Aerostar - Maintenance - Manual - Chapters - 21 To 25

or
.03
TO
CHAPTER
ENVIRONMENTAL SYSTEM
2B4
AEROSTAR AIRCRAFT \ ,
600/601/601P/602P/700P (
MAINTENANCE MANUAL
CHAPTER 21 - ENVIRONMENTAL SYSTEMS
T A B L E OF CONTENTS/EFFECTIVITY
CHAPTER
SECTION GRID
SUBJECT SUBJECT NO. EFFECTIVITY
21-00-00 GENERAL 2B12

21-01-00 Description 2B12
21-02-00 Troubleshooting 2B12
21-03-00 Precautions 2C9
21-20-00 PRESSURIZATION 2C9

21-11-00 Component Maintenance 2C9
21-11-01 Flow Control Assembly (601P) 2C9
21-11 -02 Removal of Flow Control Assembly (601P) 2C11
21-11-03 Installation of Flow Control Assembly (601P) 2C11
21 -11 -04 Adjustment/Test of Flow Control and Bleed Air
Valve/Switch Assembly (601P) 2C12
21-11-05 Flow Control Assembly (602P and 700P) 2C13
21-11-06 Removal of Sonic Nozzle (602P and 700P) 2C13
21-11 -07 Instaliation of Sonic Nozzle (602P and 700P) 2C13
21-11 -08 Removal of Flow Control Adapter/Diverter Valve
(602P and 700P) 2C13
21-11-09 Installation of Flow Control Adapter/Diverter
Valve (602P and 700P) 2C13
21-11-10 Heat Exchanger 2C16
21-11-11 Removal of Heat Exchanger 2C16
21-11-12 Installation of Heat Exchanger 2C16
21-11-13 Bleed Air Check Valve 2C16
21-11-14 Removal of Bleed Air Check Valve 2C16
21-11-15 Installation of Bleed Air Check Valve 2C17
21-11-16 Dorsal Ram Air Check Valve Assembly 2C17
21-11-17 Removal of Dorsal Ram Air Check Valve Assembly 2C17
21-11-18 Installation of Dorsal Ram Air Check Valve Assembly 2C17
21-12-00 Leak Test 2C18
21-12-01 Cabin Leak Test 2C18
21-12-02 Cabin Leak Test Termination 2C23
21-13-00 Not Used 2C24
21-14-00 Not Used 2C24
21-15-00 PNEUMATIC 2C24

21-16-00 Description 2D1
21-17-00 Component Maintenance 201
21-17-01 Engine Driven Air Pump 201
21-17-02 Removal of Engine Driven Air Pump 202
21-17-03 Installation of Engine Driven Air Pump 202
21-17-04 Inspection/Check of Engine Driven Air Pump 202
21 - ContTEffec.
Page -1
2B5 issued: June 1,1995

r
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHAPTER 21 - ENVIRONMENTAL SYSTEMS (cont)
TABLE OF CONTENTS/EFFECTIVITY
CHAPTER
SECTION GRID
21-15-00 PNEUMATIC (cont)

21-17-00 Component Maintenance (cont) —
21-17-05 Pneumatic Pressure Gauge 2D2

21-17-06 Removal/Installation of Pneumatic Pressure Gauge 2D2
21-17-07 Air Pump Inlet Filter 2D9
21-17-08 Removal of Air Pump Inlet Filter 2D9
21-17-09 Installation of Air Pump Inlet Filter 2D9
21-17-10 Pressure Regulator (600/601 Only) 2D9
21-17-11 Removal of Pressure Regulator 2D9
21-17-12 Installation of Pressure Regulator 2D10
21-17-13 Control Valve (601P, 602P and 700P) 2D10
21-17-14 Removal of Control Valve 2D10
21-17-15 Installation of Control Valve 2D10
21-17-16 Pressure Regulator (700P Only) 2D10
21-17-17 Removal of Pressure Regulator 2D10
21-17-18 Installation of Pressure Regulator 2D11
21-17-19 Manifold Assembly 2D11
21-17-20 Removal of Manifold Assembly 2D11
21-17-21 Installation of Manifold Assembly 2D11
21-17-22 Inline Air Filter 2D11
21-17-23 Removal of Inline Air Filter 2D11
21-17-24 Installation of Inline Air Filter 2D12
21-17-25 Door Seal Control Valve 2012
21-17-26 Removal of Door Seal Control Valve 2D12
21-17-27 Installation of Door Seal Control Valve 2D12
21-17-28 Inflatable Door Seals 2D13
21-17-29 Removal of Inflatable Door Seals 2D13
21-17-30 Installation of Inflatable Door Seals 2D14
21-17-31 inline Pressure Regulator 2D14
21-17-32 Removal of Inline Pressure Regulator 2D14
21-17-33 Installation of Inline Pressure Regulator 2D14
21-18-00 Tests 2D14
21-18-01 Pneumatic System Test (600, 601) 2D14
21-18-02 Pneumatic System Test (601P, 602P) 2D18
21-18-03 Door Seal Pressure Switch Test 2D21
21-18-04 Manifold Assembly Test 2D22
21 - ContTEffec.
Page - 2
Issued: June 1,1995
2B6
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHAPTER
SECTION GRID
21-20-00 DISTRIBUTION 2D23

