CHAPTER 11

ENVIRONMENTAL CONTROL

Section Title Page

11.000 Heating and Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1

11.001 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
11.002 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
11.100 Cabin Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
11.110 Control Cable and Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
11.120 Muffler Shroud Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
11.200 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
11.210 Cabin Air Vent Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
11.220 Cabin Air Vent Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
11.230 Door Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
11.300 Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7
11.310 System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9
11.320 Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.11
11.321 Refrigerant Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.11
11.322 Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.11
11.323 Leak Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.12
11.330 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.13
11.331 Compressor Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.13
11.332 Compressor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.13
11.333 Compressor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.14
11.340 Evaporator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.16
11.341 Evaporator Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.16
11.342 Evaporator Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 11.17
11.343 Evaporator Drain System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.18
11.350 Full Throttle Cut-Out Switch Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . 11.20
11.400 Drive Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.21
11.410 Drive Cartridge Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.21
11.420 Drive Cartridge Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.21

SEP 2023 Chapter 11 Environmental Control Page 11.i

 Intentionally Blank

Page [Link] Chapter 11 Environmental Control SEP 2023

ROBINSON MAINTENANCE MANUAL MODEL R44

CHAPTER 11

HEATING , VENTILATION AND AIR CONDITIONING

11.000 Heating and Ventilation

11.001 Introduction
This section contains the procedures necessary for replacement of the heater and
ventilation systems components.
11.002 Description
The cabin heater system consists of a heat shroud over the muffler, a control valve on
the forward side of the firewall, an outlet grill forward of the pilot’s tail rotor pedals, and
the interconnecting ducts between components. Air is supplied by the engine cooling
fan. The push-pull heat control is located on the face of the lower console. The heat
control actuates the control valve which directs the air either into the cabin or out an
overboard discharge on the underside of the cabin.
Fresh air vents are located in each door and in the nose of the helicopter. A push-pull
control for the nose vent is located on the face of the lower console.
11.100 Cabin Heater
Refer to Figure 11-1.

NOTE
The cabin heater is required to be installed in the R44 helicopter.
Air flow through the muffler shroud cools the muffler and engine
compartment.
11.110 Control Cable and Valve Replacement
1. Remove the aft tunnel belly panel and engine belly cowling.
2. Remove the three screws holding the C753-1 cover and remove the cover and
insulation.
3. Remove four screws holding the C625-1 box and remove the box.
4. Remove the control wire by straightening the end (if applicable) and loosening the
A462-1 fitting clamping the wire.
5. To remove the A019-3 valve assembly and A623-1 inlet, remove the two hoses and
the remaining four screws through the firewall.
6. To remove the control cable casing, open upper console. Remove the cable jam nut
behind the lower console face and the AN742-3 clamp holding the casing to the chin.
Inside the right forward baggage compartment, remove the clamp. Outboard of the
right aft floor, remove the outboard carpet from the top to access the cable casing.
Remove the two clamps under the panel outboard of the right aft seat. Remove the
clamp holding the casing to the vertical firewall and pull the casing out through the
lower console face.

DEC 2011 Page 11.1

ROBINSON MAINTENANCE MANUAL MODEL R44

11.110 Control Cable and Valve Replacement (continued)

7. To install the control cable casing, verify that an MS35489-4 or AN931-3-5 grommet
is installed in the tunnel wall next to the valve and an NAS557-3A grommet is
installed 6 places in holes through which the casing passes (each place except one
place through a vertical firewall stiffener and through the bulkhead at the front of the
right forward baggage compartment). Install the casing through the lower console
face and cable jam nut, through the stiffener on the side of the console, through
the right forward baggage compartment, outboard of the right aft floor, through the
right aft baggage compartment, through two stiffeners on the vertical firewall, and
into the tunnel. Set end of casing approximately 0.8 inches into the tunnel. Fasten
casing with AN742-3 clamps five places.
8. To install the valve and inlet, clean off the old sealant and reseal with B270-4
sealant. Install valve and inlet and fasten with screws in four places.
9. Install control cable wire through the A462-1 fitting and adjust to give approximately
0.060 springback at the knob when the valve is fully closed. Verify control operates
freely. Cut excess wire approximately 0.01 inch or less from the fitting.
10. Install the C625-1 box and seal with B270-1 sealant. Verify the valve and box are
sealed by taping the belly hole closed and applying low air pressure to the inlet.
Check for leaks inside the tunnel by using a piece of yarn at the end of a stick.
11. Install one inch thick Microlite AA insulation over the C625-1 box and install the
C753-1 cover.
12. Install heater hoses. Install belly cowling, belly cover, and close upper console.

