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BOMBARDIER AEROSPACE SD3-60 Maintenance Manual
BOMBARDIER AEROSPACE SD3-60 Maintenance Manual

BOMBARDIER AEROSPACE SD3-60 Maintenance Manual

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AIR CONDITIONING - DESCRIPTION AND OPERATION
AMM
21-00-00
1.0.0.0
General
1.
Refer to Figure
1.
A single air conditioning system supplies conditioned air to the flight and passenger
compartments with separate temperature control for each.
The system derives its hot air from bleeds on both engines but will continue to work, with reduced
performance on a supply from one engine only.
Bleed air conditioning
2.
Refer to Figure
1.
Refer to Figure 2 (Sheet
Bleed air is taken via fixed orifices from the P2.5 and P3 bleed connections on each engine. At
low power settings, when the P3 bleed pressure is below 35 p.s.i.g., the temperature control
valve (TCV) is fully open admitting P3 bleed air only, to operate the system. At high power
settings, when pressure in the P3 bleed line exceeds 35 p.s.i.g. a pressure switch operates to
initiate modulation control via the solenoid selector valve and temperature sensor (TS), initially
closing the TCV. Due to the absence of P3 pressure, the check valve in the P2.5 bleed line
opens, maintaining system requirements on P2.5 bleed air only. Should the temperature in the
common bleed line fall to below 300° F whilst operating on P2.5 bleed air, a temperature sensor
(TS) will modulate the TCV to open, allowing P3 bleed air to mix with P2.5 thus maintaining the
bleed air temperature above 250° F. To prevent spurious over-pressure warning being caused by
a cold TS, a time delay is included to postpone the opening of the TCV until 10 seconds after the
HA/SOV is selected open.
Downstream of the TS air passes through a hot air shut-off valve (HA/SOV), a venturi and a
check valve to a common line. The check valves in each half system prevent cross-flow between
engines and the dumping of all bleed air, should either duct fracture.
Air in the common line passes to a refrigeration unit consisting of a dual heat exchanger and a
three-wheel air cycle machine (ACM). In the heat exchanger the bleed air is cooled in the primary
section, compressed and then intercooled in the secondary section. The cooling medium in the
heat exchanger is ambient air driven through the heat exchanger by the fan of the ACM. The
NACA inlet for ambient air is located in the fuselage roof fairing. A flap at the top rear is spring-
loaded closed and will open inwards to supplement the supply during static running should the
demands of the ACM cause a partial depression within the fairing. A lip at the rear of the flap (aft
hinge point) provides for aerodynamic assistance of flap closure during flight (in addition to spring
action).
From the secondary section of the heat exchanger, the bleed air is ducted to the turbine inlet and
to one half of a dual bypass valve; the outlets from both units combine and deliver the air to a
water separator. The cooled air from the secondary section expands in the turbine and produces
a low temperature and condensed mixture (fog); it also provides the power to drive the
compressor and the fan. The water separator coalesces the fog into drops which, when
EFFECTIVITY: All
SD3-60 AIRCRAFT MAINTENANCE MANUAL
1).
21-00-00
z
Page 1
Jun 30/01

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Summary of Contents for BOMBARDIER AEROSPACE SD3-60

  • Page 1 SD3-60 AIRCRAFT MAINTENANCE MANUAL AIR CONDITIONING - DESCRIPTION AND OPERATION 21-00-00 1.0.0.0 General Refer to Figure A single air conditioning system supplies conditioned air to the flight and passenger compartments with separate temperature control for each. The system derives its hot air from bleeds on both engines but will continue to work, with reduced performance on a supply from one engine only.
  • Page 2 SD3-60 AIRCRAFT MAINTENANCE MANUAL collected, are delivered as water to an aspirator which sprays into the cooling air stream of the heat exchanger. Beyond the water separator, the ducting divides to provide for the various services detailed in para 4. Bleed air control, indication and warning A.
  • Page 3 SD3-60 AIRCRAFT MAINTENANCE MANUAL Air Conditioning Schematic Figure 1 21-00-00 EFFECTIVITY: All Page 3 Jun 30/01...
  • Page 4 SD3-60 AIRCRAFT MAINTENANCE MANUAL When either the temperature or pressure switch settings are exceeded the respective switch contacts make to:- (a) illuminate the BLEED air caption on the centralised warning panel and the duct OVERHEAT or OVER PRESSURE light on panel 9P as appropriate. (b) energise the control relays which 'lock on' providing a supply to the 'close' field of the HA/SOV.
  • Page 5 SD3-60 AIRCRAFT MAINTENANCE MANUAL With flow in both half systems, should the pressure at any of the three LP switches fall below the make pressure, a supply will be completed to illuminate the BLEED caption on the centralised warning panel and the DUCT LOW PRESSURE warning light on panel 9P. When there is flow in one half system only, the warning lights will illuminate should either the LP switch in that half system or in the common duct fall below the make setting.
  • Page 6 SD3-60 AIRCRAFT MAINTENANCE MANUAL A temperature sensor and a duct overheat switch are located in the common duct to the flight compartment. The temperature control is described in para 6. Except for -300F series aircraft, conditioned air from the passenger compartment NOTE: system is available through two gaspers located on the flight compartment aft bulkhead.
