps of Section 14 3 Protrusion on underside of coil ring must match hole in front housing to prevent movement and correctly locate lead wire s Pl
104. dient is listed Section 313 Specific toxic chemical listings 75 93 3 hutaniotie TSCA Toxic Substances Control Act All ingredients are listed Proposition 65 Chemicals known to cause cancer None of the ingredients is listed Chemicals known to cause reproductive toxicity Canceregenity categories International Agency for Research on Cancer Nome of the ingredients is listed Contd on page 7 25 Page 7 Mem iay d Material Safety Data Sheet IFS PN 070003 1 TOUCH UP PAINT GRE Y acc to ISO DIS 11014 Printing date 07 28 2005 Reviewed on 02 07 2005 Trade name 61003 Multi Coat Blank Aerosol Cond of page 5 NTP National Toxicology Program None of the ingredients is listed TLV Threshold Limit Value established by ACGIH acetone NIOSH Ca National Institute for Occupational Safety and Health None of the imeredients is listed OSH A Ca Occupational Safety Health Administration None of the ingredients is listed Product related hazard informations The product has been classified and marked in accordance with directives on hazardous materials Hazard symbols irritant Extremely flammable Risk phrases Extremely flammable irritating to eyes respiratory system and skin Vapours may cause drowsiness and dizziness Safety phrases Keep m a cool place Keep container in a well ventilated place Ure only in well ventilated area This material and its container must b
105. e gage This can occur when either or both of the two 2 expansion valves in the system closes or when the receiver drier becomes clogged Com pressor B C The compressor installed 15 manufactured by Sanden International A copy of Sanden Service Manual can be found on the Sanden website at www sanden com No maintenance other than clutch bearing or coil replacement should be attempted in the field Evaporator A Ifthe evaporator blower fails to run confirm that the Aircraft Master Condenser Switch is in the ON position and the Air Conditioning control Switch 15 placed in the FAN position Ifthe fan blower still does not run determine that electrical power is available to the aircraft from an outside power source such as a GPU or the aircraft power source If power is available 1t will be necessary to test with a voltmeter that electrical power is being supplied directly to the motor by the appropriate wire If power is being supplied and the motor is properly grounded then it can be assumed that the motor has failed On the blower P N 490029 the blower may be disassembled to allow removal of the motor P N 050052 1 The motor may be obtained from Integrated Flight Systems and installed in accordance with the procedures outlined in the IFS Maintenance Manual Document Number MM 109 00 O11 A The condenser blower may be checked by placing the Aircraft Master Switch ON and th
106. e assembly P N 570058 1 0 P to condenser 109 assembly and run to compressor Connect hose assembly P N 570059 1 0 to evaporator and run to compressor Connect Low Pressure Switch P N 050107 to hose assembly After those lines are tight connect line on evaporator assembly to drier bottle P N 570052 0 Service system after all lines are tight and check for leaks Follow procedure in Section 12 Instructions for Continued Airworthiness Date 08 01 07 Rev N C Section 10 Installation of Hoses Page 2 of 2 a VIEW B B RIGHT SIDE VIEW ANGLE AN960 10 WASHER AN365 1032 NEN a LOW PRESSURE SWITCH PN 050107 NUT AN3 4A Ny BOLT 10 HOSE ASS Y PN 5700059 O HIGH PRESSURE SWITCH PN 090004 VIEW D D LEFT SIDE VIEW REVISION RECORD REV DATE DESCRIPTION OF CHANGE ADDED A109A MODEL TO APPLICATION BLOCK A REVISED TITLE BLOCK ae 8 HOSE ASS Y ADEL CLAMP PN 570058 O 8 HOSE MS21919WDG4 6 HOSE ASS Y 10 HOSE MS21914WDG16 PN 570053 O a EXPANSION VALVE ub PN 090002 O 6 HOSE ASS Y 4 PN 570052 O REC DRIER BOTTLE PN 090016 5 VIEW A A LEFT SIDE FWD OF FWD ENGINE FIREWALL AGUSTA 109 A A109A A109A II A109C A109K2 INTEGRATED Systems TITLE PLUMBING DIAGRAM DRAWN BY DATE REV SCALE SHEET Ww A109A A109A II A109C A109K2 3 1 A109 NOTE 1995 AND ON RECEIVER DRIER BOTTLE PN 090016 5 L gt m
107. e disposed of as hazardous waste Special labeling of certain preparations Pressurized container protect from sunlight and do not expose to temperatures exceeding 50 electric lights Do not pierce or burn ever after use 100 0 5 by mass of the contents are flammable Keep out of he reach of children I Otherintormati orn This information is based on our present knowledge However this shall not constitute a guarantee for any xpecific product features and shall not establish a legally valid contractual relationship Department issuing MSDS Environment protection department Contact Adr George Wallace US A Integrated Flight Systems AIRCRAFT PRE INSPECTION A109 Air Conditioning Step 2 Aircraft Pre Inspection Date 09 24 09 Rev A Section 2 Aircraft Pre Inspection Page 1 of 4 Integrated Flight Systems AIRCRAFT PRE INSPECTION A109 Air Conditioning Aircraft Pre Inspection Inspect the aircraft for other kits and modifications that may effect the installation of the air conditioning kit 232 Inspect the airframe structure for any obvious structural damage or corrosion Inspect aircraft paperwork for damage history that may effect the installation of this kit Repair discrepancies that are found prior to installation of kit This kit is eligible for installation in an Agusta 109 A109A II A109C A109K2 A109E WARNING THIS INSTALLATION SHOULD NOT BE EXTENDED TO ELIGIBLE
108. e of Conformity RSG Products Inc will provide a Certificate of Conformity with each product assuring that the product has been manufactured according to its approved design drawings Any additional assurances or certifications shall be at the expense of Buyer and shall be added to the invoice as a separate charge to be paid by Buyer 11 Failed Products Should any product prove defective RSG Products Inc will either replace the item or adjust the matter fairly and promptly but under no circumstances shall RSG Products be liable for consequential or other damages losses or expenses in connections with or by reason of the use or liability to use products purchased for any purpose 12 Patents Buyer shall hold RSG Products Inc harmless from and release and not make claim or suit against RSG Products because of any suits claims losses or other liability made against or suffered by Buyer arising from any claim of or infringement of patent copyright trademark or other proprietary right at common law or claim of unfair trade or of unfair competition resulting from or occasioned by Buyer s use possession sale or delivery of the products sold to Buyer by RSG Products Inc 13 Warranty Registration and Claims The terms RSG Products Inc Limited Warranty is written on the Warranty Registration Card and published on the RSG Products Inc website www integratedflightsys com The registration form must be completed and returned to RSG Product