Page 11.2 DEC 2011

 ROBINSON MAINTENANCE MANUAL MODELR44

18 19

'~~J.. •
................ ,
·-~\
... ..,-_.:"f""',
"--
2

(SINGLE OUTLET) I

PART NO. DESCRIPTION

4 1. C522-5 Cabin Air Control (Ref.) I
5
2. A522-8 Cabin Heater Control
3. 8164-1 Heater Outlet
4.
5.
6.
A785-15
Rlll
A701-1
Hose
, Insulation
Foil Tape (Forward of item 7)
I
A701-2 Foil Tape (Aft of item 7)
7. D230-1 Bulkhead (Ref.)
8. C631-2 Clip
9. C631--l Clip
10. D164-1 Duct
11 C630-l Insulation
12 A785-14 Hose I
13 A019-3 Valve Assembly
14 C625-1 Box
15 A753-1 Cover
-16 A758-13 Hose
17 Cl69-2 Shroud Assembly
;18 A785-12' Hose I
19 C236 Cool i ng Scro 11 (Ref.)
Change 4: 1 Jun 97
Page 11.3
 ROBINSON MAINTENANCE MANUAL MOCELR44

16 17

FIGURE 11-lA CABIN HEATER

(MULTIPLE OUTLET)
DESCRIPTION
Cabin Air Control (Ref)
2 A522-8 Cabin Heater Control
3 D164-1 Heater Outlet
4 A785-24 Hose
5 D166-1 Outlet (LH)
6 A785-23 Hose
7 Rlll Insulation
8 A701-1 Foil Tape (Forward of item 9)
9 D230-1 Bulkhead (Ref)
10 A701-2 Foil Tape (Aft of item 9)
11 D164-2 Duct
12 A785-14 Hose
13 C753-1 Cover
14 C625-1 Box
15 A019-1 Valve Assembly
16 C169-2 Shroud Assembly
17 A785-12 Hose
18 C236 Cooling Scroll
19 A785-13 Hose

Page 11.4 Change 4: 1 Jun 97

 ROBINSON MAINTENANCE MANUAL MODELR44

11 .120 Muffler Shroud Replacement

a) Remove the D040-1 aft engine cowling.
b) Remove the tail pipe from the exhaust hanger at the engine cooling scroll.

c) Disconnect the two heater hoses from the shroud.

d) Remove the screws at the top of the shroud and remove the shroud over the
tail pipe. ·

e) To install the shroud, reverse steps a through d.

11.200 VENTILATION

11.210 Cabin Air Vent Cable Removal (See Figure 11-2)

a) Open upper console.
b) Remove cotter pin and clevis pin at the forward cabin vent.

c) Remove attaching clamps.

d) Remove cable jam nut at lower console face and remove cable.

11.220 Cabin Air Vent Cable Installation (See Figure 11-2)

a) Install or replace the MS3548-4 grommet in the vent box, if required.

b) Insert the A5225-5 cable through the hole in the lower console and tighten the
jam nut.

c) Secure the control wire to the vent door using one MS20392-2C13 clevis pin
and one MS24665-73 cotter pin.

d) Install the cable clamps. Adjust cable casing for proper operation of vent.
Then tighten clamps securely to insure casing does not slide when operating
the vent control knob.

e) Close and secure upper console.

11.230 Door Vent (See Figure 11-3)

The door vent hinge is riveted in place and can be replaced, if damaged, by
drilling out the rivets and replacing the vent door and/or hinge as required.

The A226-3 seal around the vent door can be replaced if damaged using 8270-
4 or 8270-13 adhesive.

The friction can be adjusted on the door vent by tightening the NAS1291-08 nut
holding the knob on the center pivot of the double arm linkage.