  • Page 7 SD3-60 AIRCRAFT MAINTENANCE MANUAL In hot, humid conditions, with the air conditioning system operating in the full cooling mode fogging may appear in the passenger compartment. This condition ensues when the passenger compartment duct sensor detects an actual temperature several degrees higher than that at the water separator inlet, modulating both portions of the dual by-pass valve to close.
  • Page 8 SD3-60 AIRCRAFT MAINTENANCE MANUAL Control Panel 9P (Pre-mod A8593) Figure 2 (Sheet 1) 21-00-00 EFFECTIVITY: All Page 8 Jun 30/01...
  • Page 9 SD3-60 AIRCRAFT MAINTENANCE MANUAL Control Panel 9P (Post-Mod A8593) Figure 2 (Sheet 2) 21-00-00 EFFECTIVITY: All Page 9 Jun 30/01...
  • Page 10 SD3-60 AIRCRAFT MAINTENANCE MANUAL (2) Flight compartment Two gaspers, one for the left side and one for the right side, are located on the main instrument panel 1P and provide cool, conditioned air for the flight compartment. Pre Mod A8593 The cool air for the flight compartment gaspers is tapped from the left and right supply to the passenger compartment.
  • Page 11 SD3-60 AIRCRAFT MAINTENANCE MANUAL switch tripped). The fan circuit is also subject to the overriding authority of the landing gear weight switch and is operational on ground only. In flight, the control valve may be opened (RAM selection) as a boost to the bleed air flow or to provide an alternative supply of air at ambient conditions following a total loss of bleed air.
  • Page 12 SD3-60 AIRCRAFT MAINTENANCE MANUAL (d) Power supplies and controls Power supplies are derived from the 28V dc Ground Services Busbar via 5 amp circuit breakers Nos 209 and 211 (for boost control valve operation) and a 15 amp circuit breaker No. 210 (for fan operation) on distribution panel 2D. Control is by a three position switch ON-RAM-OFF on the AIR CONDITIONING panel 9P.
  • Page 13 SD3-60 AIRCRAFT MAINTENANCE MANUAL (d) Power supplies and controls Electrical supplies are derived from the 28V dc ground services busbar via a 5 amp circuit breaker No. 208 (for control valve operation) and a 10 amp circuit breaker No. 207 (for fan operation) on distribution panel 2D. Control is by a GND AIR - RE-CIRC- OFF switch on panel 9P.
  • Page 14 SD3-60 AIRCRAFT MAINTENANCE MANUAL The passenger compartment automatic temperature control system consists of a controller (electronic analogue type computer) a temperature selector and two temperature sensors, one within the compartment and the other in the supply duct. The controller compares the selected temperatures with the compartment and duct sensed temperature and modulates the dual by- pass valve accordingly.
  • Page 15 SD3-60 AIRCRAFT MAINTENANCE MANUAL GASPER BOOST SYSTEM - MAINTENANCE PRACTICES 21-00-01 2.0.0.0 Adjustment/Test A. Function check the system (1) Provide electrical power and close C/B No. 209, 210 and 211 on distribution panel 2D. Refer to 12-09-03, pb301. (2) With the control switch OFF/RAM/ON on panel 9P set at OFF, check that the left and right gasper boost valves are shut (indicator modules display off-line).
  • Page 16 SD3-60 AIRCRAFT MAINTENANCE MANUAL HEAT EXCHANGER - MAINTENANCE PRACTICES 21-00-06 3.0.0.0 Removal/Installation Refer to Figure 201. A. Remove a heat exchanger. (1) Remove access panels 240 AR, 240 BR, 240 AL, 240 BL, 240 CL, 240 DL and 240 EL on forward fairing.
  • Page 17 SD3-60 AIRCRAFT MAINTENANCE MANUAL Heat Exchanger - Removal/Installation Figure 201 21-00-06 EFFECTIVITY: All Page 202 Jun 30/01...
  • Page 18 SD3-60 AIRCRAFT MAINTENANCE MANUAL Refer to Figure 201. Make the following ducting connections with reference to the appropriate detail using new 'O' ring seals where required. (a) Heat exchanger to air cycle machine (detail C). (b) Compressor to heat exchanger (detail A) using seal Pt. No. 56A 460 225. (c) Engine supply duct to heat exchanger (detail B).
  • Page 19 SD3-60 AIRCRAFT MAINTENANCE MANUAL AIR CYCLE MACHINE - MAINTENANCE PRACTICES 21-00-11 4.0.0.0 Servicing A. Check oil level in sump (1) Open access panel 240 DL in forward fairing on fuselage roof. (2) By the use of a mirror inspect the oil level sight plug, situated on the forward side of the air cycle machine beneath the outlet ducting, to ensure that the sight bulb is full of oil.
  • Page 20 SD3-60 AIRCRAFT MAINTENANCE MANUAL (4) Disconnect the following ducts at the air cycle machine:- - ACM turbine outlet (detail A) - Heat exchanger to compressor inlet (detail A) - Compressor outlet to heat exchanger (detail A). - ACM turbine inlet (detail B). - ACM to heat exchanger (detail C).