109. el 2 and E 130 amps continuous SECTION II NORMAL PROCEDURES Te turn air conditioner ON move switch to AC Prior to ON ensure ammeter indicates 65 amps or less K2 and E model 80 amps or less Totum air conditioner OFF move switch to OFF For air circulation without cooling move switch to FAN Select desired blower speed for cockpit e Select desired blower speed for cabin Do not start 2 engine with air conditioner ON Ventilation Control As desired Clase for cockpit cabin cooling amp Air Conditioning Control Switch As desired Air Conditioning Fan Speed Control Switches As desired Cockpit and cabin Tum air conditioner OFF to obtain correct Magnetic Compass heading FAA Approved Date June ZG Page 4 of Flight Systems Suppkiment Lo A gusta A DS ATI 900 Flighiline Drive Suite 3 AIC ATOSK amp ALOE Flight Manual Lincoln CA 95648 Flight Systems Ai Condibaner Supplement Ho 5 109 0020 1 STC SECTION EMERGENCY PROCEDURES Inthe event of engine failure turn air conditioner OFF 4 1 D C Generator Fai Air Conditioning OFF Note Auto Load Shedding of the Air Conditioning System is nat provided Ammeter 65 Amps or less K2 and E Model 0 amps or less Reduce electrical load Air Conditioning ON as desired Ammeter monitor 115 am
110. ems KIT INVENTORY LIST A109 00 011 Air Conditioning Step 1 Kit Inventory Date 09 24 09 Rev B Section 1 Kit Inventory Page 1 of 16 Integrated Flight Systems KIT INVENTORY LIST A109 00 011 Air Conditioning KIT INVENTORY LIST Sales Order Number Date 09 24 09 Rev B Section 1 Kit Inventory Page 2 of 16 Integrated Flight Systems KIT INVENTORY LIST A109 00 011 Air Conditioning KI T INVENTORY LIST sme _ PARTNAME pante OY Saya 53 cocar pucr assem 5 998 1 53 EVAPORATOR ASSEMBLY 39940 1 _ 58 CONDENSERIEGSUMORTASSY 502272 1 CONDENSER j ALTERNATE DELRON INSERT 504SE1032 06 02 6 Lus pem DRAINHOSE wR wor _ WS _ m O E AIR DEFLECTOR AIR DEFLECTOR L H RIVET Date 09 24 09 Rev B Section 1 Kit Inventory Page 3 of 16 Integrated Flight Systems KIT INVENTORY LIST A109 00 011 Air Conditioning AIR DEFLECTOR R H AIR DEFLECTOR L H 5 WEMAC DOUBLER L H WEMAC DOUBLER R H So WEMAC DOUBLER L H 260889 P WEMAC DOUBLER R H 260890 P RIVET MS20470AD4 3 RIVET MS20470AD4 4 RIVET MS20426AD4 3 RIVET MS20426AD4 4 RIVET MS20470AD4 3 A109 E RIVET MS
111. en placing the Air Conditioning Control Switch to the A C position and the override switch ON Ifthe 50 amp circuit breaker 1s not open then power should be supplied directly to the condenser blower which is mounted below the aft baggage area If air is being exhausted a voltmeter should be utilized to determine if the power is being supplied through the switch and relay to the appropriate wire Check that all electrical terminals are secure and that power 1s directed to the motor s terminals Inspect ground If it 1s determined that the motor has failed the screws holding the blower assembly in place should be removed The blower assembly must be removed as an entire assembly and replaced in accordance with the procedures outlined 1n the IFS Maintenance Manual Document Number MM 109 00 011 Document No ICA A109 00 01 1 Kev lk Date November 1 2008 Page of 10 Receiver Drier A The receiver drier may be replaced if required by discharging the R 134a from the system through a refrigerant hose or set of charging gauges Again all R 134a refrigerants MUST BE CAPTURED Normally the receiver drier will not need replacement unless one of two factors 15 present 1 The system has been left open for sometime and may be contaminated by air and or moisture 1 The receiver drier has become plugged which ts evident by a large temperature differential on either side of the receiver drier Normally the liquid l
112. g 6 1 A109 sheet 1 and 2 of 3 For A109 E Installation utilize Belt Adjustment Assy P N 510263 P and drawings 6 1 A109P Sheets 1 and 2 of 3 Safety wire Compressor bolts and Bracket Assy bolts at this me Caution Un tape Engine Inlet Re install engine air inlet box assembly and screen Date 07 06 09 Rev A Section 8 Installation of Compressor Page 3 of 3 D gt SEQUENCE FOR BELT TIGHTENING A LEAVE THE COMPRESSOR ANCHORING BOLTS LOOSE LEAVE THE ANCHOR BOLT FOR P N 530088 LOOSE UNTIL BELT TENSION 15 SET B ADJUST BELT TENSION BY ADJUSTING BY ADJUSTING THE NUTS ON P N 530088 BELT ADJUSTMENT ASSY UNTIL A MIN OF 5 TO A MAX OF 75 DEFLECTION IS ACHIEVED AT 10 Ibs PRESSURE AT MID SPAN OF THE BELT LOCK BELT BRACKET ASSY P N 510263 IN PLACE C TIGHTEN AND SAFETY THE COMPRESSOR TO BELT BRACKET ASSEMBLY BOLTS D TIGHTEN AND SAFETY THE COMPRESSOR TO COMPRESSOR BRACKET ASSEMBLY BOLTS TIGHTEN ANCHOR BOLT ON E P N 530088 E AFTER INSTALLATION OF BOLTS INTO SELF LOCKING HELI COILS SAFETY WIRE 032 MIN TO EACH OTHER __ 8 L BELT PN 060031 D gt AN6H10A BOLT 2 NAS1149F0633P OR NAS1149F0632P 2 TYP BOTH ENDS AN4H7A BOLT 4 NAS1149F0463P WASHERS 4 L WITH NUTPLATES SECURE W SAFETY WIRE 032 MIN OR i A AN4H10A BOLT 4 PLC S NAS1149F0463P OR NAS1149F0432P WASHER 8 PLC S MS21044N4 NUTOR MS20364 424C 4 PLC S S