Change 4: 1 Jun 97 Page 11.5

 ROBINSON MAINTENANCE MANUAL MODELR44

C522-5 CABIN AIR

VENT CONTROL

MS35489-4
GROMMET

FIGURE 11-2 CABIN AIR VENT INSTALLATION

-- .
-··

--- ·-----._\
~--·
~/
B266-3
SEAL

MS20470AD3
RIVET ~1 \\ ~
\ k

B~i~/ ~---,--:--\\~ -__y;

1/1''" -
//2
'fl
C285-l KNOB

FIGURE 11-3 VENT DOOR \Wr (\ -\ VENT

I • :
DOOR
MS20470AD3
RIVET

Page 11.6 Change 4: 1 Jun 97

11.300 Air Conditioning

NOTE
Air conditioning service procedures and required equipment
are generally similar to those for standard R134a automotive
systems. In the United States, only personnel with EPA
certification under Section 609 of the Clean Air Act may charge
the system with refrigerant or work on the refrigerant system
once it has been charged. Different requirements may apply in
countries other than the United States.

A. Description
The optional cabin air conditioning system is shown schematically in Figures 11-4 &
11-4A. The system is similar to conventional automotive and light aircraft systems and
consists of a compressor accessible through the left engine cowl door, a condenser
mounted on the left side of the engine cooling fan scroll, an evaporator and fan
assembly mounted to the aft cabin wall, an overhead outlet duct, and interconnecting
lines and hoses. The system uses R134a refrigerant.
The compressor is belt-driven from an engine accessory drive cartridge and equipped
with an electromagnetic clutch. When the system is off, the compressor clutch is
disengaged, allowing the compressor pulley to freewheel.
The evaporator fan draws warm cabin air though the evaporator inlet grill and
evaporator where it is cooled. Cooled air is drawn through the fan and blown through
the overhead duct.
The system is controlled by a toggle switch on the overhead duct which allows selection
of off, low, and high fan settings. The compressor is automatically engaged by
switching the fan on. A temperature (freeze) switch disengages the compressor when
evaporator temperature drops below freezing. Safety (pressure) switches disengage
the compressor if excessive refrigerant leakage occurs or if refrigerant pressure is
excessive. A full-throttle switch disengages the compressor when the engine is near
full throttle to ensure that aircraft performance is not affected. The compressor clutch
and fan circuits are protected by the A/C circuit breaker. Later helicopters also have a
3-amp fuse to protect the relays and a 10-amp fuse to protect the compressor circuit.

SEP 2023 Chapter 11 Environmental Control Page 11.7

 FIGURE 11-4 AIR CONDITIONING SYSTEM SCHEMATIC
R44 II S/Ns 14412 thru 29999
R44 Cadet S/Ns 30071 and subsequent

Page 11.8 Chapter 11 Environmental Control SEP 2023

 FIGURE 11-4A AIR CONDITIONING SYSTEM SCHEMATIC
R44 II S/Ns 10001 thru 14411
R44 Cadet S/Ns 30002 thru 30070

SEP 2023 Chapter 11 Environmental Control Page 11.8A

 Intentionally Blank

Page 11.8B Chapter 11 Environmental Control SEP 2023

 ROBINSON MAINTENANCE MANUAL MODEL R44

11.310 System Troubleshooting

Two likely system difficulties are:

1. Failure to cool the air flowing through the evaporator and overhead duct.

2. Excessive condensate (water) in the evaporator box area when the system 1s
operating.

Failure to cool is most likely caused by either refrigerant loss or interruption of the compressor
clutch power supply (by one of the in-line switches or a wiring fault, see Figure 11-4
schematic). Excessive condensate is most often caused by an improperly assembled or
blocked evaporator drain system. Both difficulties can usually be corrected with minimum
effort and expense if careful troubleshooting is done prior to major component maintenance.
A troubleshooting chart follows.