  • Page 21 SD3-60 AIRCRAFT MAINTENANCE MANUAL Air Cycle Machine - Removal/Installation Figure 201 21-00-11 EFFECTIVITY: All Page 203 Jun 30/01...
  • Page 22 SD3-60 AIRCRAFT MAINTENANCE MANUAL WATER SEPARATOR - MAINTENANCE PRACTICES 21-00-16 5.0.0.0 Servicing A. Clean a coalescer (1) Remove from water separator as detailed in para 2.C. (2) Mix a solution of 2 ounces of Basic 1 (Shaklee Products, Hayward, Calif.) in 1.0 gallon of water heated to 100 to 130 degrees F (38 to 54 degrees C).
  • Page 23 SD3-60 AIRCRAFT MAINTENANCE MANUAL (2) Fit securing straps and secure T-bolt latches with nuts. (3) Make the following ducting connections with reference to the appropriate detail. - Outlet duct from unit (detail A) - Inlet duct to unit (detail A) - Drain tube from unit C.
  • Page 24 SD3-60 AIRCRAFT MAINTENANCE MANUAL Water Separator - Removal/Installation Figure 201 21-00-16 EFFECTIVITY: All Page 203 Jun 30/01...
  • Page 25 SD3-60 AIRCRAFT MAINTENANCE MANUAL RAM/MAIN FAN - MAINTENANCE PRACTICES 21-00-21 6.0.0.0 Removal/Installation Refer to Figure 201. A. Remove a ram/main fan. (1) Isolate electrical supply by opening C/B No. 211 on distribution panel 2D. (2) Remove access panel 240 AR and 240 BR on forward fairing. Refer to 6-30-00, pb1.
  • Page 26 SD3-60 AIRCRAFT MAINTENANCE MANUAL Ram/Main Fan - Removal/Installation Figure 201 21-00-21 EFFECTIVITY: All Page 202 Jun 30/01...
  • Page 27 SD3-60 AIRCRAFT MAINTENANCE MANUAL RAM/MAIN FAN SHUT-OFF VALVE - MAINTENANCE PRACTICES 21-00-26 7.0.0.0 Removal/Installation Refer to Figure 201. A. Remove a shut-off valve. (1) Isolate electrical supply by opening C/B No. 211 on distribution panel 2D. (2) Remove access panel 240AR and 240BR on forward fairing. (3) Disconnect electrical connection from unit.
  • Page 28 SD3-60 AIRCRAFT MAINTENANCE MANUAL Ram/Main Fan Shut-off Valve - Removal/Installation Figure 201 21-00-26 EFFECTIVITY: All Page 202 Jun 30/01...
  • Page 29 SD3-60 AIRCRAFT MAINTENANCE MANUAL RECIRCULATION FAN - MAINTENANCE PRACTICES 21-00-31 8.0.0.0 Removal/Installation Refer to Figure 201. A. Remove a re-circulation fan (1) Isolate electrical supply by opening circuit breaker No. 208 on distribution panel 2D. Refer to 6-30-00, pb1. Remove panels 240AR, 240BR, 240AL, 240EL and 240CL to provide access to fan situated on aircraft centre line between stations 137 and 179.
  • Page 30 SD3-60 AIRCRAFT MAINTENANCE MANUAL Recirculation Fan - Removal/Installation Figure 201 21-00-31 EFFECTIVITY: All Page 202 Jun 30/01...
  • Page 31 SD3-60 AIRCRAFT MAINTENANCE MANUAL RECIRCULATION/GROUND INTAKE SHUT-OFF VALVES - MAINTENANCE PRACTICES 21-00-36 9.0.0.0 Removal/Installation Refer to Figure 201. A. Remove a recirculation or ground intake shut-off valve. (1) Isolate electrical supply by opening circuit breaker No.208 on distribution panel 2D. Refer to 6-30-00, pb1.
  • Page 32 SD3-60 AIRCRAFT MAINTENANCE MANUAL Recirculation/Ground Intake Shut-Off Valves - Removal/Installation Figure 201 21-00-36 EFFECTIVITY: All Page 202 Jun 30/01...
  • Page 33 SD3-60 AIRCRAFT MAINTENANCE MANUAL DUAL BY-PASS VALVE - MAINTENANCE PRACTICES 21-00-41 10.0.0.0 Removal/Installation Refer to Figure 201. A. Remove a dual by-pass valve (1) Isolate electrical supply by opening C/B No.211 on distribution panel 2D. (2) Remove access panel 240CL on forward fairing. (3) Unscrew electrical connection from unit.
  • Page 34 SD3-60 AIRCRAFT MAINTENANCE MANUAL Dual By-Pass Valve - Removal/Installation Figure 201 21-00-41 EFFECTIVITY: All Page 202 Jun 30/01...
  • Page 35 SD3-60 AIRCRAFT MAINTENANCE MANUAL BY-PASS VALVE - MAINTENANCE PRACTICES 21-00-46 11.0.0.0 Removal/Installation Refer to Figure 201. A. Remove a by-pass valve (1) Isolate electrical supply by opening C/B No.90 on distribution panel 1D. (2) Remove access panel 240CL on forward fairing. (3) Disconnect electrical connection from unit.