113. he preparation the chemical mixture Selection of the glove material on consideration of the penetration times rates of diffusion and the degradation Material of gloves The selection of the suitable gloves does not only depend on the material but also on further marks of quality and varies from manufacturer fo manufacturer As the product is a preparation of several substances the resistance of the glove material can not be calculated in advance and has therefore to be checked prior to the application Penetration time of glove material The exact break trough time has to be found out by the manufacturer of the protective gloves and has to be observed Contd om page 4 1184 Page 4 7 THIS INFORMATION PERTAINS TO ET IFS PN 070003 TOUCH UP PAINT TEAL Material Safety Data Sheet IFS PN 070003 1 TOUCH UP PAINT GREY ace to ISO DIS 11014 Printing date 07 28 2005 Reviewed on 02 07 2005 Trade name 61003 Multi Coat Blank Aerosol Cont d of page 3 Eye protection Tightly sealed goggles 9 Physical and chemical properties General Information Form Aerosol Colar According to product specification Odor Characteristic Change in condition Melting point Melting range Undetermined Boiling point Boiling range OC 32 F OC lt 32 F 445 0 C 569 F Product is not selfigniting Lower 7 Vol Upper 13 0 Vol Vapor pressure at 209C 689F 5300 0 hPa 6226 mm Hg Density at 209C 68 F
114. icable Agusta service manuals STEP PROCEDURE MECH INSP 3 0 Remove or disconnect the battery 3 1 Remove pilot and co pilots door 3 2 Remove rear doors as needed STEPS INSP KE NEN EN s panel covers ia ia EN 3 g Remove the tail rotor drive shaft cover between engines 3 9 Remove right hand engine air inlet assembly NOTE After installation of system a thorough inspection of all areas affected must be performed to determine security component installations and workman ship standards prior to reassembly of aircraft and return to service by a qualified individual Date 08 01 07 Rev N C Section 3 Aircraft Preparation Page 2 of 2 Integrated Flight Systems REMOVAL OF FACTORY INSTALLED COMPONENTS A109 Air Conditioning Step 4 Removal of Factory Installed Components Date 08 01 07 Rev N C Section 4 Removal of Factory Installed Components Page of 2 Integrated Flight Systems REMOVAL OF FACTORY INSTALLED COMPONENTS A109 Air Conditioning Removal of Factory Installed Components NOTE Step 4 to be completed in accordance with applicable Agusta service manuals STEP PROCEDURE MECH INSP If installed remove the ram air scoop on forward transmission deck Date 08 01 07 Rev N C Section 4 Removal of Factory Installed Components Page 2 of 2 Integrated Flight Systems INSTALLATION OF EVAPORATORS A109
115. ight Systems KIT INVENTORY LIST A109 00 011 Air Conditioning KI T INVENTORY LIST Chk d Verf d STEP PART NAME PART Y o BELT ADJUSTMENT ASSEMBLY BELT BRACKET ASSEMBLY 530088 510263 MS21044N8 NAS1149F0863P AN6H10A NAS1149F0663P NAS1149F0632P NAS1149F0616P WASHER BOLT WASHER WASHER WASHER 9 1 ELECT PANEL ASSEMBLY 540028 C 3 SHURLOCK ALTERNATE DELRON INSERT SL601 3 3A 504SE1032 06 02 BOLT WASHER AN3 4A AN960 10 HARNESS ASSEMBLY HARNESS ASSEMBLY 540045 1 540059 1 BOLT NUTPLATE RIVET WASHER AN3 4A MS21059 L3 CCR264 SS3 3 AN960 10 HI PRESSURE SWITCH LOW PRESSURE SWITCH HANDSHAKE HEATSHRINK 090004 050107 14 16 Ya X 6 00 rA m Date 09 24 09 Rev B Section 1 Kit Inventory Page 10 of 16 Integrated Flight Systems KIT INVENTORY LIST A109 00 011 Air Conditioning KI T INVENTORY LIST STEP PART NAME PART go d ee d CIBSOAMP 050129 1 EE wre 88 ef RING TERMINAL 8X8 2 _ RING TERMINAL 4 8X38 1 SWITCH ASSEMBLY SHRINK AFT SWITCH ASSEMBLY 540061 HOSE ASSEMBLY 570053 0 HOSE ASSEMBLY 570058 1 0 ADEL CLAMP MS21919WDG 14 SCREW MS35207 265 WASHER AN960 10 HOSE ASSY 10 COMP TO EVAP 570059 1 0 ADEL CLAMP MS21919WDG 16 SCREW MS35207 265 WASHER AN960 10 AN365 1032A 540060 Ya X 6
116. ine to and from it would be of approximately equal temperature and will be quite warm IF one side 1s relatively warm and the other side 1s very cool or attempts to frost then blockage of the receiver drier has been determined The receiver drier should be removed and a new one installed in its place The P N is 090016 5 O ring type The charging instructions should be followed in recharging the system Expansion Valve A The Expansion Valve is of O ring type P N 090002 O B NOTE THE EXPANSION VALVE OF THE ABOVE PART NUMBER CONTAINS A CHARGE IN THE HEAD OF THE VALVE CONTAINING R 134A C It is EXTREMELY IMPORTANT that the sensing bulb be clamped tightly to the suction return line in the same manner as removed Also the line is to be clean so good contact takes place between the sensing bulb and the line This area must be re insulated as in the original manner Leak test and recharge in accordance with the procedures outlined in the IFS Maintenance Manual Document Number MM 109 00 011 and applicable sections of this Document Hoses A Nylon barrier type hoses with Bubble crimped ferrules are utilized with O ring fittings They are found at all fitting locations and should be inspected for security crimped fitting for leakage and obvious defects Low Pressure Switch A This switch 15 a non adjustable type normally open and is located in the engine compartment near the compressor P N 05010
117. is usually cold but becomes warm when pressure reading drop Cause Excessive moisture in the system The drying agent in the receiver drier is saturated with moisture which is released to the system when outside temperature increased Moisture in the system collects and freezes on the expansion valve stopping the flow or refrigerant Correction Suck all the CFC 12 from the system Replace of rebuild the receiver drier Evacuate and recharge Trouble Air in the system Symptoms Insufficient cooling Low side pressure normal but does not drop when the clutch cycles High side pressure high Receiver drier sight glass shows occasional bubbles Note again that with HFC 134A the sight glass should be milky when the system is fully charged Air in ducts only slight cool Cause Refrigerant contains non condensable in the form of air and moisture Correction Leak test watch for bad compressor seals Drain the system Repair leaks as needed Replace or rebuild the receiver drier Check the compressor oil Evacuate and recharge MM 109 00 01 1 4 Agusta 109 Series Trouble Shooting Guide INTEGRATED Trouble Condenser malfunction or system overcharge Symptoms No cooling Low side pressure too high High side pressure too high Receiver drier sight glass may show occasional bubbles Liquid line very hot Air in ducts is warm Cause The condenser is not function properly because of high head pressure System may