Change 13: OCT 2006 Page 11.9

 ROBINSON MAINTENANCE MANUAL MODEL R44

11.310 System Troubleshooting (cont'd)

PROBLEM POSSIBLE CAUSE TROUBLESHOOT /CORRECTIVE ACTION

Recover refrigerant per Section 11.321. System
should operate normally on approximately 0. 75
Low Refrigerant Charge/ to 1.25 lb refrigerant.
Refrigerant Leak If less than 0. 75 lb refrigerant is recovered, leak
test per Section 11 .323, repair leaks if any, and
recharge per Section 11.322.
With aircraft not running, turn on Master switch
and A/C switch on overhead duct (low or high
setting ok). Have observer listen to and observe
compressor clutch through left cowl door.
Clutch should engage (click and snap against
pulley) whenever A/C is switched on.
Check wiring at freeze switch (behind D798-1
Switch or Wiring Problem
evaporator assembly), high and low pressure
Interrupting Compressor
switches (behind left rear seat back), and full-
Clutch Power
throttle cutout switch (in control tunnel). Repair
Air is not cold any damaged wmng or connectors. Verify
correct rigging per Section 11.350. Check
continuity through each switch. All switches
should be closed with a properly charged
system and aircraft at rest on ground. Replace
any defective switch.
Inspect belt.
Failed Compressor Belt
Replace belt per Section 11. 331 as required.
Inspect condenser installation (left side of fan
scroll). Verify no blockage and all seals in
Insufficient Condenser
place.
Airflow
Remove blockage and/or repair seals to ensure
airflow through core.
Extreme temperature and humidity may result in
Extreme Environmental
cooling effect less than a typical automobile.
Conditions
No corrective action available.
Blocked or Kinked Verify system is draining normally. After several
Evaporator Drain Line minutes ground run in humid conditions with A/
C on, water should be seen draining from the
drain tube.
If water drainage 1s not observed, inspect
drain line (see Section 11.343). Correct any
Excessive damaged or kinked lines. Clean sediment trap
condensate as required. Verify proper function of check
around ball.
evaporator Damaged Insulation Verify evaporator assembly and duct insulation
assembly and are installed correctly and undamaged (see R44
overhead duct Parts Catalog).
Correct any insulation deficiencies.
Extreme Humidity Some condensation is unavoidable in extreme
humidity.
Ensure all fresh air vents closed. Limit opening
and closing cabin doors as much as practical to
limit humidity entering cabin.

Page 11.10 Change 13: OCT 2006

 ROBINSON MAINTENANCE MANUAL MCCEL R44

11 .320 REFRIGERANT

11 . 321 Refrigerant Recovery

If a leak or other service problem is encountered after system is charged with

refrigerant, refrigerant must be recovered before work on system can proceed.

Automotive-style air conditioning service equipment is required to recover refrigerant.

This equipment is available from many manufacturers in varying levels of automation
and complexity. Minimum components include a vacuum pump, storage container,
pressure/vacuum gauge, and appropriate lines and fittings. Ensure equipment is
compatible with R 134a refrigerant and technician is appropriately qualified before
attempting refrigerant recovery.

Automotive-style high and low side system service ports are located on the vertical
firewall inside the left-hand engine cowl door.

Connect service equipment to system service ports and recover refrigerant per
equipment manufacturer's instructions.

11.322 Refrigerant Charge

Automotive-style air conditioning service equipment is required to charge system

with refrigerant. This equipment is available from many manufacturers in varying
levels of automation and complexity. Minimum components include a vacuum
pump, pressure pump, refrigerant supply, scale to measure refrigerant charge,
pressure/vacuum gauge, and appropriate lines and fittings. Service system only with
R 134a refrigerant, and ensure technician is appropriately qualified before attempting
refrigerant charge.

CAUTION

Proper lubrication is required to minimize compressor wear. Verify

compressor oil level per Section 11.333.5 before beginning charge
procedure.

The R44 air conditioning system is not equipped with a traditional

receiver-dryer. Ensure system is under full vacuum to eliminate
all moisture before charging.

Automotive-style high and low side system service ports are located on the vertical
firewall inside the left-hand engine cowl door.

Connect service equipment to system service ports, vacuum system, and charge with
R134a refrigerant per equipment manufacturer's instructions. Correct charge is 1.25
lb (1 lb 4 oz, or 0.567 kg) refrigerant.

CAUTION
Do not overcharge system. If a slow leak is suspected, find and
correct per Section 11 .323 first, then use correct charge.