  • Page 36 SD3-60 AIRCRAFT MAINTENANCE MANUAL By-Pass Valve - Removal/Installation Figure 201 21-00-46 EFFECTIVITY: All Page 202 Jun 30/01...
  • Page 37 SD3-60 AIRCRAFT MAINTENANCE MANUAL SPAR BOX HEAT PROTECTION SYSTEM - MAINTENANCE PRACTICES 21-00-51 12.0.0.0 Removal/Installation A. Remove a thermostat assembly (1) Open access panel 510ET (left) or 610ET (right) on upper surface of wing between front and rear spar and adjacent to wing rib Stn.68.8. (2) Open circuit breaker No.
  • Page 38 SD3-60 AIRCRAFT MAINTENANCE MANUAL (4) Remove assembly from aircraft with the electrical leads (extended) still attached to terminal block TB.91 (left) or TB.90 (right) and place on wing upper surface, using a suitable mat to insulate the wing surface from the heat source. (5) Close circuit breaker No.
  • Page 39 SD3-60 AIRCRAFT MAINTENANCE MANUAL CHECK VALVES (PT.NO. HTE4187) - MAINTENANCE PRACTICES 21-00-56 13.0.0.0 Adjustment/Test A. Function check a valve Special tools and equipment. Compressed air source capable of 37 p.s.i. (1) Close circuit breakers Nos.90 and 211 or respective distribution panel 1D and 2D. (2) On AIR CONDITIONING PANEL 9P check that:- (a) All indicator modules display 'off line'.
  • Page 40 SD3-60 AIRCRAFT MAINTENANCE MANUAL LEFT ENGINE Test Blank Apply Check Valve Sequence Pressurised Air Discharge Pressure Function P2.5 Pipe At common 1L + 2L - Open Connection line duct Common Line P3 Pipe Maintained 1L + 2R - Closed Duct Connection at 37 p.s.i.
  • Page 41 SD3-60 AIRCRAFT MAINTENANCE MANUAL Check Valve - Function Test Figure 201 21-00-56 EFFECTIVITY: All Page 203 Jun 30/01...
  • Page 42 SD3-60 AIRCRAFT MAINTENANCE MANUAL L.P. SWITCHES - MAINTENANCE PRACTICES 21-00-61 14.0.0.0 Adjustment/Test A. Perform operational check on left and right LP switches. (1) Inhibit centre duct LP switch as follows:- (a) Open circuit breaker No. 196 on distribution panel 2D. Refer to 6-30-00, pb1.
  • Page 43 SD3-60 AIRCRAFT MAINTENANCE MANUAL H.P. SWITCH - MAINTENANCE PRACTICES 21-00-66 15.0.0.0 Adjustment/Test A. Function check the switch Refer to Figure 201. Refer to 6-30-00, pb1. Remove access panel 240CL and locate the switch. (2) Disconnect signalling input pipe at tee junction and blank off. (3) Fit a suitable adapter to tee junction and connect a dry air supply regulated to a pressure of 50 p.s.i.
  • Page 44 SD3-60 AIRCRAFT MAINTENANCE MANUAL Location of H.P. Switch Figure 201 21-00-66 EFFECTIVITY: All Page 202 Jun 30/01...
  • Page 45 SD3-60 AIRCRAFT MAINTENANCE MANUAL DUCT/FLIGHT COMPARTMENT /PASSENGER COMPARTMENT OVERHEAT SWITCHES - 21-00-71 16.0.0.0 MAINTENANCE PRACTICES Removal/Installation Refer to Figure 201 A. Remove a switch (1) Isolate electrical supply by opening circuit breaker No. 196 on distribution panel 2D. (2) Obtain access to appropriate switch (HE-18 - Flight Compt., HE17 - passenger compt., HE16 - duct) by removing respective access panels 240 AR, 240 AL and 240 BL.
  • Page 46 SD3-60 AIRCRAFT MAINTENANCE MANUAL Overheat switches Figure 201 21-00-71 EFFECTIVITY: All Page 202 Jun 30/01...
  • Page 47 SD3-60 AIRCRAFT MAINTENANCE MANUAL Adjustment/Test A. Function test switches Special tools and equipment:- Thermometer (suitably calibrated from 32°F to 570°F (0-300°C)). Hot air source or electrically heated muff. (1) Identify and reconnect electrical connector/s to switch/es. Refer to 12-09-03, pb301. Provide electrical power and close circuit breaker No. 196 on distribution panel 2D.
  • Page 48 SD3-60 AIRCRAFT MAINTENANCE MANUAL HOT AIR SHUT-OFF VALVES (PT NO HTE9215) - MAINTENANCE PRACTICES 21-00-76 17.0.0.0 Removal/Installation Refer to Figure 201. A. Remove a HA/SOV unit Refer to 12-09-03, pb301. Open circuit breakers No.90 and 211 on distribution panels 1D and 2D for left and right engines respectively and tag as detailed in general precautions.