21-21-01 -Models 600 and 601 2D23
21-21-02 Models 601 P,602P and 700P 2D23
21-22-00 Ventilation Fan Blower and Plenum Box Assembly 2D24
21-22-01 Removal of Plenum Box Assembly 2D24
21-22-02 Installation of Plenum Box Assembly 2E3
21-23-00 Ducts 2E4
21-23-01 R/H Duct Assembly (Cabin) 2E4
21-23-02 . Removal of R/H Distribution Duct Assembly 2E4
21-23-03 Installation of R/H Distribution Duct Assembly 2E4
21-23-04 MH Duct Assembly (Cabin) 2E9
21-23-05 Removal of LTH Distribution Duct Assembly 2E9
21-23-06 Installation of UH Distribution Duct Assembly 2E10
21 -24-00 Radio Fan Blowe r Asse mbly 2 E10
21-30-00 PRESSURIZATION CONTROL 2E10

21-31-00 Description 2E10
21-32-00 Pressure Regulating Outflow Valve and Safety Valve
(601P, 602P. and700P) 2E14
21-32-01 Removal of Pressure Regulating Outflow Valve
and Safety Valve 2E14
21-32-02 Installation of Pressure Regulating Outflow Valve
21-32-03 Adjustment/Test of Pressure Regulating Outflow Valve
21-33-00 NLG Squat Switch) 2E16
21-33-01 Removal of NLG Squat Switch 2E17
21-33-^02 Installation of NLG Squat Switcfi ^ . •- 2E17
21-34-00 Cabin Altitude Controller 2E20
21-34-01 Removal of Cabin Altitude Controller 2E20
21-34-02 Installation of Cabin Altitude Controller 2E20
21-24-03 Resetting Procedure of Cabin Altitude Controller 2E20
21-35-00 Bleed Air, Inflatable Door Seal and Safety Valve Switches . 2E20
21-35-01 Removal of Bleed Air, Inflatable Door Seal and
: Safety Valve Switches . 2E20
21 -35-02 Installation of Bleed Air, Inflatable Door Seal and
. . Safety Valve Switches 2E22
21 - ContTEffec.
Page - 3
Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602PA700P
MAINTENANCE MANUAL
CHAPTER
SECTION GRID ' ^ .
21-40-00 HEATING 2E22

21-41-00 Description 2E22
21-41-01 Model 600 2E23
21-41-02 Model 601 2E24
21-41-03 Models 601 P,602P and 700P 2E24
21 -41 -04 Inspection of Heater and Heater Components 2F2
21-41-05 Daily Inspection 2F2
21-41-06 100 Hour Inspections 2F3
21-41-07 Overhaul Instructions 2F3
21-42-00 Heater, Blower and Plenum Assembly 2F4
21-42-01 Removal of Heater, Blower and Plenum Assembly 2F4
21-42-02 Installation of Heater, Blower and Plenum Assembly 2F9
21-42-03 Heater System Operational Check 2F9
21-42-04 Heater Plenum Assembly 2F10
21-42-05 Removal of Heater Plenum Assembly 2F10
21-42-06 Installation of Heater Plenum Assembly 2F11
21-42-07 Heater Blower Motor Assembly 2F11
21 -42-08 Removal of Heater Blower Motor Assembly 2F11
21 -42-09 Installation of Heter Blower Motor Assembly 2F12
21-42-10 Inspection of Heater Blower Motor Assembly 2F13
21-42-11 Heater Assembly 2F13
21-42-12 Removal of Heater Assembly 2F13
21-42-13 Installation of Heater Assembly 2F14
21 -42-14 Combustion Air Blower Assembly 2F14
21-42-15 Removal of Combustion Air Blower Assembly 2F14
21-42-16 . Installation of Combustion Air Blower Assembly 2F14
21-42-17 Inspection/Check of Combustion Air Blower Assembly 2F17
21-42-18 Heater System Relays 2F17
21-42-19 Removal of Heater System Relays 2F17
21-42-20 Installation of Heater System Relays 2F19
21-42-21 Sparkplugs 2F19
21-42-22 Removal of Spark Plug 2F19
21-42-23 Installation of Spark Plug 2F19
21 -42-24 Adjustment/Test of Spark Plug 2F20
21-42-25 Cleaning Spark Plug 2F23
21-42-26 Fuel Feed, Nozzle Holder and Valve Assembly 2F23
21-42-27 Removal of Fuel Feed, Nozzle Holder and
Valve Assembly 2F24
21-42-28 Installation of Fuel Feed, Nozzle Holder and
Valve Assembly 2F24
21 - ContyEffec.
Page - 4
Issued: June 1,1995 2B8
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHAPTER
GRID
SECTION.
SUBJECT NO. EFFECTIVITY
SUBJECT'^
21-42-00 HEATING (cont.)