118. m of three hoses should be connected to the high side and low side service ports provided The sight glass 1s located in the 6 line in the doghouse on the cabin roof Charge the system in accordance with the procedures outlined in the IFS Maintenance Manual Document Number MM 109 00 011 Oil Charging R 134a Refrigerant A Prior to the use of R 134a refrigerant R 12 refrigerant was used in all IFS systems The PROPERTIES OF R 134a REFRIGERANT AND THE VARIOUS TYPES OF OIL USED WITH THIS REFRIGERANT ARE COMPLETELY DIFFERENT The Sanden compressor uses a 500 viscosity SP 20 type oil ISO 100 100 O A T or higher ISO 68 100 or lower or an ESTER type oil vellow label No other type oil can be utilized Charge the system in accordance with the procedures outlined in the IFS Maintenance Manual Document Number MM 109 00 01 1 Initial Charging A Charge the system in accordance with the procedures outlined in the IFS Maintenance Manual Document Number MM 109 00 01 1 Document No ICA A109 00 0 Kev IR Date November 1 2008 Page 5 of 10 Adding R 134a Refrigerant to System A If the system is found to be completely empty of R 134a a set of charging gauges should be connected to both high and low side service ports and to a cylinder of R 134a Purge the charging hoses from the cylinder to the service ports with R 134a vapor Open both the low and high side charging valves and allow pressure from the
119. n aircraft flange Then install Camloc P N 50 052 1 See drawing 8 A109 Sheet 1 of 1 For A109 E Installation utilize drawings 8 1 A109P Sheet 1 of 1 Install Camloc P N 50 052 5 1 in aircraft cowl See drawing 8 A109 Sheet of 1 For A109 E Installation utilize drawings 8 1 A109P Sheet 1 of 1 If existing aft cabin ventilation system 15 not installed Position aft cabin duct P N 520066 as shown in drawing 5 A109 Sheet 4 of 4 For AIO9A II C or K2 Model If existing aft cabin ventilation system 15 not installed Position aft cabin duct P N 520066 as shown in drawing 5 A109P Sheet 4 of 4 For AIO9E Model If existing aft cabin ventilation system 15 not installed Position aft cabin duct P N 520066 A as shown in drawing 5 A109 Sheet 4 of 4 For AI09A Model For aircraft with existing aft cabin ventilation system utilize drawings 5 1 A109P Sheet 4 of 4 Install Hose Nipple PN 250509 per drawing 5 A109 Sheet 4 of 4 For pre existing ventilation system utilize drawings 5 1 A109P Sheet 4 of 4 Install duct per drawing 5 A109 Sheet 4 of 4 if ventilation duct 1s required For pre existing ventilation system utilize drawings 5 1 A109P Sheet 4 of 4 Attach with 6 AN525 10R8 Screws and 6 AN960 10 Washers Shim with washers as needed Attach 2 each placards PN 120071 as shown in drawing Re install duct PN 520061 Wrap ends of duct at attachment points with aluminum tape PN 070076 Attach supports with AN3 4A bolts and AN960 10 washers Cau
120. of some basic information on Freon System Operation We should probably define cold Actually for our purpose cold 15 a relative term Your air conditioner should produce air measured at the duct that 1s 36 to 50 F at 70 ambient temperature 40 to 52 F at 80 ambient temperature 46 to 60 F at 90 ambient temperature 50 to 75 F at 100 ambient temperature An Empty System If the system is empty the search for leaks should begin with a good visual check Is it a fast leak or a slow leak When was the system last charged If it s a newly installed and filled system then look for obvious leaks like a chaffed punctured or ruptured hose or a loose fitting See the recharge and leak testing section for hints on charging new systems Freon leaks can be very tough to find Freon 15 colorless odorless heavier than air and it evaporates as soon as it hits the atmosphere The only helpful thing about it 1s the fact that the oil carried with the refrigerant so any sizable leak will leave a trail of oil at the offending hose or fitting It will often just be a dark area and the amount of oil might be slight But if you find and air conditioning fitting with an oily residue and the area around it 1s dry you ve probably found you leak A good electron detector can verify your visual diagnosis Because the system carries the oil in suspension with the refrigerant any sizable leak will leak oil as well as refrigerant
121. old There were large warning signs on this service cart designated HELICOPTER SERVICE ONLY They had one for ground equipment AII of the mechanics were well trained except for the management janitors and their family members of the company It can happen to any operator 6 Compressor clutch does not engage but air conditioner fans work A Check clutch for power 1 If power clutch coil may be bad or air gap in clutch face may be too excessive 2 If NO power check system for total Freon loss 3 If system 15 serviced and still no Power and you have an optional temperature controller you can bypass by jumping pins 3 and 4 on CP102 to check if faulty MM 109 00 01 1 Agusta 109 Series Trouble Shooting Guide INTEGRATED 7 System not cooling A Check that air condenser fan fans are blowing B Check clutch engagement Is clutch staying engaged or cycling Check belt tension C Check to see if air condenser coil is free from debris and fins are clean and not rolled over blocking air flow D Check evaporator return air inlets that they are not blocked and fins are clean and not rolled over blocking airflow E Put gauges on system Run system and check pressures also measure Delta temperature from both evaporators Measure inlet temperature and outlet temperature to get Delta This 15 a must do not rely on just using your hand and guessing F Check sight glass NOTE There are several ways to service Freon systems
122. on valve may not be working If expansion valve 15 not throttling it will dump too much Freon This can add excessive heat to condenser and can also freeze up coil 2 If Delta is below 14 F Change valves they may be blocked internally MM 109 00 01 1 9 Agusta 109 Series Trouble Shooting Guide INTEGR ALED 13 Blower Motor Brush Inspection A 5 0 Blower motors have brushes 13 16 long Brushes should be inspected every 200 hours When brushes wear down to 5 16 replace them MM 109 00 01 1 10 Agusta 109 Series Trouble Shooting Guide INTEGRATED Systems Blower motor Brush change Procedure 1 The following brush inspection change procedure is applicable to the blowers listed below 050143 series all dash numbers and or applicable motors 2 Disassemble the motor for brush inspection or replacement as follows a Remove the two each 5 Blower Remove the brushes for inspection or discard b Clean motor with dry compressed air by blowing air into the brush holder openings to remove any loose carbon dust as needed 3 Reassemble the motor after brush inspection or replacement as follows a Install new brushes and reinstall brush caps finger tight only b Confirm that the motor turns freely and operates normally c Runin the brushes for a minimum of five minutes to allow them to seat properly 4 Brush inspection for length or damage is determined as follows a Brush for 050143 5 Blower should not be les