  • Page 49 SD3-60 AIRCRAFT MAINTENANCE MANUAL (3) Release LEFT ENGINE HA/SOV switch to OFF position and check that indicator displays 'off line'. (4) Repeat (3) and (4) reading right for left. 21-00-76 EFFECTIVITY: All Page 202 Jun 30/01...
  • Page 50 SD3-60 AIRCRAFT MAINTENANCE MANUAL Hot Air Shut-Off Valve - Removal/Installaion Figure 201 21-00-76 EFFECTIVITY: All Page 203 Jun 30/01...
  • Page 51 SD3-60 AIRCRAFT MAINTENANCE MANUAL TEMPERATURE CONTROL VALVE PT NO 750655-4 MAINTENANCE PRACTICES 21-00-81 18.0.0.0 Removal/Installation Refer to Figure 201. A. Remove a TCV unit Refer to 12-09-03, pb301. Open circuit breakers No 90 and 211 on distribution panels 1D and 2D for left and right engines respectively and tag as detailed in general precautions. Refer to 6-30-00, pb1.
  • Page 52 SD3-60 AIRCRAFT MAINTENANCE MANUAL Temperature Control Valve - Removal/Installation Figure 201 21-00-81 EFFECTIVITY: All Page 202 Jun 30/01...
  • Page 53 SD3-60 AIRCRAFT MAINTENANCE MANUAL PRE-COOLER OVERHEAT SWITCH - MAINTENANCE PRACTICES 21-00-86 19.0.0.0 Removal/Installation A. Remove a switch (1) Check that circuit breaker No. 196 on right distribution panel 2D is open. (2) Obtain access to switch by removing access panel 240CL (zone 200). (3) Disconnect electrical connection to switch.
  • Page 54 SD3-60 AIRCRAFT MAINTENANCE MANUAL (4) Remove overheat switch from aircraft, leaving electrical connection still attached to the switch, and place on fuselage upper surface using a suitable mat to insulate the fuselage surface from the heat source. (5) Close circuit breaker No. 196. (6) Apply heat and slowly raise temperature with the thermometer in close proximity to the switch probe, noting that the amber OVERHEAT warning light on panel 9P in flight compartment illuminates when 274°...
  • Page 55 SD3-60 AIRCRAFT MAINTENANCE MANUAL AIRCRAFT COOLING SYSTEMS - GENERAL 21-50-00 20.0.0.0 General Freon cooling systems are provided for the flight compartment and cabin of aircraft to post-mod 8121, 8122 & 8309 standard. Refer to 21-52-00, pb1. The flight compartment is also equipped with two fans, one for each pilot. Refer to 21-51-00, pb1.
  • Page 56 SD3-60 AIRCRAFT MAINTENANCE MANUAL 1ST & 2ND PILOTS FANS - DESCRIPTION & OPERATION 21-51-00 21.0.0.0 Description The 1st and 2nd pilots are each provided with a fan to provide additional air movement in the flight compartment. The fans, left and right, are attached to the coaming at station 37.5 and are individually controlled by an adjacent ON/OFF switch.
  • Page 57 SD3-60 AIRCRAFT MAINTENANCE MANUAL 1ST & 2ND PILOTS FANS - MAINTENANCE PRACTICES 21-51-00 22.0.0.0 Adjustment/Test A. Function/Test (1) Function check. Refer to 12-09-03, pb301. Provide electrical power. (b) Close circuit breaker No. 75 on distribution panel 1D. (c) Select control switch for left fan ON and check that left fan operates satisfactorily. (d) Select control switch OFF and ensure that fan stops.
  • Page 58 SD3-60 AIRCRAFT MAINTENANCE MANUAL FREON COOLING - DESCRIPTION & OPERATION (POST MOD 8121, 8122 & 8309) 21-52-00 23.0.0.0 Description A. General Refer to Figure The Freon cooling system consists of two sub-systems; a forward system which provides cooling of the forward end of the passenger cabin and flight deck and an aft system which provides cooling of the rear of passenger cabin.
  • Page 59 SD3-60 AIRCRAFT MAINTENANCE MANUAL Block Diagram of Forward and Aft Systems Figure 1 21-52-00 EFFECTIVITY: All Page 2 Jun 30/01...
  • Page 60 SD3-60 AIRCRAFT MAINTENANCE MANUAL System Component Location and Pilots Control Pane Figure 2 21-52-00 EFFECTIVITY: All Page 3 Jun 30/01...
  • Page 61 SD3-60 AIRCRAFT MAINTENANCE MANUAL The left and right evaporators modules are similar and consist of a coil assembly and a blower assembly which are respectively located at frame stations 104 and 74 The flight deck module and aft module are similar in respect that they contain their evaporator and blower units as one assembly.
  • Page 62 SD3-60 AIRCRAFT MAINTENANCE MANUAL Circuit Breaker Panel and Flight Attendants Control Panel Figure 3 21-52-00 EFFECTIVITY: All Page 5 Jun 30/01...
  • Page 63 SD3-60 AIRCRAFT MAINTENANCE MANUAL FREON COOLNG - TROUBLESHOOTNG 21-52-00 24.0.0.0 General A list of symptoms, probable causes and possible solutions are given in the table which follows: Table 101 SYMPTON PROBABLECAUSE POSSBLESOLUTON No system power External power source not Connect external power supply connected Electrical Master switch is off Select the ELECTRCAL...