Change 13: OCT 2006 Page 11.11

 ROBINSON MAINTENANCE MANUAL MODEL R44

11.323 Leak Detection

Leaks may be detected using several techniques, depending on equipment available.

Leak detection should not be attempted with the aircraft/system running. In addition
to safety hazards, leaks are more difficult to detect with the varying pressures and
temperatures of an operating system.

An empty system should hold full vacuum (27 to 29 in Hg vacuum at sea level) with
no assistance from the vacuum pump for 20 minutes or more. If a vacuumed system
creeps up in pressure, a leak may be present. Technician should be thoroughly
familiar with vacuum equipment to ensure leak is in aircraft system and not in vacuum
equipment or connections.

Leaks in a charged system may be detected using a mild soap and water solution
applied to lines and fittings in suspected leak areas (bubbles indicate leaks) or
using commercially available electronic refrigerant detectors. Follow detector
manufacturer's instructions. Large leaks may be detected audibly if area is quiet or
by formation of frost in area of leak.

NOTE

Frost does not necessarily indicate a leak. Normal system operation

and/or charging procedures can cause frost to accumulate on
some components.

NOTE

System pressure is not a reliable indicator of charge state or the

presence of leaks. Because R 134a is a liquid/vapor mixture with
the system at rest, pressure will remain constant as more liquid
vaporizes until majority of charge is lost.

Very small leaks can be detected by charging the system with helium gas. Helium
molecules are smaller than R 134a molecules and will leak more quickly. Charge system
to 200 psi maximum. Use commercially available electronic helium detector or soap
and water solution to locate leaks.

Leaks are most likely to occur at fittings and crimped transitions between hard line and
flexible hose. Concentrate initial leak detection efforts in these areas.

Page 11.12 Change 13: OCT 2006

 ROBINSON MAINTENANCE MANUAL MODEL R44

11.330 COMPRESSOR

11 .331 Compressor Belt Replacement

Compressor belt replacement is based on belt condition. Replace any belt exhibiting
frayed edges, excessive cracking, heat damage, or rubber deterioration.

To replace belt, loosen NAS6604 bolt through 0782-3 adjusting arm slot, and loosen
all three NAS6606 bolts through compressor lugs. Rotate compressor up and inboard
as required to disengage belt from either compressor or drive pulley, and remove
belt.

CAUTION

Do not rotate compressor further than necessary to avoid

damage to refrigerant lines and fittings. Do not use refrigerant
lines or fittings for leverage; handle compressor body or lugs.

Slip new belt over both pulleys, and rotate compressor down and outboard to tension
belt. Tension belt such that a 4.5 to 5.5 lb force applied mid-span produces 0.14
inch belt deflection. Tighten compressor mount and adjustment hardware.

11.332 Compressor Removal

1 . Remove engine left cowling.

2. Disconnect and remove battery as required for compressor access.

3. Recover refrigerant per Section 11.321.

4. Disconnect compressor clutch wiring from airframe harness.

5. Disconnect refrigerant lines from compressor. Protect all open lines and fittings
from contamination.

6. Remove belt from compressor drive pulley per Section 11.331.

7. Remove three compressor lug bolts loosened in step 6, and remove compressor.

Change 13: OCT 2006 Page 11.13

 ROBINSON MAINTENANCE MANUAL MODEL R44

11.333 Compressor Installation

1. Install compressor using three NAS6606 bolts at mount lugs and NAS6604 bolt
at D782-3 adjusting arm slot. Refer to R44 Illustrated Parts Catalog for hardware
stack up. Leave all hardware loose enough to rotate compressor.

2. Install compressor drive belt, tension per Section 11.331, and tighten mount and
adjusting hardware.

3. Connect refrigerant lines to compressor. Torque low-pre_ssure (large) fitting to

300 in.-lb. Torque high-pressure (small) fitting to 210 in.-lb.