123. or A109 E Installation utilize drawings 4 1 A109P Sheet 2 of 2 If no hole exists align 3 4 Nipple P N 250279 to clear controls and align with aft fan elbow Mark position Should be centered between fore and aft in cabin within 5 5 Cut 3 1 2 hole and cut back inner core 1 Rivet in place aft air duct doublers P N 261510 with 557 CR3243 4 2 rivets 24 places and fill with Metalset M Allow Metalset M to cure per manufacturers instructions Remove all shavings or debris Drill 3 each 10 holes through Install hose nipple 5 58 P N 250279 with 3 AN3 13A bolts 3 MS21044 N3 nuts 3 AN960 10 Washers and 3 AN970 4 Washers Remove all shavings or debris Connect 3 5 inch hose P N 060024 1 from fan 5 50 elbow to hose nipple on deck using 2 each 3 Band Clamps PN 060036 Wrap 3 5 inch hose P N 060024 1 with foam insulation tape P N 070078 then cover with aluminum foil tape P N 070076 Connect evaporator drain line Y P N 100181 to tube from fan elbow using tube P N 090018 1 See drawing 4 A109 Sheet 1 of 2 for detail For A109 E Installation utilize drawings 4 1 A109P Sheet 1 of 2 PROSEAL 890 B 2 or B 1 2 around all bolt heads above deck and any fastener on cabin ceiling Date 09 24 09 Rev A Section 5 Installation of Evaporators Page 9 of 10 Integrated Flight Systems INSTALLATION OF EVAPORATORS A109 Air Conditioning Install DZUS support assemblies P N 510300 with MS20426 3 X rivets i
124. ps maximum continuous Except K2 and E Model 130 amps continuous 3 2 Excessive T Inthe event of the following turn Air Conditioner OFF Cabin or other fire e Presence of smoke FAA Approved Date June 18 2009 Page i Integrated Flight Systems Supplement to the Agusia Model ALISAN Flighiline Drive Suite 3 amp ALOE Flight Manual Lincoln CA 95648 Integrated Flight Systems Air Conditicmer Supplement REM SA 109 000 1 1 STU No SRIKKHAIDE SECTION IV PERFORMANCE With the Air Conditioner ON decrease Rotorcraft Flight Manual data by e Reduce Hover Gross Weight by 100 pounds Reduce Rate of Climb by 50 feet per minute NOTE 1 Engine Anti Ice OFF 2 Indicates performance degradation when operating on an engine power limit TOTH I SECTION V WEIGHT AND BALANCE Weight and Balance must be computer with air conditioning system installed Ensure that empty weight and CG of aircraft is within manufacturer s limits per the FAA Approved Flight Manual FAA Approved Die Pune 14 2006 Page 6 of E Fliglu Systems REM Supplement to the Agusia Model 900 Flighiline Drive Suite 3 AMR A103K2 amp ALGE Flight Manual Lincaln CA 95648 Imsegrabed Flight Systems Air Conditioner Supelement Ho RFMS A 1 09 00501 1 STE SECTION YI MANUFACTURER S INFORMATION x1 Systems amp Description The Air Conditioning System consists
125. ratedflightsys com is used on an aggregate basis to evaluate and effectiveness of our Site to analyze trends and to administer the Site This navigational information allows us to determine such things as which areas are most visited and difficulties our visitors may experience in accessing out Site Voluntarily provided information is collected online if you elect to e mail RSG Products Inc Whenever this act is made the information you voluntarily provide name e mail address phone number specific information comments or questions is not distributed and is confidential All information collected from our site and or information voluntarily provided is kept confidential and is not distributed for any reason without your approval 14 Acceptance This is not a firm offer and may be changed or revoked at any time Acceptance of this offer 15 expressly limited to the exact terms contained herein or as may be changed by a prior written contract between the Buyer and RSG Products Inc and any attempt to alter or omit any of such terms shall be deemed a rejection and a counteroffer RSG Products Form 33 40 Rev 09 19 2011 WARRANTY REGISTRATION FORM DATE CUSTOMER NAME ADDRESS CITY STATE ZIP PHONE NUMBER _ FAXNUMBER COMPONENT NAME PART NUMBER SERIAL NUMBER TYPE AIRCRAFT N S N AIR CONDITIONING INSTALLATION DATE AIR CON INSTALLATION COMPANY DATE INSTALLED T T AT INSTALLATION COPY OF T T LOG BOOK ENTRY OF A C
126. res 5 Delays RSG Products Inc will not be liable for any delay in the performance of orders or contracts or in the delivery or shipment of goods or for any damages suffered by Buyer by reason of such delays 6 Technical Advice RSG Products Inc technical support staff is available for telephone consultation concerning the products it manufactures however RSG Products does not warrant or guarantee such advice 7 Aircraft Variation Due to aircraft manufacturing variations alterations and other factors there are differences between aircraft of a certain make and model Because of these variations RSG Products Inc does not guarantee that Buyer has purchased the correct product or that a specified product will fit the intended aircraft Further RSG Products does not guarantee the number of labor hours required to install its products 8 Returns All sales are final unless a return is approved at the sole discretion of RSG Products Inc If RSG Products Inc does agree to accept a return a twenty percent 20 restocking fee will be charged items returned to RSG Products Inc must be sent freight prepaid and must have a return material authorization RMA number clearly marked on the shipping container 9 No Fault Found If items are sent to RSG Products Inc for evaluation and no problem is found or if Buyer elects not to make the required repairs then Buyer shall be responsible for the payment of 250 evaluation fee 10 Certificat