21-42-00 Heater, Blower and Plenum Assembly (cont.)
2F24
21-42-29 Blower Delay Switch
21-42-30 Removal of Blower Delay Switch 2G1
21 -42-31 Installation of Blower Delay Switch 2G1
21-42-32 Cycling Switch and Limit (Overheat) Switch 2G1
21-42-33 - Removal of Cycling Switch and Limit
(Overheat) Switch 2G1
21 -42-34 Installation of Cycling Switch and Limit
(Overheat) Switch 2G2
21-42-35 Combustion Air Pressure Switch 2G2
21-42-36 Removal of Combustion Air Pressure Switch 2G2
21-42-37 installation of Combustion Air Pressure Switch 2G2
2G2
21-42-38 Ignition Assembly
21-42-39 Removal of Ignition Assembly 2G2
21-42-40 Installation of Ignition Assembly 2G3
•21-42-41 Cabin Heat Duct Switch 2G3
21-42-42 Removal of Cabin Heat Duct Switch 2G3
21 -42-43 Installation of Cabin Heat Duct Switch 2G5
21-43-00 Heater System Fuel Pump 2G5
21-43-01 Removal of Heater System Fuel Pump 2G5
21-43-02 Fuel Pump Disassembly 2G8
21-43-03 Fuel Pump Assembly 2G8
21-43-04 Fuel Pump Installation 2G8
21-43-05 Fuel Pump Inspection Check 2G9
21-43-06 Fuel Pump Parts Cleaning 2G9
21 -44-00 Fuel Regulator and Shutoff Valve 2G9
21 -44-01 Removal of Fuel Regulator and Shutoff Valve 2G9
21-44-02 Installation of Fuel Regulator and Shutoff Valve 2G10
21-44-03 Adjustment/Test of Fuel Regulator and Shutoff Valve 2G10
21 -45-00 Windshield Defrost Blower Assembly 2G11
21-45-01 Removal of Windshield Defrost Blower Assembly 2G11
21-45-02 Installation of Windshield Defrost
Blower Assembly 2G13
21 - ContTEffec.
Page - 5
issued: June 1,1995
2B9
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHAPTER
SECTION
GRID
SUBJECT SUBJECT NO.
21-50-00 COOLING
2G14
21-51-00 Air Conditioning System, Description and Operation 2G14
21-52-00 Safety Precautions 2G14
21-53-00 Servicing/Testing 2G20
21-53-01 Special Sen/icing Procedures 2G20
21-53-02 Evacuation and Charging Procedures 2G21
21-53-03 Material Requirements 2G21
21-53-04 Connecting the Manifold and Hose 2G22
21-53-05 Checl<ing the System for Leaks 2G24
21-53-06 Initial Charging of the System 2G24
21-53-07 Adding Refrigerant to a System with a Low Charge 2H3
21-53-08 Charging the System with a Charging Stand 2H3
21-53-09 Performance Testing the System 2H4
21-53-10 Discharging the System 2H5
21-53-11 Flushing a Contaminated System 2H6
21-54-00 Compressor, Motor and Condenser Assemblies 2H7
21-54-01 Removal of Assemblies 2H7
21-54-02 Installation of Assemblies 2H7
21-54-03 Compressor Removal 2H8
21-54-04 Compressor Removal Leaving System Charged
(Vorlt Compressor) 2H8
21-54-05 Compressor Removal with System Discharged
(York or Sankyo Compressor) 2H8
21-54-06 Compressor Installation 2H9
21-54-07 Cleaning, Inspection and Repair 2H10
21-54-08 Checking Compressor Oil Level (York Compressor) 2H10
21-54-09 Checking Compressor Oil Level (Sankyo Compressor) 2H11
21-54-10 Replacement of Drive Belts
2H14
21 - ContTEffec.
Page - 6
Issued: June 1,1995
2B10
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHAPTER
SECTION GRID
21-50-00 COOLING (cont.) —

21-54-00 Compressor, Motor and Condenser Assemblies (cont.) —
21-54-11 - Magnetic Clutch (York Compressor) 2H15
21-54-12 Magnetic Clutch Removal (York Compressor) 2H15
21-54-13 Magnetic Clutch Installation (York Compressor) 2H15
21-54-14 Magnetic Clutch, Pulley and Coil (Sankyo Compressor) 2H17
21-54-15 Removal of Magnetic Clutch, Pulley, and Coil
(Sankyo Compressor) - 2H17
21-54-16 Installation of Magnetic Clutch, Pulley and Coil
(Sankyo Compressor) 2H17
21 - ContTEffec.
Page - 7
2B11 Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
GENERAL.
The environmental system will provide ventilation, heating, windshield defrost and cooling to the cabin
interior inflight and on the ground; additionally, the radio stack mounted in the instrument panel is fitted with a
blower fan. System configuration is affected by airframe effectivity and by optional equipment installation.
On Model 601P, 602P and 700P the turbocharger and pneumatic systems are interfaced with the pressur-
ization system. The standard pressurization system provides for a maximum differential pressure of 4.25 psi. Aircraft
equipped with Option 262 (5.5 PSID Pressurization System) have a maximum differential pressure of 5.5 psi.
DESCRIPTION. i
1. Refer to Figure 21-1, for schematics of the environmental systems functional interface.
TROUBLESHOOTING.
Troubles peculiar to the environmental system along with probable causes and suggested remedies are
listed in the Troubleshooting Charts 2101 through 2105.
CHART 2101. TROUBLESHOOTING (PRESSURIZATION)
Trouble Cause Remedy
Cabin fails to pressurize Defective pressure dump Replace switch.