4. Connect compressor clutch wiring to airframe harness.

5. Check and adjust compressor oil quantity as follows:

CAUTION

Recover refrigerant prior to checking oil level.

a. Remove compressor oil fill cap (black hex-head cap on upper outboard surface
of compressor body behind clutch and pulley).

b. Turn compressor shaft clockwise until clutch plate counterweight is positioned

per Figure 11-5.

c. Insert Airpro P/N 90-3028 or equivalent dipstick per Figure 11-5, and take oil
level reading.

d. Add A257-20 oil as required to bring dipstick reading to 8 to 10 notches.

Approximately 2 to 3 ounces total oil is required for completely empty
compressors. Compressors are typically shipped at least partially filled with
oil.

e. Reinstall fill cap. Torque to 156 in.-lb.

6. Perform vacuum or helium leak check per Section 11.323.

7. Charge system with refrigerant per Section 11 .322.

8. Install and connect battery (if removed).

9. Install engine left cowling.

Page 11.14 Change 14: JUL 2008

 ROBINSON MAINTENANCE MANUAL MOCEL R44

COUNTERWEIGHT
DIPSTICK - INSERT INTO OIL FILLER
POSITION APPROX
HOLE UNTIL STOP IS FLUSH AGAINST
AT 2:30 O'CLOCK
COMPRESSOR CASE

COUNTERWEIGHT

FIGURE 11-5 COMPRESSOR OIL FILL

Change 13: OCT 2006 Page 11.15

 ROBINSON MAINTENANCE MANUAL MODEL R44

11.340 EVAPORATOR ASSEMBLY

11 .341 Evaporator Assembly Removal

1. Recover refrigerant per Section 11.321.

2. Remove overhead duct as follows:

a. Remove screw aft of rotor brake knob.

b. Slide duct forward and down to disengage tabs from evaporator box and
windshield frame.

c. Push rotor brake knob through slot in duct.

d. Disconnect electrical connector.

e. Remove duct.

3. Remove screws (4 each side) securing headset jack boxes to evaporator

assembly.

NOTE

Two different length screws and two different length spacers are
used to mate headset jack boxes to evaporator. Use caution to
retain spacers during disassembly and note hardware arrangement
for re-assembly.

NOTE

The entire decorative (headliner) cover is secured to the evaporator

box via hook and loop fastening material and may be removed if
desired. It is necessary to remove the headset hangers in order
to remove the cover. Refer to R44 Illustrated Parts Catalog for
details.

4. Remove trim securing headliner between seats, and remove left rear seat back.

5. Remove and discard safety wire, and remove drain tube from drain fitting at base
of evaporator box (right side).

6. Disconnect refrigerant lines at vertical connection nuts near upper inboard seat
back corner.

7. Push back headliner as required, and remove 6 screws securing evaporator box
flanges to aft cabin bulkhead. Tilt top of evaporator box forward and lift up and
out.

Page 11.16 Change 1 3: OCT 2006

 ROBINSON MAINTENANCE MANUAL MODEL R44

11.342 Evaporator Assembly Installation

1. Secure evaporator box to aft cabin bulkhead using 6 screws through box
flanges.

2. Verify 0-rings are clean and undamaged, and connect refrigerant line connection
nuts. Torque insulated line to 210 in.-lb and uninsulated line to 150 in.-lb.

3. Connect drain tube to evaporator box drain fitting and secure using 0.032 in
diameter safety wire.

4 Secure headset jack boxes to evaporator assembly. Use screw and spacer
arrangement retained from Section 11.341 or refer to R44 Illustrated Parts Catalog
for hardware details.

5. Install overhead duct as follows:

a. Position duct approximately, feed rotor brake knob through slot in duct, and
connect electrical connector.

b. Slide duct up and aft such that tabs engage evaporator box fan opening and
windshield frame.

c. Install screw aft of rotor brake knob.

6. Verify no leaks (refer to Section 11.323 as required). Charge system per Section
11.322.

7. Install left rear seat back, and secure headliner between seat backs using trim.

Change 13: OCT 2006 Page 11.17

 ROBINSON MAINTENANCE MANUAL MODEL R44

11.343 Evaporator Drain System

The evaporator drain system, shown schematically in Figure 11-6, is designed to

prevent condensate from backing up in the evaporator box and leaking into the
passenger compartment. All components are necessary for proper drainage. Blockage 1

or kinking of a drain line may result in water damage to the cabin interior near the
evaporator box.

