Enviro PILATUS PC12 Component Maintenance Manual With Illustrated Parts List
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Enviro PILATUS PC12 Component Maintenance Manual With Illustrated Parts List

Enviro PILATUS PC12 Component Maintenance Manual With Illustrated Parts List

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12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
http://www.enviro-ok.com
Component Maintenance Manual
OPERATING, SERVICING, AND COMPONENT
MAINTENANCE MANUAL
WITH ILLUSTRATED PARTS LIST
PILATUS PC12
R-134a AIR CONDITIONING SYSTEM COMPONENTS:
1) COMPRESSOR CONDENSER MODULE ASSEMBLY, PART # 1134400-53
(Supersedes 1134400-13, 1134400-56), 1134400-59
2) EVAPORATOR MODULE ASSEMBLY, PART # 1134200-60 (L) /-61 (R) /-63 (C)
(Supersedes 1134200-42, L /-43. C&R)
ATA SPECIFICATION
21-00-23
Copyright © 2017
Original Release
ATA 21-00-23
January 2008

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  • Page 1 Component Maintenance Manual OPERATING, SERVICING, AND COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST PILATUS PC12 R-134a AIR CONDITIONING SYSTEM COMPONENTS: 1) COMPRESSOR CONDENSER MODULE ASSEMBLY, PART # 1134400-53 (Supersedes 1134400-13, 1134400-56), 1134400-59 2) EVAPORATOR MODULE ASSEMBLY, PART # 1134200-60 (L) /-61 (R) /-63 (C) (Supersedes 1134200-42, L /-43.
  • Page 2 Section 7 Inspection Schedule Table 3.5. Remove IPL item numbers from Sections 2 thru 10. Continued Next Page NOTE: Check Enviro Systems Inc. web site to verify current revision. www.enviro-ok.com Copyright © 2017 ATA 21-00-23 P a g e...
  • Page 3 1134104-1 motor with an 1134104- 6 motor. - Removed Section 13.6 Motor brush seating procedure - Updated Table 2 Consumable Products to include Pilatus part number where applicable and to specify Enviro part number. Copyright © 2017 ATA 21-00-23 P a g e...

  • Page 4: Record Of Temporary Revisions

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual RECORD OF TEMPORARY REVISIONS DESCRIPTION OF CHANGE DATE APPROVAL Copyright © 2017 ATA 21-00-23 P a g e Revision 10 June 1, 2017...

  • Page 5: List Of Service Bulletins

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual LIST OF SERVICE BULLETINS SERVICE DESCRIPTION DATE BULLETIN # RELEASED Copyright © 2017 ATA 21-00-23 P a g e Revision 10 June 1, 2017...

  • Page 6: List Of Effective Pages

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual LIST OF EFFECTIVE PAGES CHAPTER / SECTION PAGE DATE CHAPTER / SECTION PAGE DATE 5/5/08 7/7/08 9/22/08 08/17/10 11/04/10 08/15/11 11/11/11 XX/XX/2017 Copyright © 2017...

  • Page 7: Table Of Contents

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual TABLE OF CONTENTS RECORD OF TEMPORARY REVISIONS ......................4 LIST OF SERVICE BULLETINS ......................... 5 LIST OF EFFECTIVE PAGES ..........................6 TABLE OF CONTENTS ............................7 LIST OF ILLUSTRATIONS ..........................
  • Page 8 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual ASSEMBLY ............................... 48 R-134A AIR CONDITIONING SYSTEM COMPONENT - ASSEMBLY ..........48 9.1 General: ..............................48 9.2 Compressor Condenser Module Assembly Procedures ..............49 9.3 Evaporator Module Assembly Procedures ..................

  • Page 9: List Of Illustrations

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual LIST OF ILLUSTRATIONS Figure 1 R-134A Refrigerant Flow Schematic ....................25 Figure 3.3: Commutator Excellent Condition Example ................39 Figure 3.4: Commutator Serviceable Condition Example ................40 Figure 3.5: Commutator Unserviceable Condition Example ..............

  • Page 10: Introduction

    Although Enviro Systems tries to cover all conceivable issues that may arise, there may be issues that are not covered in this manual. In these cases, please call Enviro Systems customer service.