or only partial pressuriz- switch. Stuck at "DUMP."
ation occurs.
Open or defective circuit Close or replace circuit breaker.
breaker.
Defective NLG squat switch. Replace switch.
Sticking squat switch actu- Repair/replace pin.

ator pin.
Safety valve solenoid in- Replace solenoid.

operative.
Defective dorsal air inlet Replace valve.

check valve. .
Ruptured diaphragm in Repair/replace valve.

pressure regulating (out-
flow) valve.
Ruptured diaphragm in Repair/replace valve.

safety valve.
Door seals not properly Check pneumatic system

inflated. pressurization.
Wiring to safety dump valve Repair/replace wiring.

faulty.
21-02-00
Page 21-01
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHART 2101. TROUBLESHOOTING (PRESSURIZATION) (cont)
Trouble Cause Remedy.
Cabin fails to pressurize or only Leak(s) in bleed air system Visually inspect system-for
partial pressurization occurs. including ducting aft of leaks. Repair leak(s).
. (cont) F.S. 240.00
Internal poppet valve in Set controller to 10,000 feet

controller stuck or opening cabin altitude; blow air through
plugged. cabin pressure sensing port and
note that air does not flow out of
port going to outflow valve, if it
does, replace controller.
Cabin pressure goes to Diaphragm in outflow valve Inspect and clean valve. Check
max differential pressure not seating properly due that diaphragm seats properly.
or pressure higher than to excess dirt build-up.
selected regardless of
controller position. Leak in pneumatic system Check pneumatic system
plumbing. pressurization.
Adjustable bleed valve Remove obstructions from line.

and/or line plugged.
(Line from outflow valve
to static port at F.S.
204.00.)
Failure of internal bellows Set controller to sea level; blow

in controller. through cabin sensing port. If air
does not emit from port going to
outflow valve, replace
controller;
Insufficient or no bleed Defective left and/or Replace defective switch.

air. right bleed air switch
on pilot's console.
Bleed valve stuck in Verify proper operation per

•
closed position. instructions in this chapter.
Replace valve, if defective.
Bleed valve stuck in Check for obstructions. Replace

partially open position. valve, if defective.
Turbocharger problems. Refer to Chapter 81.
21-02-00
Page 21-02
Issued: June 1,1995
2B13
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
~ Trouble - Cause • Remedy
Cabin pressure sensitive-to Power reduced below that Refer to chart in airplane flight
throttle movement.' required to maintain selected manual.
altitude. ,
When throttles are retarded, Indicates a leak in the cabin. Locate and repair.
cabin pressure decreases.
When throttles are retarded, Defective outflow valve. Replace.

cabin pressure increases.
Rapid fluctuation of cabin

altitude. . . .
a. @ 1.2 diff. press. Normal.
b. @ .8 to 1.5 diff. press, Check valve at base of dorsal fin Normal; decrease rate of descent
in rapid high speed descent. being forced open by ram air airspeed.
pressure exceeding bleed air
system pressure.
c. Diff. press, other than maximum Cabin controller defective. Replace.
Cabin controller poppet valve or Clean poppet valve, replace

cigarette filter dirty. cigarette filter.
d. @ maximum differential pressure. Outflow valve. On new or lowtime airplane

replace outflow valve. On high-
time airplane clean outflow
valve diaphragm and replace
cigarette filter.
Cabin fails to pressurize on take- "Normal/Dump" switch in Reposition to "Normal" mode.

off. "Dump" mode.
•
Nose Landing Gear squat switch Adjust squat switch.
not being activated on rotation.
Wiring to safety dump valve Repair wiring.

faulty.
Cabin climbs past max. Sense line from controller to Locate and repair.
differential pressure and safety outflow valve leaking.
dump valve starts to regulate
(Indicated by differential
pressure gauge being over 4.35
psi or 5.60 psi on aircraft equipped
with Option 262)
21-02-00
Page 21-03
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
Cabin will not pressurize to Door seals not properly inflated. Inspect door seals and perform
max. differential pressure. required repairs.
Check valve at base of dorsal fin

intake duct blocked partially
Repair or replace check valve.
open.
Oxygen bottle supply line hitting

aft side of outflow valve.
Reposition.
Spring on aft side of dump valve Readjust (should be screwed

screwed in too far. down five tums from start to
first thread engagement.)
Cabin controller stops rotating Broken wire in electrical circuit Locate and repair break.
before indices are lined up. to controller.
Broken wire in controller. Replace controller.
Outer select ring on face of Adjust select ring.