  • Page 64 SD3-60 AIRCRAFT MAINTENANCE MANUAL SYMPTON PROBABLECAUSE POSSBLESOLUTON Excessive moisture in the system Replace the receiver-dryer assembly Noisy evaporator module Blower wheel is loose Replace the blower wheel Blower wheel hitting scroll Align the blower wheel Defective blower motor bearing Replace the motor Loose mounting bracket(s) Tighten the bracket(s) Air inlet is blocked...
  • Page 65 SD3-60 AIRCRAFT MAINTENANCE MANUAL SYMPTON PROBABLECAUSE POSSBLESOLUTON Evaporator module coil is No air flow Switch on the fan freezing Expansion valve failed Replace the expansion valve Expansion valve is blocked Remove any debris Expansion valve setting is too low Re-set to obtain 26-30 psig suction press High pressure switch is System is over charged...
  • Page 66 SD3-60 AIRCRAFT MAINTENANCE MANUAL FREON SYSTEM - MAINTENANCE PRACTICES 21-52-00 25.0.0.0 Adjustment/Test A. Function check of the shedding relays There are two methods for performing this check, Engines shut down and Engines running (1) Engine shut down Do not allow the Freon System to operate for longer than required when the NOTE: compressor motor is being powered from battery power.
  • Page 67 SD3-60 AIRCRAFT MAINTENANCE MANUAL (o) Ensure the Freon Air Conditioning System in the flight compartment is operating. Select this switch to NORMAL and ensure the air conditioning is now off. (p) Select the ON/FAN ONLY/OFF switch on the Flight Compartment Freon Control Panel to OFF and select both LOAD SHEDDING switches (4P) to NORMAL.
  • Page 68 SD3-60 AIRCRAFT MAINTENANCE MANUAL (s) Set the left generator ON/OFF/COUPLE switch (4P) to ON and the right generator TRIP/RESET switch (4P) to RESET. (t) Ensure that the left generator is on line and the aft fan is operating. (u) Set the ON/FAN ONLY/OFF switch on the flight attendants control panel to OFF. (v) Ensure the aft fan is off.
  • Page 69 SD3-60 AIRCRAFT MAINTENANCE MANUAL (16) Select the ON/OFF and ON/FAN ONLY/OFF switches on the Pilots Freon Control Panel to OFF. C. Function check of the evaporator system thermostats Each thermostat should be removed and placed in a calibrated oven. The required test values are 250 ±...
  • Page 70 SD3-60 AIRCRAFT MAINTENANCE MANUAL (4) Allow the heater output to stabilise for approximately 10 minutes. The thermostats are designed to drop out at 93 °C and to pick up at 82 °C. Their NOTE: correct operation can be confirmed by observing the heater elements through the front grill of the heater and ensuring that they cycle from ON to OFF periodically (ie from a warm red glow to OFF).
  • Page 71 SD3-60 AIRCRAFT MAINTENANCE MANUAL FREON COOLING - SERVICING 21-52-00 26.0.0.0 Servicing A. Evacuation Procedure REFRIGERANT IS EXTREMELY COLD AND MAY CAUSE BURNS. HAND, EYE AND WARNING: MOUTH PROTECTION SHOULD BE WORN AT ALL TIMES. USE REFRIGERANT (R-12) ONLY. CAUTION: Refer to 12-09-03, pb301.
  • Page 72 SD3-60 AIRCRAFT MAINTENANCE MANUAL (15) Open the can shut off valve. (16) Loosen the manifold service fitting slightly to vent the hose. (17) Tighten the hose fitting. (18) Open both manifold valves and allow 7 oz of refrigerant to enter the system. (19) Close both manifold valves.
  • Page 73 SD3-60 AIRCRAFT MAINTENANCE MANUAL (7) Close both manifold valves and the can shut off valve. (8) Disconnect the service valve from the refrigerant can. (9) Repeat (3) thru (8) until tbe system pressure has stabilized at approximately 50 psig. It may be necessary to feed 28 to 42 oz of refrigerant into the system until ressure NOTE: stabilizes.
  • Page 74 SD3-60 AIRCRAFT MAINTENANCE MANUAL DO NOT OVERCHARGE THE SYSTEM. CAUTION: The following charges are the maximums:- FORWARD SYSTEM CHARGE: 3.1 lb (3.5 cans) AFT SYSTEM CHARGE : 4.4 lb (5 cans) (21) With the system fully charged and operating, observe the suction and discharge valves. Typical pressures at various ambient temperatures with hot passenger and crew NOTE: compartments are shown below:...
  • Page 75 SD3-60 AIRCRAFT MAINTENANCE MANUAL FREON COOLING - ADJUSTMENT/TEST 21-52-00 27.0.0.0 Adjustment/Test A. Test with ground power supply (1) Ensure that all the air-conditioning control switches on both the flight compartment (HEA5) and flight attendants control panels are set to OFF. (2) Select the START MASTER on panel 4P to NORMAL.