  • Page 11: Acronyms, Abbreviations, And Symbols

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 1.1.6 A complete Illustrated Parts Listing (IPL) is supplied as additional documentation (Section 11) to provide service technicians access to exploded views and a parts list while performing maintenance, testing, disassembly and assembly procedures.

  • Page 12: Standard Torque Values

    270-350 IN LBS CONNECTIONS Table 1 Standard Torque Values SUBTASK 21-00-23-99F-004 Documents required: • Illustrated Parts Listings (IPL) (included with this manual) • Pilatus PC12 Aircraft Maintenance Manual SUBTASK 21-00-23-99F-005 Consumable Products: ENVIRO PART DESCRIPTION REMARKS/ALTERNATE PILATUS PART NUMBER NUMBER...

  • Page 13: Description And Operation

    General: 2.1.1 The air conditioning system installed on the Pilatus PC12 Aircraft is not considered a primary flight system. However, an air conditioning system does perform the important function of providing passenger and flight crew comfort during aircraft movement on the ground and while in flight.

  • Page 14: System Description And Operation

    System Description and Operation: 2.2.1 The cabin cooling system installed in the Pilatus PC12 Aircraft operates using a closed vapor cycle concept using refrigerant R-134A as the heat absorption media. The R-134A air conditioning system cools the aircraft in a similar manner as systems found in an automobile or home.

  • Page 15: System Component Description And Operation

    The COMPRESSOR CONDENSER MODULE ASSEMBLY (PN 1134400-13/-53/-56/-59) has a rated cooling capacity of 17,350 BTUH when operating with the other components in the Pilatus PC12 Aircraft at an ambient temperature of 95°F OAT. Under this condition, the nominal current draw is 100 AMPS at 28 VDC.
  • Page 16 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 2.3.3.3 CONDENSER COIL ASSEMBLY: The condenser coil assembly is a copper tube and aluminum fin configuration with 6061-T6 aluminum support brackets. The coil heat rejection is 30,400 BTUH based on a 95°F ambient day.
  • Page 17 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 2.3.5.2 BLOWER MOTOR: The blower motor operates on 28 VDC with a rated current draw of 10 AMP and has a design RPM of 5250-6250. The blower motor is a brushless design with an integrated controller and was selected for its efficiency, excellent controllability, long life and low vibration at high speeds.

  • Page 18: Testing And Fault Isolation

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual TESTING AND FAULT ISOLATION TASK 21-00-23-70-801 R-134A AIR CONDITIONING SYSTEM COMPONENT – TESTING AND FAULT ISOLATION SUBTASK 21-00-23-99F-009 General: 3.1.1 Testing and Fault Isolation of the R-134A Air Conditioning System may be necessary if the system does not operate and/or perform in accordance with information contained herein.

  • Page 19: System Leak Check Testing Procedure

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 3.3.2.1 Verify that there is a distinct and noticeable change in sound of blower motor when changing from low to high speed positions. This indicates that the cockpit selector switch is functioning properly and that the blower motor is responding accordingly.
  • Page 20 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual • Thread sealant primer, PN 7471 (Loctite) • Thread sealant, PN 569 (Loctite) • Hose adapter (1/2 in. male acme to ¼ in. female flare) 3.4.3.1...

  • Page 21: Fault Isolation (Trouble Shooting)

    Use this trouble shooting list as well as all information contained in this manual, to aid in diagnosing system faults. Contact Enviro Systems customer service for any items not listed in this trouble shooting list.

  • Page 22: Table 3 Trouble Shooting List

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual NOTE: Refer to Refrigerant Flow (Figure 1), Section 4. INDICATION PROBABLE CAUSE POSSIBLE SOLUTION A. No System Power 1. Ground power not connected 1.

  • Page 23: Table 3 Trouble Shooting List

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual INDICATION PROBABLE CAUSE POSSIBLE SOLUTION C. System Operates But Does 1. Low refrigerant charge 1.Charge as required Not Cool 2. Overcharged system cutout 2.