127. running cooling may be provided Controls for the air conditioning system are located on the switch panel in the cabin overhead Two switches are provided The Master Control Selector consists of a rocker type switch labeled OFF and FAN Selecting the A C position turns on the system s evaporator fan condenser blower and belt driven compressor The second rocker switch 15 HIGH LOW evaporator fan speed selection for the forward cockpit Document No 109 00 01 1 Rev IR Date November 1 2008 Page 4 of 10 4 Servicing Information All components are readily accessible for inspection or servicing Major components are accessed as follows A B Compressor Remove transmission cowling in accordance with the Agusta Maintenance Manual Condenser Condenser Blower Remove doghouse in accordance with Agusta Maintenance Manual Evaporator Evaporator Blower Remove doghouse in accordance with Agusta Maintenance Manual Service Ports Sight Glass Remove doghouse in accordance with Agusta Maintenance Manual Charging Refrigerant R 134a Into System A The refrigerant used in this system is R 134a and no other refrigerant is to be considered Normal safety practices such as wearing of gloves and the use of goggles should be utilized Charging of the system 15 a simple procedure whether on initial or recharging after leakage repair A set of refrigerant gauges with a minimu
128. s Inc upon receipt of a product The completed form may be faxed to 1 817 624 6601 Failure to complete the Warranty Registration Card may result in denial of a claim In order to process a warranty claim call RSG Products Inc at 1 817 624 6600 or fax 1 817 624 6601 A Warranty Claim without a Return Material Authorization RMA Number will cause delays and a possible denial of the claim RSG Products Form 33 40 Rev 09 19 2011 bi PRODUCTS INC WEBSITE Terms of Use When you access browse or use this Site you accept without limitation or qualification the terms and conditions set forth below If you do not agree to them do not use the Site or download any materials from integratedflightsys com The information herein contained may include technical inaccuracies or typographical errors Changes may periodically be made to the information and will be incorporated in new editions of this document without notice In no event will RSG Products Inc be liable to any party for any direct indirect special or other consequential damages for any use of this web site or any other hyper linked site including without limitation any lost profits business interruption loss of programs or other data on your information handling system Site Information Site information regarding RSG Products Inc services technical parts and components including their availability appearance price and specifications are subject to change
129. s than 185 of an inch over all length They should be inspected every 200 hours 8 NEW 2 H ii TR mr Wis acd RR PR 185 MIN je NOTE IF THERE IS ANY SUSPECTED OR NOTICABLE DAMAGE AND OR BRUSH LENGTH IS QUESTIONABLE THE BRUSHES ARE TO BE DISCARDED AND REPLACED WITH GENUINE INTEGRATED FLIGHT SYSTEMS PARTS MM 109 00 01 1 1 Agusta 109 Series Trouble Shooting Guide SERVICE OPERATIONS INTEGRATED Systems CLUTCH 14 1 Armature Assembly Removal 1 oJ MM 109 00 01 1 If armature dust cover is present remove the 3 or 6 bolts holding it in place and remove cover If auxiliary sheet metal pulley is present remove the screws holding it in place Then remove pulley Insert pins of armature plate spanner into threaded holes of armature assembly Hold armature assembly stationary while removing retaining nut with 3 4 19mm or 14mm socket wrench as appropriate Remove armature assembly using puller Thread 3 puller bolts into the threaded holes in the armature assembly Turn center screw clockwise until armature assembly comes loose If shims are above shaft key remove them now If shims are below shaft key the key and bearing dust cover if present must be removed before the shims can be removed Remove bearing dust cover if present Use caution to prevent distorting cover when removing it Remove shaft key by tapping loose with a flat bla
130. sale or the performance or breach or any condition of warranty there under or from the manufacture delivery or use of the Equipment shall be the repair or replacement of defective equipment upon return of the defective equipment to RSG Products Inc with transportation customs and any applicable import duties prepaid and provided that an inspection by RSG Products Inc discloses that the equipment is defective and covered by this warranty RSG Products Inc shall not be liable for any labor or other charges necessary to remove or reinstall the Equipment In no event whether as a result of a breach of contract warranty tort including negligence or otherwise shall RSG Products Inc be liable for any special consequential incidental or penal damages or expenses including but not limited to loss of profit goodwill or revenues loss of use of the Equipment or any associated equipment damage to associated equipment cost of capital cost of substitute products facilities or services down time or costs or claims of third parties for such damages or expenses THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OR REMEDIES WHETHER WRITTEN ORAL IMPLIED OR STATUTORY ANY AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE COURSE OF DEALING OR USAGE OF TRADE ARE HEREBY EXPRESSLY DISCLAIMED AND EXCLUDED Acceptance of the Equipment by you shall constitute your acknowledgement and acceptance of the terms
131. shed by placing the selector switch in the FAN position System electrical protection is provided by two circuit breakers 15 A and 20A labeled EV AP EV AP and two circuit breakers 20A and 20 labeled COND COND These circuit breakers are located in the Aur Conditioning Master Electrical Panel This panel i5 located on the transmission deck A circuit breaker 1A also protects the Condenser Fans and Compressor Clutch If a high pressure occurs in the system the High Pressure Switch will open the A circuit breaker The condenser fans and compressor clutch will then shut off but the cabin fans will continue t operare FAA Approved Dae Pane 14 1009 Page Iniezraied Flaght Systemes RFM Supplemen ta the Agusta Mosel A 119411 Flightline Drive Susie 3 ALAR K ALOSE Flight Manual Lincoln CA 93648 Integrated Flight Systems Air Conditioner Tappen No 109 004 STC Mo A Master Air Conditioning System Circuit Breaker is provided im the aircraft s auxiliary electrical panel located behind and above the pilot s head If this circuit breaker is pulled for any reason all electrical power to the Air Conditioning System is disconnected A Soft Start Mode is provided electrically far this system When the Master Control Selector labeled AAC is turned ON both evaporator fans having total electrical requirement of 20 amps is immediately energized A few seconds later the dual