  • Page 76 SD3-60 AIRCRAFT MAINTENANCE MANUAL (14) Select the HI/LO switch on the FLIGHT COMPARTNENT CONTROL PANEL to HI. (15) Ensure that the fan on the flight deck is operating at high power. (16) Select the ON/FAN ONLY/OFF switch on the FLIGHT COMPARTMENT CONTROL PANEL to ON.
  • Page 77 SD3-60 AIRCRAFT MAINTENANCE MANUAL (30) Ensure that the aft blower is now operating at high power. (31) Select the ON/FAN ONLY/OFF switch on the FLIGHT ATTENDANTS CONTROL PANEL to ON. (32) Ensure the aft compressor lamp illuminates. (33) Select the HI/LO switch representing the aft cabin to LO. (34) Ensure that the aft blower is operating at low power and delivering cold air.
  • Page 78 SD3-60 AIRCRAFT MAINTENANCE MANUAL (6) Ensure that all lamps indicating that the forward compressor is operative extinguish. (7) Reset the right generator. (8) Ensure that the flight deck and forward systems restart and that the lamps indicating the forward compressor is operative are illuminated. (9) Trip the left generator.
  • Page 79 SD3-60 AIRCRAFT MAINTENANCE MANUAL FREON COOLING - INSPECTION/CHECK 21-52-00 28.0.0.0 Inspection/Check REFRIGERANT IS EXTREMELY COLD AND MAY CAUSE BURNS. HAND, EYE AND WARNING: MOUTH PROTECTION SHOULD BE WORN AT ALL TIMES. USE REFRIGERANT (R-L2) ONLY. CAUTION: This procedure should be carried out; after a new system plumbing is installed; after any NOTE: plumbing system component is replaced;...
  • Page 80 SD3-60 AIRCRAFT MAINTENANCE MANUAL (9) Remove any shrouds, panels or flooring or any other covering which prevents access to the refrigerant fittings or connections. (10) Ensure that all plumbing connections are tight. (11) Ensure the charging manifold is properly connected and the manifold charging hose is connected to the shut-off valve on the refrigerant can.
  • Page 81 SD3-60 AIRCRAFT MAINTENANCE MANUAL (26) Tighten joints as required to stop all leaks. DO NOT OVER TIGHTEN THE PLUMBING CONNECTIONS. STRIPPED CAUTION: THREADS OR CRACKED FLARES MAY RESULT. (27) When the system is free of leaks, turn off the nitrogen supply. (28) Disconnect the charging hose.
  • Page 82 SD3-60 AIRCRAFT MAINTENANCE MANUAL COMPRESSOR/CONDENSER MODULE - SERVICING 21-52-05 29.0.0.0 Servicing A. Drive belt alignment procedure ALL BOLTS AND NUTS MUST BE TIGHTENED SLIGHTLY BEFORE ALIGNMENT; WARNING: OTHERWISE MAJOR BELT AND/OR COMPRESSOR DAMAGE MAY RESULT. (1) If required, loosen the motor pulley set screws. (2) Rotate the compressor pulley clockwise.
  • Page 83 SD3-60 AIRCRAFT MAINTENANCE MANUAL COMPRESSOR/CONDENSER MODULE - REMOVAL/INSTALLATION 21-52-05 30.0.0.0 Removal/Installation A. Remove a compressor/condenser module. (1) Evacuate the appropriate system. (2) Disconnect the high end and low pressure hoses and cap off. (3) Remove the pressure switch connections. (4) Remove and retain the four bolts and wedges from the base plate and mounting track. (5) Slide the mounting tracks from the compressor/condenser assembly.
  • Page 84 SD3-60 AIRCRAFT MAINTENANCE MANUAL (7) Remove the belt guard and drive belt, taking care not to damage the belt - refer to para 1.H. (8) Remove the system suction and discharge hose and cap-off immediately. (9) Remove the compressor adjustment and support bolts. (10) Remove the compressor from the mounting bracket.
  • Page 85 SD3-60 AIRCRAFT MAINTENANCE MANUAL (12) Apply 3 oz. of Suniso 5GS viscosity oil to the compressor. Apply the oil to the port located between the service ports at the top of the compressor. If the failed compressor did not contaminate the system, no additional oil is NOTE: required.
  • Page 86 SD3-60 AIRCRAFT MAINTENANCE MANUAL (8) Install the flat washer and lock nut. (9) Tighten the set screw on the flat surface of the shaft. (10) Torque the lock nut. (11) Tighten the other set screw. (12) Replace fan shroud, ensuring the fan blade does~not rub on the shroud and seal the shroud with RTV sealant.
  • Page 87 SD3-60 AIRCRAFT MAINTENANCE MANUAL H. Install a drive belt (1) Verify the belt size and part number before installing as using the wrong part may damage the unit. (2) Ensure that the rod end adjustment nut is positioned at the end of the threads. (3) Swing the compressor to the lowest position.
  • Page 88 SD3-60 AIRCRAFT MAINTENANCE MANUAL (4) SLOWLY, release the brush spring onto the brush. (5) Ensure the brush is seated flatly on the commutator and that there is no binding in the holder. (6) Align the brush spring in the centre of the brush groove. (7) Install the terminal screw and lock washer on the brush shunt lead and other leads and tighten the screw.