  • Page 24: Table 3 Trouble Shooting List

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual INDICATION PROBABLE CAUSE POSSIBLE SOLUTION G. Compressor Assembly Will 1. Circuit Breaker failed or off 1. Energize or replace Not Operate 2. Relay failed 2.

  • Page 25: Schematic And Wiring Diagrams

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual SCHEMATIC AND WIRING DIAGRAMS 21-00-23-99-801 R-134A AIR CONDITIONING SYSTEM SCHEMATIC AND WIRING DIAGRAMS SUBTASK 21-00-23-99-001 R-134A Refrigerant Flow Schematic: 4.1.1 The following schematic shows an air conditioning system and its associated components as well as the flow of the R-134A refrigerant.

  • Page 26: Disassembly

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual DISASSEMBLY TASK 21-00-23-00-801 R-134A AIR CONDITIONING SYSTEM COMPONENT - DISASSEMBLY SUBTASK 21-00-23-99F-010 General: WARNING: SERVICE TECHNICIANS ARE ADVISED TO OBSERVE STANDARD SAFETY PRECAUTIONS, SUCH AS WEARING PERSONAL SAFETY GEAR, TO PREVENT INJURY WHILE PERFORMING SERVICE TO THE UNIT.

  • Page 27: Compressor Condenser Module Disassembly Procedures

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual NOTE: Do not disassemble the parts unnecessarily. 5.1.6 Refer to Illustrated Parts Listing (IPL) for figure/item numbers (Section 11). 5.1.7 Tools, fixtures, equipment, or consumable items required: •...
  • Page 28 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 5.2.3.2 Slightly loosen the compressor mounting bolts. 5.2.3.3 Loosen drive motor pulley set screws. 5.2.3.4 Slide upper compressor in towards drive motor, slide drive pulley and belt from motor shaft, while at the same time sliding the drive belt off the compressor pulley.
  • Page 29 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual CAUTION: DO NOT ALLOW MOTOR TO FALL ON POWER RELAY DURING THIS PROCEDURE OR DAMAGE MAY RESULT. 5.2.6.4 Remove motor mounting bolts and washers from motor support bracket.
  • Page 30 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 5.2.11.2 Remove attaching screws, washers, and nuts. 5.2.11.3 Carefully slide hour meter from receiver dryer bracket. 5.2.12 Removal of Drive Motor Brushes 5.2.12.1 Locate and remove the safety wire and screws securing the brush cover.
  • Page 31 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 5.2.12.2 Remove the Brush Cover 5.2.12.3 Disconnect the brush shunt wire terminals. Copyright © 2017 ATA 21-00-23 P a g e | 31...
  • Page 32 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 5.2.12.4 With a 90° pick, lift brush spring and remove the worn brushes from the brush guides. 5.2.12.5 Upon removal, ensure that no FOD remains in the brush guide that may prevent smooth brush travel upon reassembly.

  • Page 33: Evaporator Module Assembly Disassembly Procedures

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual SUBTASK 21-00-23-00-002 Evaporator Module Assembly Disassembly Procedures (Refer to Figure 10002/10003): 5.3.1 Removal of Evaporator Module Assembly 5.3.1.1 Refer to aircraft maintenance manual for removal of Evaporator Module Assembly.

  • Page 34: Cleaning

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual CLEANING TASK 21-00-23-10-801 R-134A AIR CONDITIONING SYSTEM COMPONENT – CLEANING PROCEDURES SUBTASK 21-00-23-99F-011 General: 6.1.1 This section details the procedures required to perform certain cleaning functions. The components listed have certain cleaning procedures associated with them, however these procedures are in no way an all-encompassing list of what may be required.

  • Page 35: Compressor Condenser Module Cleaning Procedures

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual SUBTASK 21-00-23-10-001 Compressor Condenser Module Cleaning Procedures: 6.2.1 The following components of the Compressor Condenser Module will require periodic cleaning (refer to the Inspection Schedule in section 7 for time intervals). This is in no way an all-encompassing list.