132. small quantities Danger to drinking water if even extremely small quantities leak into the ground 1 Disposal considerations Product Recommendation not be disposed of together with household garbage Do allow product to reach sewage system Uncileaned packagings Recommendation Disporad must be made according to official regulations 14 Transport information Hazard class 2 1 Identification number UN1950 Packing group Proper shipping name technical name AEROSOLS flanunable Label 21 Land transport AD R RID cross border ADR RID class 2 SF Gases Danger code Kemler 33 UN Number 1950 Packaging group Label 21 Contd page UBA Page 6 7 THIS INFORMATION PERTAINS TO Material Safety Data Sheet IFS PN 070003 TOUCH UP PAINT TEAL IFS PN 070003 1 TOUCH UP PAINT GRE Y to ISO DIS 11014 Printing date 07 28 2005 Reviewed on 02 07 2005 Trade mame 61003 Multi Coat Blank Aerosol Contd of page 5 Description of goods 1950 AEROSOLS Maritime transport IMDG IMDG Class 2 3 UN Number 1950 Label 2 4 Packaging group EMS Number F DS U Marine pollutant No Propper shipping name AEROSOLS Air transport ICAO TI and 1ATA DGR Class 2 4 UNID Number 1950 Label 2 4 Packaging group Propper shipping name AEROSOLS flammable RE Section 355 extremely hazardous substances None of the ingre
133. smission deck drill 4 each 515 diameter holes Remove all shavings or debris Pot in Shurloks or Delrons P NS504SE 1032 06 02 or SL601 3 3A as shown in detail A 2 1 109 allow Metalset M to cure per manufacturers instructions For 109 utilize drawing 2 1 A109P 94 Install electric box with AN4 4A bolts and AN960 10 washers Connect wire harness assembly P N 540059 1 and P N 540045 1 See 2 1 A109 Sheet 1 thru 3 For A109 E Installation utilize drawings 2 1 A109P Sheet 1 thru 3 Run wires left side of aircraft forward and across to evaporator Tie off with Zip ties and Tie blocks Run CP102 and power wire P N 540045 1 through cockpit 9 7 overhead electric panel Run J104 wire from electric box direct to aft evaporator air supply hole in center of deck Connect CP103 to forward evaporator fan Ground both ground wires to deck as shown in drawing 4 9 10 A109 Sheet 2 of 2 For A109 E Installation utilize drawings 4 1 A109P Sheet 2 of 2 Burnish mounting spot for ground Install Nutplate PN MS21059 L3 Run high and low pressure switch wires Install High Pressure Switch PN 090004 and Low Pressure Switch PN 050107 and connect wires see drawing 2 1 A109 Sheet 2 of 3 For A109 E Installation utilize drawings 2 1 A109P Sheet 2 of 3 Run condenser fan wires J106 and J105 to condenser fans 9 12 per labeling on wire leads Run aft evaporator fan wires to resistor on evaporator assembly Conne
134. t 8 2 8 3 8 4 8 4 Install drive pulley P N 300333 2 rotor disc and both belts P N 06003 1 060031 P for AIO9E in place See drawing 6 1 8 5 A109 Sheets 1 2 and 3 of 2 For A109 E Installation utilize drawings 6 1 A109P Sheet 1 2 and 3 of 3 Safety wire bolts per drawing 8 7 8 8 8 10 Position compressor bracket with 4 each AN4H7A 4 each NAS1149F0463P or NAS1149F0432P washers 4 each MS21044 N4 nuts alt ANA4HIOA W MS20364 424C if no nutplates present Make cut out in forward engine firewall per drawing 6 1 A109 sheet 3 of 3 For A109 E Installation utilize drawings 6 1 A109P Sheet 3 of 3 Remove all shavings or debris Temporarily install compressor PN 010001 3 O per drawing 6 1 A109 Sheets 1 and 2 of 3 For A109 E Installation utilize drawings 6 1 A109P Sheets 1 and 2 of 3 Check belt fit and alignment Do not safety wire at this time Remove compressor Re install tail rotor drive shaft per Agusta Service manual Remove compressor bracket and bolt caliper in place loosely mE Date 07 06 09 Rev A Section 8 Installation of Compressor Page 2 of 3 Integrated Flight Systems INSTALLATION OF COMPRESSOR A109 Air Conditioning STEP PROCEDURE MECH INSP Install compressor bracket and bolt in place per drawing 6 1 A109 sheet 1 of 3 For A109 E Installation utilize drawings 6 1 A109P Sheet 1 of 3 Check alignment between caliper and rotor disc IAW 6 1 A109 Sheet 2 of 3 For A109E utilize 6 1
135. tch engages in a positive manner If clutch plate and pulley show signs of excessive heat replace clutch pulley assembly bearing and coil The compressor mounts should be inspected for possible cracks deterioration and that all bolts are firmly attached Check condition of belt Inspect for cracks deterioration separation worn or flat spots Change belt whenever any of these conditions exist or one thousand hours which ever comes first Document No 109 00 01 1 Rev IR Date November 1 2008 Page 6 of 10 Inspect hoses for general condition cuts or swelling Replace as required Check security of clamps and anti chaff material Evaporator i The evaporator blower motor is a permanent magnetic type No repair is recommended other than replacement of the brushes Unit should be returned to IFS for overhaul If brush height is 5 16 or less replace Inspect every 200 hours Run the evaporator blower in the FAN position and perform visual inspection of the assembly to see that foreign materials have not been ingested into the blower which might cause blade damage The blower should also be run at the various speeds available to check motor operation Condenser i ii iii Either four 4 or two 2 brushes are located under caps on each side of the motor Inspect brushes every 400 hours for wear If brush length is 3 8 or less replace brush NOTE TAKE CARE WHEN INSTALLING BRUSHES THAT BR