  • Page 89 SD3-60 AIRCRAFT MAINTENANCE MANUAL COMPRESSOR/CONDENSER MODULE - INSPECTION/CHECK 21-52-05 31.0.0.0 Inspection/Check A. Inspect the compressor PROTECTIVE GLASSES AND GLOVES MUST BE WORN DURING THIS CHECK. CAUTION: (1) Render the aircraft electrically safe. (2) Remove access doors, exhaust ducts and roof fairing (panels 240EL, 240BR, 240ER, 240DL and 240HL) to gain access to the compressors.
  • Page 90 SD3-60 AIRCRAFT MAINTENANCE MANUAL Brush Wear Rate Check Figure 601 21-52-05 EFFECTIVITY: All Page 602 Jun 30/01...
  • Page 91 SD3-60 AIRCRAFT MAINTENANCE MANUAL (7) Loosen and unsnap the brush cover assembly and remove the assembly from the motor. (8) Using a wire hook or scribe, lift the brush spring and remove the brush. (9) Inspect the brush for cracks, chipped edges, frayed leads, loose rivets or shunt connections.
  • Page 92 SD3-60 AIRCRAFT MAINTENANCE MANUAL (7) Check belt alignment and tension. (8) Replace brush cover. (9) Tighten the clamp nuts. (10) Connect the power leads to the motor terminals and tighten the nuts. D. Motor Insulation Resistance Check Refer to 12-09-03, pb1.
  • Page 93 SD3-60 AIRCRAFT MAINTENANCE MANUAL EVAPORATOR AND BLOWER MODULE(S) - REMOVAL/INSTALLATION 21-52-10 32.0.0.0 Removal/Installation A. Remove a flight deck blower motor (1) Remove panel 210CZ. (2) Render the aircraft electrically safe. (3) Evacuate the forward system. (4) Disconnect the drain, suction and discharge hoses and cap off. (5) While supporting the evaporator, remove bolts A, B, C and D.
  • Page 94 SD3-60 AIRCRAFT MAINTENANCE MANUAL Blower Motor Removal Figure 401 21-52-10 EFFECTIVITY: All Page 402 Jun 30/01...
  • Page 95 SD3-60 AIRCRAFT MAINTENANCE MANUAL (7) Apply a small bead of RTV sealant on the scroll. (8) Install the blower wheel and motor with the motor wires positioned near the resistor wires and mounting screw. (9) Install and tighten the mounting screws. (10) Using the access through the blower outlet, rotate the blower wheel to ensure that no rubbing exists.
  • Page 96 SD3-60 AIRCRAFT MAINTENANCE MANUAL (4) Disconnect the wire splice from the resistor wire. (5) Remove all other electrical connections, noting wire colours, connections and terminations. (6) Remove the four motor mounting screws. (7) Using a small knife, slide the tool between the motor and the plastic scroll to cut the RTV sealant bonding.
  • Page 97 SD3-60 AIRCRAFT MAINTENANCE MANUAL (c) Connect the black cable to the appropriate earth point. Anti-clockwise rotation (d) Butt connect the black motor wire to the orange resistor wire and connect to the appropriate cable. (e) Cover the red motor wire with black heatshrink and connect to the appropriate earth point.
  • Page 98 SD3-60 AIRCRAFT MAINTENANCE MANUAL (14) Remove the blower wheel. (15) Discard the blower motor. F. Install an aft blower motor (1) Replace the motor wheel on the new motor shaft, ensuring the back of the wheel is 0.25 inches from the motor mounting surface. (2) Ensure the set screw on the wheel of the hub is located on the flat section of the motor shaft.
  • Page 99 SD3-60 AIRCRAFT MAINTENANCE MANUAL (f) Cover the red motor wire with black heatshrink and connect to the appropriate earth point. (g) Butt connect the red resistor wire to the appropriate cable. (h) Route all cables through the wire clamp and secure with mounting screw and washer.
  • Page 100 SD3-60 AIRCRAFT MAINTENANCE MANUAL DO NOT OVER TORQUE NUT 'B'. CAUTION: (6) Connect the valve inlet port tubing and tighten. (7) Check the system for leaks and vacuum. (8) Charge the system. (9) Test the system. 21-52-10 EFFECTIVITY: All Page 408 Jun 30/01...
  • Page 101 SD3-60 AIRCRAFT MAINTENANCE MANUAL EVAPORATOR AND BLOWER MODULE(S) - INSPECTION CHECK 21-52-10 33.0.0.0 Inspection/Check A. Evaporator Coil Inspection (1) Inspect for excessive lint and/or contamination in the coil fins. (2) Clean as required using a vacuum or low pressure air source. B.
  • Page 102 SD3-60 AIRCRAFT MAINTENANCE MANUAL PASSENGER COMPARTMENT TEMPERATURE INDICATION - DESCRIPTION & OPERATION 21-61-00 34.0.0.0 Description Crew indication of temperature in the passenger compartment is provided by a gauge mounted on AIR CONDITIONING panel 9P. The gauge is calibrated from 0°C to 100°C and operates in response to a temperature sensitive bulb located in the extraction duct above the galley units.