controller binding.
Select shaft bent. Replace controller.
Excessive cabin dive on a. New or lowtime aircraft out- a. Replace.

application of full power for flow valve bad.
takeoff. b. Older aircraft - outflow valve b. Clean diaphragm.
diaphragm sticking.
Excessive cabin dive on rotation Safety dump valve spring (aft Readjust spring (spring should
of aircraft during takeoff. side of valve) not adjusted be screwed down five turns from
properly. start to first thread engagement.)
No cabin dive on rotation. "Normal/Dump" switch in Place switch in "Normal" mode.

"Dump" mode.
Safety dump valve not closing Replace squat switch.

due to defective nose landing
gear squat switch.
21-02-00
Page 21-04
Issued: June 1,1995
2B15
AEROSTAR AIRCRAFT
600/601/60.1 P/602P/700P
MAINTENANCE MANUAL
-Trouble Cause Remedy
Cabin vertical speed indicator Static setting cabin vertical Zero instrument on ground.
always shows rate of climb or speed indicator not correct.
rate of descent even in nomnal
cruise flight with cabin-altitude Isobaric valve requires Normal adjusting range - one
at or near selected altitude. adjustment. turn open from full closed, then
tum either way to maximum
allowable adjustment.
Cabin goes to maximum Sense line between controller Reconnect line.

differential pressure immediate- and outflow valve disconnected.
ly after takeoff.
Isobaric valve left closed.
Cabin selected altitude vs. actual Indicating disc has slipped on Adjust disc.
cabin altitude differs by more , shaft.
than 500 ft.
21-02-00
Page 21-05
2^*10 Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHART 2102. TROUBLESHOOTING (PNEUMATIC SYSTEM) .
Inflatable door seal(s) Open or defective circuit Close or replace circuit breaker.
fail to inflate - door breaker ("Seal Press").
seal pressure switch
does not indicate • Defective door seal switch. Replace switch.
"INFLATED" (Single or
dual pump operation). Cabin pressure safety Ensure emergency exit door
switch (emergency exit) secured and switch contact
not actuated or defective. made. Replace if defective.
Disconnected or broken Inspect and replace faulty

wiring between circuit wiring. — ; ,r
breaker door seal press-
ure switch, safety switch,
door seal control valve,
and pressure regulating
valve.
Inflatable door seal(s) Door seal valve inopera- Replace valve.

fail to inflate - door tive. (Check for click-
seal pressure switch ing sound when valve
indicates "INFLATED" energized).
(Single or dual pump
operation). Defective air pump. Replace pump.
Air pump inlet filter Replace filter(s).

or in-line filter
clogged.
Bad connection between Inspect and repair.

pressure switch and
pressure regulating
valve.
Defective pressure switch. Perform checkout, replace if

defective.
Defective pressure regu- Replace valve.

lating valve (solenoid not
operating).
21-02-00
Page 21-06
Issued: June 1,1995
2B17
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHART 2103. TROUBLESHOOTING (GYRO PRESSURE SYSTEM)
. . -Trouble Cause Remedy
Gyro pressure gauge shows Defective air pump. Check pump for operation by
little or nopressure, • pulling propeller through and
with red indicators in observing shaft for rotation.
view. Replace if defective.
Air pump inlet filter Replace filter(s).
or in-line filter
clogged.
Both indicators in Pneumatic air distribution Repair/replace manifold.

pressure gauge disappear manifold @ F.S.
from view when starting 176.88 defective.
only one engine.
21-02-00
Page 21-07
2Q 'I g Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHART 2104. TROUBLESHOOTING (HEATER)
Heater fails to light. Master switch or circuit Turn on master switch, or.
breal<er off. close circuit breaker.
Defective spark plug. Inspect spark plug and re-

place if necessary.
Fan switch or circuit Turn on fan switch or close

breaker off, or defective. circuit breaker. Replace if
defective.
Low voltage supply. Apply APU. Attempt to start

heater. (Refer to Heater Sys-
tem Operational Check.)
Suction leak ahead of Secure all fittings.

pump.
Insufficient fuel pressure. Low or no current to heater

fuel pump. Check for oper-
ation of pump and remove for
repairs if not operating.
Regulator not operating Check for low pressure or

properly. replace regulator. When
making fuel pressure check,
be sure fuel is flowing through
nozzle. Tum adjusting screw
clockwise to increase fuel pres-
sure and counterclockwise
to decrease.
Fuel pump operating but Remove and repair or re-

not building up sufficient place fuel pump.
pressure.
Restriction in fuel nozzle Remove the nozzle and clean

orifice. or replace it.
Fuel heater solenoid not Remove and check solenoid.