  • Page 36: Evaporator Module Assembly Cleaning Procedures

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual SUBTASK 21-00-23-10-002 Evaporator Module Assembly Cleaning Procedures: 6.3.1 The following components of the Evaporator Module Assembly will require periodic cleaning (refer to the Inspection Schedule in section 7 for time intervals) (refer to Figure 10002/10003): •...

  • Page 37: Check (Inspection Schedule)

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual CHECK (INSPECTION SCHEDULE) TASK 21-00-23-21-801 R-134A AIR CONDITIOING SYSTEM COMPONENT – INSPECTION SCHEDULE SUBTASK 21-00-23-21-001 Compressor Condenser Module Assembly Inspection Schedule: NOTE: This is the recommended visual inspection schedule for the Compressor Condenser Module Assembly.
  • Page 38 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 7.1.3 Brush Inspection (1134400-59 Only) 7.1.3.1 Determine how many hours the installed brushes have accumulated since new. If the compressor condenser module was installed new and the motor and/or brushes have never been replaced, then the hours shown on the compressor/condenser hour meter may be used.

  • Page 39: Figure 3.3: Commutator Excellent Condition Example

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 7.1.4 Commutator Inspection Inspect commutator per following figures for excessive or uneven wear. The commutator should have a burnished appearance with light filming. If the commutator is black, burned, pitted, grooved, or excessively worn, the motor should be replaced.

  • Page 40: Figure 3.4: Commutator Serviceable Condition Example

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 7.1.4.2 Commutator in serviceable condition shows some signs of wear and carbon film. Figure 3.4: Commutator Serviceable Condition Example Copyright © 2017 ATA 21-00-23...

  • Page 41: Figure 3.5: Commutator Unserviceable Condition Example

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 7.1.4.3 Commutator in unserviceable condition shows excessive pitting and chipping on commutator. Figure 3.5: Commutator Unserviceable Condition Example Copyright © 2017 ATA 21-00-23...

  • Page 42: Evaporator Module Assembly Inspection Schedule

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual SUBTASK 21-00-23-21-002 Evaporator Module Assembly Inspection Schedule: NOTE: This is the recommended visual inspection schedule for the Evaporator Module Assembly. Adherence to this schedule will ensure that all components of the assembly are in accordance with the manufacturer’s specifications and is necessary to detect structural failure, deterioration or damage, and to...

  • Page 43: Repairs

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual REPAIRS TASK 21-00-23-30-801 R-134A AIR CONDITIONING SYSTEM COMPONENT – REPAIR PROCEDURES SUBTASK 21-00-23-99F-012 General: 8.1.1 Refer to Illustrated Parts Listing (IPL) for figure/item numbers (Section 12).
  • Page 44 If assembly is out of alignment, system will need to be aligned and tensioned. Refer to Disassembly (Section 5) and Assembly (Section 9). Contact Enviro Systems customer service to order new components.
  • Page 45 If coil fins are bent, use a fin comb and try straightening the fins. If fins are excessively damaged or the return bends are excessively damaged, the entire compressor condenser module assembly must be removed (refer to Disassembly, Section 5) and sent to Enviro Systems for repair. Contact Enviro Systems customer service. 8.2.1.9...

  • Page 46: Evaporator Module Assembly Repair Procedures

    RTV and smooth. Allow RTV to cure for a minimum of 24 hours before operating system. If housing assembly is damaged in any way other than seam separation, the entire assembly must be removed and sent to Enviro Systems for repair. Contact Enviro Systems customer service.
  • Page 47 It is essential that the drain remains in excellent condition for proper operation of the evaporator coil assembly. If the condensate drain is damaged, the entire assembly must be removed and sent to Enviro Systems for repair. Contact Enviro Systems customer service.

  • Page 48: Assembly

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual ASSEMBLY TASK 21-00-23-40-801 R-134A AIR CONDITIONING SYSTEM COMPONENT - ASSEMBLY SUBTASK 21-00-23-99F-013 General: 9.1.1 Refer to Illustrated Parts Listing (IPL) during assembly procedures for figure/item numbers (Section 11).