136. ter It is a system utilizing R 134a non CFC type refrigerant This kit is compatible with utility corporate and EMS configurations An Integrated Flight Systems unit 15 designated to be as maintenance free as possible It incorporates in the design components that have proven themselves to be highly reliable Description The Integrated Flight Systems IFS Air Conditioning System 15 a vapor R134a refrigerant recovery system The compressor uses an IFS bracket attached to mounting points on the transmission case A single evaporator 15 used for this system mounted on the cabin roof in the doghouse A single 24 volt fan motor is used to circulate the cabin air through the evaporator Air distribution 15 accomplished through the ducts in the cabin The ducts are equipped with directional valves The condenser 1s also mounted on the cabin roof in the doghouse Another 24 volt fan motor circulates air through the condenser The air enters through the intake sereen in a scoop on the aircraft The system is activated by an On Off switch in the pilot s compartment and a selector switch to provide high or low air velocity distribution options Operation The air conditioning installation consists of a belt driven vapor cycle air conditioning system using R 134a as the refrigerant The air conditioning system provides for cabin comfort during all operations both on the ground and in flight During ground operations when the engines are
137. tion Make sure all controls clear duct by 15 minimum Date 09 24 09 Rev A Section 5 Installation of Evaporators Page 10 of 10 REVISION RECORD REV DESCRIPTION OF CHANGE REV 1 BY ADDED A109A MODEL TO APPLICATION BLOCK n REVISED TITLE BLOCK CIRCUIT BREAKER LOCATION FOR MASTER AIR CONDITIONING 50 AMP CIRCUIT BREAKER PN 050012 9 AFT OF PILOTS HEAD AND PLACARD PN 120009 2 NEW WEMACS SHOWN PILOTS CONDENSER COMPRESSOR LOCATED AFT OF TRANSMISSION Z 4 EVAPORATOR 2 ASSEMBLY SN NS MASTER A C lt gt ASSEMBLY MASTER ELECTRICAL CONTROL BOX NEW COCKPIT YALSVW O V AIR DUCT ASSEMBLY POSITION PLACARD r DUM E uy UPSIDE DOWN AS uv SHOWN QUEM Y XY COMPRESSOR RETURN AIR AGUSTA 109 y NEW WEMACS A109A 109 A109C A109K2 CO PILOTS INTEGRATED MASTER AIR CONDITIONING CONTROLS amp FORWARD FAN SPEED CONTROL SWITCHES OVER PILOTS HEAD TO RIGHT OF THROTTLE Systems TITLE AIR CONDITIONING RETURN AIR SCREEN PN 080036 OVERVIEW ABOVE AND BEHIND CO PILOTS HEAD DATE REV SCALE SHEET NEW CO PILOTS WEMACS a P 08 01 07 NONE fori OF 1 O PILOTS OPPOSITE REVISION RECORD COMPRESSOR LOCATED AFT OF TRANSMISSION 2 x EVAPORATOR 7 ASSEMBLY NEW WEMACS PILOTS NEW COCKPIT m i AIR DUCT we 3 ASSEMBLY gt 2 LOCATION FOR MASTER AIR
138. ts and remove Cut off marked piece on lower duct For A109 E Disregard this step Cleco ducts together and re install Trim as necessary to make duct removable as one piece For A109 E Disregard this step Rivet duct together using ABA4 4 rivets while duct is in place For A109 E Disregard this step Remove duct assembly Insulate assembly with Foam Tape PN 070078 cover with Aluminum Foil Tape PN 070076 Install 2 Delrons or Shurlocks for mounting duct supports P N s 510230 510231 Per instruction and Detail A on drawing 4 A109 Sheet 2 of 2 For A109 E Disregard See Step 5 53 Install Return Air Duct PN 060012 Attach each end with leach band clamp PN 060035 Secure middle with 2 each TY5224M per Drawing 4 1 A109P Sheet 2 of 2 Date 09 24 09 Section 5 Installation of Evaporators Page 8 of 10 Integrated Flight Systems INSTALLATION OF EVAPORATORS A109 Air Conditioning STEP PROCEDURE MECH INSP AFT CABIN VENTILATION NOTE For models NOT equipped with a factory aft cabin ventilation system utilize drawing 4 A109 Sheet 2 of 2 and 5 A109 Sheet 4 of 4 For models pre equipped with aft cabin ventilation system this is an optional installation only the aft cabin air duct PN 520066 is not required Utilize drawings 4 1 A109P and 5 1 A109P sheet 4 of 4 If required enlarge fresh air inlet hole in deck from 2 1 2 to 3 1 2 See drawing 4 A109 Sheet 2 of 2 Detail B F
139. ty reasons unsuitable extinguishing agents Water with full jet Protective equipment No special measures required lcctdental release measures Person related safety precautions Wear protective equipment Keep unprotected persons away Measures for environmental protection Do not allow fo enter sewers surface or ground water Measures for cleaning collecting Ensure adequate ventilation Do not flush with water or aqueous cleansing agents 7 Handling and storage Handling Information for safe handling Open and handle receptacle with care Information about protection against explosions and fires Do not spray on a naked flame or incandescent material Keep ignition sources away Do not smoke Protect against electrostatic charges Pressurized container protect from sunlight and do not expose to temperatures exceeding 50 C i e electric lights Do not pierce or burn even afier use Storage Requirements fo be met by storerooms and receptacles Store in a cool location Observe official regulations on storing packagings with pressurized containers Information about storage in one storage facility Not required Further information about storage conditions Keep receptacle tightly sealed De not gas tight seal receptacie Store in cool dry conditions in well sealed receptacles Contd on page 3 Page 3 7 THIS INFORMATION PERTAINS TO ws PN 079893 TOUCH up pair tear Material Safety Dat
140. ystems DIAGRAM DRAWN BY DATE REV SCALE SHEET JTYE 08 01 07 A NONE 20F3 A APPLICATION DWG No A109A A109A II A109C A109K2 2 1 A109 AIR CONDITIONER MASTER ELECTRICAL STA BOX W HARNESS 2000 ASSY S CONNECTED PN 540028 C 3 HARNESS ASSEMBLY PN 540059 1 RELOCATE WIRE BUS BELOW R A CUTOUT OR ABOVE MASTER ELECTRICAL BOX ASSY P N 5540026 C 3 DETAIL A 4 BOLTS AN960 10 WASHER TYP 4 PLS ELECTRICAL BOX ASSEMBLY P N 540028 C 3 TYP BOTH ENDS OF ELECTRICAL BOX SHURLOK INSERT FILL W A 4 SL601 3 3A METAL SET ALT DELRON PN 504SE 1032 06 02 TYP 4 A C SPEED CONTROL RESISTOR PN 050024 2 R H CONDENSER WIRES HARNESS ASSEMBLY PN 540045 1 FWD OUTBOARD LOOKING IN AT A C MASTER ELECTRICAL BOX INSTALLATION REVISION RECORD REV DESCRIPTION OF CHANGE DESCRIPTION OF CHANGE BY ADDED A109A MODEL TO APPLICATION BLOCK REVISED TITLE BLOCK AN3 4A BOLT WITH AN960 10 WASHER INTO SHURLOCK PN SL601 3 3A ALTERNATE DELRON INSERT PN 504SE1032 06 02 POTTED FITTING TYP 4 5 FROM WALL A C CLUTCH WIRE IN LINE WITH HIGH PRESSURE AND AFT CABIN A C SPEED LOW PRESSURE SWITCHES CONTROL SWITCH ASS Y PN 540061 AGUSTA 109 Tp A A109A A109A II A109C A109K2 AIR CONDITIONER DETAIL A INTEGRATED ALTERNATE LOCATION TRIM PLACARD AS NECESSARY Systems

IM-109-00-011 Rev B Installation Manual

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