operating. Replace if faulty.
Fuel lines clogged or Inspect all lines and connec-

broken. tions. It may be necessary
to disconnect lines at various
points to determine where the
restriction is located.
21-02-00
Page 21-08
Issued: June 1,1995
2B19
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHART 2104. TROUBLESHOOTING (HEATER) (cont)
,. Trouble Cause Remedy
Heater fails to light, (cont) Fuel filter clogged (pump). Clean fuel filter element.
Check for ice in fuel system.
Ignition vibrator in- Replace vibrator; check for

operative. defective radio noise filter.
Manual reset limit (over- Press reset button firmly and

heat) switch open. recheck to determine reason
for switch opening.
Combustion air pressure Check for low blower output

switch open. (Defective due to low voltage and correct
switch or low combustion it. If switch is defective re-
air blower output.) place it.
Cycling switch open. Replace if defective.
Duct switch open. Operate control to see if switch

will come on. Replace switch if
defective.
Ventilating air blower fails Fan switch OFF, or de- Energize the fan switch or
to run. fective. Broken or loose replace if defective. Check
wiring to motor. and repair wiring.
Circuit breaker open or Close or replace faulty

defective. circuit breaker.
Worn motor brushes. Replace motor brushes.
Blower wheel jammed. Remove and check the

ventilating air blower wheel
and realign if necessary.
Motor burned out. Remove blower assembly

and replace motor.
Defective radio-noise filter. Replace filter.
Landing gear switch de- Check switch. Replace or

fective or misrigged. readjust per Chapter 32, if
required.
Relay defective. Check and replace if

necessary.
21-02-00
Page 21-09
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHART 2104. TROUBLESHOOTING (HEATER) (cont)
Combustion air blower fails Faulty wiring to motor. Inspect and replace faulty
to run. wiring.
Poor ground connection. Tighten ground screw. Be

sure any metal preservative
has been removed for good
ground connection.
Worn motor bmshes. Replace motor brushes.
Blower wheel jammed. (Us- Overhaul combustion air

ually indicated by hot blower.
motor housing.)
Defective radio-noise filter. Replace filter.
Faulty or burned-out Remove combustion air

motor. motor for overhaul or re-
placement of motor.
Relay defective. Check and replace if necessary.
Heater fires but burns Insufficient fuel supply. Ice Inspect fuel supply to heater
unsteadily. or water in system fuel including shutoff valve, sole-
lines. noid valve, fuel pump, fuel
filter and fuel lines. Make
necessary repairs.
Spark plug partially fouled. Replace spark plug.
— CAUTION —
Do not create spark gap by

holding lead to heater jacket.
This can result in damage to
lead and ignition unit and
operator may receive an elec-
trical shock.
Loose primary connection at Tighten connection.

ignition assembly.
Faulty vibrator. Replace vibrator.
21-02-00
Page 21-10
Issued: June 1,1995
2B21
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
y CHART 2104. TROUBLESHOOTING (HEATER) (cont)
Trouble . Cause Remedy
Heater fires but burns Combustion air blower speed Remove and overhaul the
unsteadily, (cont) fluctuates. (Can be caused by combustion air blower as-
low voltage, loose blower sembly as required or correct
wheel, worn brushes or low voltage condition.
motor.)
High-voltage leak in lead Replace ignition assembly.

between ignition assembly
and spark plug.
Inoperative ignition as- If vibrator is in good condi-

sembly. tion, replace ignition as-
sembly only.
Restriction in fuel nozzle Remove nozzle for cleaning

orifice. or replacement.
Nozzle loose in retainer or Tighten or replace the nozzle

improper spray angle. as required.
Heater starts then goes out. Lack of fuel to heater. Check fuel supply through
all components from the tank
to the heater. Make necessary
corrections.
Inoperative or chattering Check, adjust or replace

combustion air pressure switch.
switch.
Inoperative overheat switch. Check or replace switch.
Inoperative cycling switch. Adjust or replace switch.
Low voltage. . Attach APU.
Heater fails to shut off. Fuel solenoid valve in Remove and replace sole-
heater stuck open. noid assembly.
Inoperative duct and Check and repair

cycling switch.
Defective "Master" switch. Replace "Master" switch.
21-02-00
Page 21-11
Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHART 2105. TROUBLESHOOTING (AIR CONDITIONING SYSTEM)
Insufficient or no cooling. Inoperative evaporator blower. Check wiring, circuit breaker,

repair or replace blower.
Complete loss of Freon charge. Evacuate system. Recharge

system and check for leaks.
Partial loss of Freon charge Recharge system and check for

(continual foam in sight glass leaks.
after turning system on).
Low side gauge reads high, high Compressor malfunction. Head Replace compressor
side gauge reads low. gasket failure or valves not
seating.
Low side gauge reads high, high Condenser malfunction. Check fan circuit to verify
side gauge reads high. Condenser fan malfunction. correct functioning.
Condenser blocked. Blow out or replace condenser.
Expansion valve malfunction. Purge system, replace valve,

evacuate and recharge.
Low side gauge reads low, high Expansion valve malfunction. Purge system, replace valve,
side gauge reads low. evacuate and recharge.
Service valves improperly set

(should be maximum
counterclockwise.)
Insufficient or no cooling. Compressor belts broken. Replace belts. (Tension to 30

(Gauges read pressure as pounds.)
nomnal.)
Expansion valve inoperative, Replace expansion valve.

stays open or closed.
fvioisture or air in system. Evacuate system and re-charge

(per charging procedure).
Inoperative compressor motor. Inspect wiring, circuit breakers.