  • Page 49: Compressor Condenser Module Assembly Procedures

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 9.1.5 Tools, fixtures, equipment, or consumable items required • Small hand tools and socket set • Gates Sonic Tension Meter 508C or equivalent •...
  • Page 50 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 9.2.1.1 Ensure the brush guide interior is free of debris and the surfaces are smooth to allow for proper brush travel. 9.2.1.2 Prepare each brush by guiding the brush lead across the top of the brush as shown below.
  • Page 51 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 9.2.1.3 Ensure that brush lead does NOT extend out past the edge of the brush as shown below. This will cause the brush not to pass through the brush guide properly.
  • Page 52 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 9.2.1.6 Using a 90° scribe, lift the brush tension spring to allow brush installation. Insert brushes into slots ensuring that the curvature of the brush matches the armature.
  • Page 53 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 9.2.1.7 Rotate the motor through 5 revolutions in the CCW direction as viewed from the brush end. 9.2.1.8 Raise the brushes approximately half way and allow the spring to hold the brush in this position by pressing against the side of the brush.
  • Page 54 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 9.2.1.10 Lower the brushes back into position on the commutator. 9.2.1.11 Attach field winding leads and brush shunt wires to the terminals as shown. Place the brush shunt terminal on the top of the other terminals.
  • Page 55 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 9.2.1.12 Install the fan blade per Section 9.2.4 9.2.1.13 Install the motor into the Compressor Condenser Module Assembly per Section 9.2.5 9.2.1.14 Operate the motor for 1 hour without the belt installed (no load). After 1 hour the brushes must be checked for proper seating as illustrated below.
  • Page 56 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual Note: The Brush Shunt Wires shall locate in the slot of the brush guide as shown above; this will ensure the brush travel will not be inhibited by improper shunt wire routing. Proper shunt wire routing for 2 brush locations shown below.
  • Page 57 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 9.2.1.16 Reinstall the brush cover and screws. Use safety cable or wire to secure the brush cover in place. Copyright © 2017 ATA 21-00-23...
  • Page 58 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 9.2.1 Assembly of Drive Motor (10C) CAUTION: TAKE EXTREME CARE WHEN INSTALLING DRIVE MOTOR ONTO ASSEMBLY OR DAMAGE TO COIL OR FAN SHROUD COULD OCCUR.
  • Page 59 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 9.2.3 Assembly of Compressor 9.2.3.1 Position compressor in mounting bracket and install 3 mounting bolts. Finger tighten bolts only. 9.2.3.2 Rotate upper compressor towards drive motor. Tighten mounting hardware only after tensioning and alignment have been accomplished (refer to installation of drive belt and pulley, 9.2.4).
  • Page 60 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 9.2.4.3.5 Push the measure button on the meter, hold the sensor approximately 1 cm (0.4 in) above the belt at the midway point between the pulleys.

  • Page 61: Figure 4 Belt Tensioning Reference

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual Figure 4 Belt Tensioning Reference Tensioning Information: (Sonic Tension Meter 508C, www.gates.com) New Belt Used Belt Belt Frequency (Hz) Sonic Tension Meter (N) Table 4 Gates Sonic Tension Meter Data 9.2.5...
  • Page 62 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 9.2.6.3 Attach fan shroud to coil with mounting bolts, washers and nuts (refer to table 1, Section 1.3 for torque specifications). 9.2.7 Assembly of Outlet Shroud 9.2.7.1...
  • Page 63 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 9.2.9.4 Apply thin film of refrigerant oil to flare and connect condenser fitting to receiver dryer and tighten (refer to table 1, section 1.3 for torque specifications).

  • Page 64: Evaporator Module Assembly Procedures

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual SUBTASK 21-00-23-40-002 Evaporator Module Assembly Procedures (refer to Figure 10002/10003): 9.3.1 Assembly of Expansion Valve (FIG. 10002, 10), (FIG. 10003, 60A) 9.3.1.1 Set new valve adjustment screw to same position as failed valve.
  • Page 65 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 9.3.3.4 Slide motor/blower wheel into scroll and attach with upper motor screws and washers. 9.3.3.5 Attach drip tray to motor with lower motor attachment screws and washers, ensuring that spacers and clamp have been installed properly (refer to table 1, Section 1.3 for...