The flexible tube drains condensate to the tee located behind the right rear seat back.
At tee, a sediment-tube extends several inches down to a plug. The sediment-tube
is designed to allow contamination to settle out without clogging the main drain
system. Inspect tube periodically. Remove plug and clean out tube if sediment
build-up nears tee fitting.

Just above tee fitting is a ball retained in upper flex tube. Normally a small amount
of water is retained in the loop formed by drain tube and tee fitting. If the system is
dry, the ball seats against the tee and prevents the evaporator fan from drawing air
up through the drain system until water fills this area.

The hard drain tube runs along the aft, inboard corner of right-rear baggage
compartment and out the belly. Normal system operation in humid conditions should
result in condensation dripping from the tube. In extremely dry conditions there may
be little or no condensation. Periodically inspect evaporator drain assembly to verify
it has not been damaged or dislodged.

Page 11.18 Change 14: JUL 2008

 ROBINSON MAINTENANCE MANUAL MOCEL R44

EVAPORATOR DRAIN TUBE

rTUBE
I

-TEE

'
I I FORWAR~
''
I ' / ~ SEDIMENT TUBE
'
'
DRAIN TUBE _,/ ' \' PLUG
I
' I
i
' __I
I'

FIGURE 11-6 EVAPORATOR DRAIN SYSTEM

Change 1 3: OCT 2006 Page 11.19

 ROBINSON MAINTENANCE MANUAL MOCEL R44

11. 350 Full Throttle Cut-Out Switch Rigging

A full-throttle cut-out switch is designed to disengage the compressor clutch

approximately 1 inch MAP below full throttle. This guarantees that air conditioning
operation does not affect aircraft performance at altitude. Full throttle cut-out is
controlled via a microswitch located near the bellcrank assembly at the aft end of
the throttle push -pull tube in the main control tunnel. The switch is normally closed
(allows current flow to the compressor) when its button is not depressed. A cam
on the bellcrank assembly depresses the button and opens the switch near full
throttle.

Adjust switch so button is depressed by cam when throttle arm at fuel control is
0.15 to 0.20 inch away from full-open throttle stop.

D731 -1 BellCrank Assembly

Cam

0731 - 11 Plate Assembly

('r\~ MS35206-219 Screw

(2 places)

__ - V3-1 sw;tch • I FORWAR~

~+---~
:: --~ Screws and Lockwashers
supphed w;th Switch

--------
JV-5 Actuator

C059-1823 Wire

C059- 1822 W i r e _ /

* Adjust position of V3 - 1 switch so that switch opens when

fuel control throttle arm is 0.15 - 0 .20 off full throttle stop.

FIGURE 11-7 AIR CONDITIONING CUTOFF SWITCH

(View looking outboard from centerline)

Page 11.20 Change 14: JUL 2008

 ROBINSON MAINTENANCE MANUAL MODEL R44

11 .400 DRIVE CARTRIDGE

11 .41 0 Drive Cartridge Seal Removal

1. Remove engine left cowling.

2. Disconnect and remove battery as required for access.

3. Loosen belt tension and remove belt from pulley.

4. Refer to Figure 11-7. Remove B330-19 palnut and MS21042L6 nut.

5. Remove pulley from shaft to expose A966-5 seal and woodruff key.

6. Remove seal using appropriate tool being careful not to damage housing. Do
not remove shims under seal.

11 .420 Drive Cartridge Seal Installation

1. Ensure seal recess area is clean and free of debris.

2. Ensure shims are in place, and install A966-5 seal flush with the housing.

3. Install woodruff key and pulley on shaft.

4. Install MS21042L6 nut and special torque per Section 1.330. Install B330-19
palnut and standard torque per Section 1.320. Apply B270-22 protectorant
to exposed surfaces of shaft.

5. Install compressor drive belt, tension per Section 11.331, and adjusting
hardware.

Change 14: JUL 2008 Page 11.21

 ROBINSON MAINTENANCE MANUAL MODEL R44

FIGURE 11-7 CARTRIDGE ASSEMBLY - COMPRESSOR DRIVE

Page 11 .22 Change 14: JUL 2008