Repair or replace compressor
motor.
21-02-00
Page 21-12
Issued: June 1,1995
2B23
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHART 2105: TROUBLESHOOTING (AIR CONDITIONING SYSTEM) (cont)
Noisy compressor. Loose, torn or misaligned belt. Align or replace belt.
Foreign material or damaged Remove and replace

port in compressor. compressor.
Compressor loose on bracket. Tighten compressor.
Noisy fan. Fan striking housing. Align fan travel.
Fan shaft bearings out. Replace bearings.
21-02-00
Page 21-13

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
2903
F.S. • F.S.
54.25 . .204.00
PASSENGER COMPARTMENT
(PRESSURIZED) BLEED AIR FROM
RIGHT E N G I N E -
ll-
16
DEF BLWR. SW. 23 \
DEFROST 20- 3
HEATER TEMP.
i—r~>
© © • ^11
21
©
19. 22
J
•2
1 = ^
10 11
R A M AIR - — OVERBOARD
12
WING
,-15
14-
ENGINE NACELLE INSTR. PANEL

AIR FROM TIJRBO
TO ENG.
r— MANIFOLD
NOTE
THIS ILLUSTRATION CONTINUED ON
V ENG. AIR
FOLLOWING PAGE. AIR FROM TURBO - ^ I ^ ,3 DIST BOX
Figure 21-1. Environmental Systems Schematic

(Model 601P A/F 0456 and up)
21-02-00
Page 21-14
Issued: June 1,1995
2C1
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
2903
LEGEND
FLEXIBLE DUCT -I >- FIXED AIR VENTS
« CONTROL CABLE (PUSH-PULL) ® DIRECTIONAL AIR VENTS
ELECmiCAL ACUIATION ^
TOGGLE SIVITCH
[jg ROCKER-SWITCH
CiD PUSH ON - PUSH OFF SWITCH
NOTE:
SCHEMATIC SHOWN IN PRESSURIZED NODE
WITH HEATER AND DEFROST TURNED ON.
HEATBLWR.
SWITCH
] HEAT SW.
INSTR. PANEL
1 HEATER 15 AIR FILTER

2 HEAT. BLWR 14 BLEED AIR VALVE
3 HEATER TEMP CONTROL RELAY 15 SONIC NOZZLE
4 DEFROST BDVR 16 HEATER DUCTING
5 DEFR. BUTTERFLY VALVE 17 CHECK VALVE (FLAPPER)
6 DEFROST DUCTS 18 DORS.U AIR SCOOP
7 RIGHT HOT AIR DIST. DUCT 19 AIR PLENUM
8 VENT. AIR DIST. SYSTEM 20 PLENUM STATIC AIR DOOR
9 PILOT HOT AIR OUTLET 21 CABIN VENTILATION FAN
10 LEFT HOT AIR DIST. DUCT 22 CABIN PRESSURE REGULATOR
11 CHECK VALVE ASSY (FLAPPER) VALVE
12 HEAT EXCHANGER 23 CABIN PRESSURE SAFETY
VALVE
Figure 21-1. Environmentai Systems Schematic (cont)

(IVIodel 601P A/F 0456 and up)
21-02-00
Page 21-15
2C2 issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
2902
F.S.
204'. 00
.P.ASSENGER COPARTMENT
(PRESSURIZED) BLEED AIR FROM
RIGHT E N G . - ^
±
I 11-
4h
1 16
DEF. BLl\fR. Slv.:
DEFROST
HEATER TEMP. 21
MR ( A / F 01S7
thru
0212)1
©
N
20
7-
10
RAM AIR- • O\T:RBO.ARD
13 i:i 12
iVIN'G
15
14 ^ Jfl
ENGINE NACELLE l.NSTR. P.A.VEL

AIR FROM TURBO
'^-Z^ TO E \ G .
- MANIFOLD
NOTE ENG. AIR
THIS ILLUSTRATION C O N T I N U E D O N AIR FROM TURBO- DISTO. BO.K
FOLLOWING PAGE. 19
Figure 21-1. Environmental Systems Schematic (cont)

(Model 601P A/F 0157-0455)
21-02-00
Page 21-16
Issued: June 1,1995
2C3
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
2902
LEGEND
FLEXIBLE DUCT FIXED AIR VENTS
^ CONTROL CABLE (PUSH-PULL) ® DIRECTIONAL AIR VENTS
ELECTRICAL ACTUATION
|T| CHECK VALVE
[|^ TOGaE SWITCH
[}g ROCKER SIVITCH
PUSH ON - PUSH OFF SWITCH
NOTE:
SCHEMATIC SHOWN IN PRESSURIZED MODE
Wim HEATER AND DEFROST TURNED ON.
HEAT BLWR
SWITCH
H HEAT SW.
LNSTR. PA.N'EL
1 HEATER 12 HEAT EXCHANGER