  • Page 66: Special Tools, Fixtures, And Equipment

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual SPECIAL TOOLS, FIXTURES, AND EQUIPMENT TASK 21-00-23-99F-803 10.0 SPECIAL TOOLS/EQUIPMENT SUBTASK 21-00-23-99F-014 10.1 General: 10.1.1 This section describes the necessary tools and test equipment required to perform maintenance, functional testing, troubleshooting, and repair procedures.
  • Page 67 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual • Straight Edge • Measuring Device • Micrometer • Scribe or Wire Hook • Volt-OHM Meter • Gates Sonic Tension Meter 508C or equivalent Copyright ©...

  • Page 68: Illustrated Parts List

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual ILLUSTRATED PARTS LIST TASK 21-00-23-98-801 11.0 R-134A AIR CONDITIONING SYSTEM COMPONENT ILLUSTRATED PARTS LISTING SUBTASK 21-00-23-99F-015 11.1 Introduction: This Illustrated Parts Listing (IPL) is intended for use during testing and isolation, disassembly, cleaning, check (inspection), repair, assembly, and issuing the replaceable equipment components as well as in identification of new and reclaimed parts.

  • Page 69: Figure 10001 Compressor Condenser Module Assembly 1134400-53

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual Figure 10001 Compressor Condenser Module Assembly 1134400-53 Supersedes 1134400-13 and 1134400-56 – All three configurations shown here Copyright © 2017 ATA 21-00-23 P a g e...

  • Page 70: Figure 10001 Compressor Condenser Module Assembly (1134400-53) Details

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual FIG. ITEM PART NUMBER NOMENCLATURE UNITS ASSY. 10001-10C 1134104-1 DC MOTOR (-13 CONFIG ONLY) See note below* DC MOTOR ASSEMBLY (-56 CONFIG ONLY)
  • Page 71 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual UNITS FIG. ITEM PART NUMBER NOMENCLATURE ASSY. -42A 10MM SPLIT WASHER 1134125-3 MANIFOLD ASSEMBLY AS568-013-HNBR-70 O-RING 1134125-4 MANIFOLD ASSEMBLY 901V212-10 O-RING TO FLARE ADAPTER...
  • Page 72 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 1134400-59 Compressor Condenser Module Assembly Copyright © 2017 ATA 21-00-23 P a g e | 72 Revision 10 June 1, 2017...
  • Page 73 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual FIG. ITEM PART NUMBER NOMENCLATURE UNITS ASSY. 1134104-9 28VDC Motor Assembly Item Not Shown 1251171-11 Motor Brush Set (Contains 4 Brush Pairs) 1260970...

  • Page 74: Figure 10002 Evaporator Module Assembly 1134200-42 (L) /-43 (C,R)

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual Figure 10002 Evaporator Module Assembly 1134200-42 (L) /-43 (C,R) (Superseded by 1134200-60, L /-61, R /-63, C) Copyright © 2017 ATA 21-00-23 P a g e...

  • Page 75: Figure 10002 Evaporator Module Assembly (1134200-42/-43) Details

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual FIG. ITEM PART NUMBER NOMENCLATURE UNITS ASSY. 10002-10 1134218 EXPANSION VALVE (-42) 1134218-1 EXPANSION VALVE (-43) 1250540-11 AIR FILTER 190940 VELCRO (HOOK) (2.6 FT.) 190911 VELCRO (LOOP) (2.6 FT.)

  • Page 76: Figure 10003 Evaporator Module Assembly 1134200-60/-61/-63 (-60 Shown)

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual Figure 10003 Evaporator Module Assembly 1134200-60/-61/-63 (-60 Shown) Copyright © 2017 ATA 21-00-23 P a g e | 76 Revision 10 June 1, 2017...

  • Page 77: Figure 10003 Evaporator Module Assembly (1134200-60/-61/-63) Details

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual FIG. ITEM PART NUMBER NOMENCLATURE UNITS ASSY. 10003-10B 1133210-16 BRUSHLESS DC MOTOR (-60) 1133210-15 BRUSHLESS DC MOTOR (-61) 1133210-17 BRUSHLESS DC MOTOR (-63)

  • Page 78: Special Procedures

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual SPECIAL PROCEDURES TASK 21-00-23-82-801 12.0 SPECIAL PRODECURES SUBTASK 21-00-23-82-001 12.1 Expansion Valve Alignment: 12.1.1 The expansion valve is set at the factory, but there may be times when it must be adjusted to assure proper refrigerant flow at the desired evaporating temperature;...

  • Page 79: Table 5 Typical Operating Values

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual • Verify that system leak check and refrigerant charging has been performed and system is operating at typical values as outlined in table 5.

  • Page 80: 12.2 Balancing Multiple Evaporators

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual SUBTASK 21-00-23-82-002 12.2 Balancing Multiple Evaporators: 12.2.1 If system contains multiple evaporator modules, balancing of evaporators must be accomplished for refrigerant flow between evaporators to achieve equal evaporator air outlet temperatures.

  • Page 81: Motor Bearing Inspection

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual SUBTASK 21-00-23-20-001 12.4 Motor Bearing Inspection: 12.4.1 Motor bearing will be inspected according to Section 8 Inspection Schedule Table 3.5 to ensure that premature seizure does not occur.

  • Page 82: Compressor Oil Level Check

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual SUBTASK 21-00-23-20-003 12.6 Compressor Oil Level Check: NOTE: Checking compressor oil quantity is only required if an excessive amount of oil is observed due to leaking or the system has been vented quickly thereby causing a loss of oil.

  • Page 83: Servicing

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual SERVICING TASK 21-00-23-60-801 13.0 R-134A AIR CONDITIONING SYSTEM SERVICING PROCEDURES SUBTASK 21-00-23-99F-016 13.1 General: 13.1.1 Reclaiming the system (R-134A) refrigerant charge is required on systems before system removal, after an accidental line break, component failure or when the system has excessive leaks.

  • Page 84: Evacuating The System (R-134A)

    12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual • Hose adapter (1/2 in, male acme to ¼ female flare) SUBTASK 21-00-23-60-001 13.2 Evacuating the system (R-134A): NOTE: The system must be evacuated for a minimum of 45 minutes to remove air and moisture which can cause the system to have less than optimal performance.

  • Page 85: Flushing The System (R-134A)

    SYSTEM OR REFRIGERANT CONTAINER. R-134A IN THE PRESENCE OF AIR OR OXYGEN ABOVE ATMOSPHERIC PRESSURE MAYFORM A COMBUSTABLE MIXTURE. CAUTION: ENVIRO SYSTEMS INC. DISCOURAGES THE USE OF ALL OTHER FLUSHING AGENTS DUE TO THE DIFFICULTY OF ASSURING THAT ALL THE SOLVENT HAS BEEN REMOVED. FLUSH AGENTS REMAINING IN THE SYSTEM RESULT IN POOR COMPRESSOR LUBRICATION AND PREMATURE COMPONENT FAILURE.
  • Page 86 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 13.4.7 Remove the receiver dryer and install a jumper hose between the open ports. 13.4.8 Apply power to recovery unit and run for a minimum of 15 minutes.

  • Page 87: Storage

    NOTE: When installing unit with MFG date in excess of 12 months prior to installation date, verify record of preventive maintenance. If no maintenance record exists, contact Enviro Systems Inc. prior to installation. 14.2.2 For internal pressures within a range of 5-15 PSIG, rotate compressor by hand through a minimum of 10 revolutions.

  • Page 88: System Off-Season/On-Aircraft Functional Tests

    14.2.4.2 Drain old oil into measuring cup to verify amount of oil being replaced. CAUTION: ONLY AN ENVIRO APPROVED TYPE OF OIL MAY BE USED IN THIS TYPE OF COMPRESSOR. CAUTION: DO NOT OVERFILL COMPRESSOR WITH OIL OR SYSTEM PERFORMANCE WILL BE AFFECTED.
  • Page 89 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 Fax (405) 382-0737 http://www.enviro-ok.com Component Maintenance Manual 14.4.1.4 If the component is removed from the original packaging and is not installed on the aircraft immediately and the original packaging is not available for repackaging, ensure that the component is packaged in the following manner.

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