2 HEAT. BLIVR 13 BUTTERFLY VALVE ASSY
3 HEATER TEMP CONTROL RELAY (A/C 0157 thru 0212 only)
4 DEFROST BDVR 14 BLEED AIR VALVE
5 DEFR. BUTTERFLY VALVE 15 SONIC NOZZLE
6 DEFROST DUCTS 16 BLEED AIR DUCTING
7 RIGHT HOT AIR DIST. DUCT 17 CHECK VALVE (FLAPPER)
8 VENT. AIR-DIST. SYSTEM 18 DORS.AL AIR SCOOP
9 PILOT HOT AIR DUCT 19 AIR FILTER
10 LEFT HOT AIR DIST. DUCT 20 CABIN PRESSURE REGULATOR
11 CHECK VALVE ASSY (FLAPPER) VALVE
21 CABIN PRESSURE SAFETY
VALVE

(Model 601P A/F 0157-0455)
21-02-00
Page 21-17
2C4 Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
2901
10 11
1. .-MR INLET 11. HEATER FAIL LIGHT

i.. AIR VENT COOTROL KNOB 12. AIRPLANE FUEL TANK
5. CABIN DIRECTIONAL AIR VENT (TYP.) FUEL SUPPLY
4. BLOIVEI^ MOTOR (OPTIONAL) 13. SUMP
5. DOOR (OPTIONAL WITH 14. FUEL REGULATOR AND

BLOIVER MOTOR) SHUTOFF VALVE
6. HEATER ASSEMBLY 15. FUEL PUMP
7. IGNITION ASSBIBLY 16. DUCT SWITCH CONTROL KN'OR

8. CABIN HEAT SIVITCH 17. DEFROST BLOWER MOTOR
9. CABIN FAN SIVITCH 18. DEFROST CONTROL KNOB
10. C/B MANUAL RESET 19. DEFROST OUTLET MANIFOLD
20. VERTICAL STABILIZER INTAKE

(Model 600/601, A/F No. 0456 and up)
21-02-00
Page 21-18
Issued: June 1,1995
2C5
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
2900
PH tEATER AIR
• FUEL PRESSURE
1. AIR IN'LEF 11. SUMP

2. AIR VENT CCWROL KNOB 12. FUEL REGULATOR ANT) SHUTOFF VALW
5. Q/VBIN D I R E C r i a m AIR VENT 13. FUEL PUMP
4. liEATER ASSEMBLY 14. AIR CO.NTROL KNOB
5. IGNITION ASSBIBLY 15. DUCT SWITQl CONTROL KN'OB
6. CABIN lEAT "SWITCH 16. DEFROST BLOWER NKJTOR
7. CABIN FAN SWITCH 17. DEFROST CONTROL KNOB
8. C/B MANUAL RESET (A/F 0356 and UP) 18. DEFROST CWTLET MANIFOLD
9. HEATER FAIL LIGIfT (A/F 0356 AND UP) 19. VERTICAL STABILIZER INTAKE
10. AIRPLANE FUEL TANK FUEL SUPPLY

(Model 600/601, A/F No. 0001 thru 0455)
21-02-00
Page 21-19
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
C530
F.S. F.S.
54.25 204.00
.PASSEVGER COMPARBENT
CPRESSURIZED) . BLEED AIR FROM
RIOfT E \ G . -
ENGINE NACELLE
-15
AIR FROM TURBO
TO ENG..
NOTE MANIFOLD
THIS ILLUSTRATION CONTINUED O N
, f \ _ ENG. AIR
FOLLOWING PAGE.
AIR FROM TURBO ^12, I5ISTR. BOX
Figure 21-1. Environmental Systems Schematic (cont) f

(Model 602P and 700P) V
21-02-00
Page 21-20
Issued: June 1,19SC 2C7
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
C531
LEGEND
FLEXIBLE DUCT FIXED AIR VENTS
t = = * CONTOOL CABLE (PUSH-PULL) ® DIRECn-IONAL AIR VENT^
ELECTRICAL ACTUATION
i)^ TOGGLE SWITCH W CHECK VALVE
(jg ROCKER SWITCH
i PUSH ON - PUSH OFF SWITCH
18
NOTE:
SQIENUTIC SHOWN IN PRESSURIZED ^DDE
RAM A I R -
WITH HEATER AND DEFROST TURNED O N .
HEAT Bim
SWITQl
{]HEAT SW.
INSTR. PANEL
HEATER 13 AIR FILTER

HEAT. BLWR 14 DIVERTER VALVE
HEATER TEMP CONTROL RELAY 15 SONIC NOZZLE '
DEFROST BLWR 16 HEATER DUCTING
DEFR. BUTTERFLY VALVE 17 CHECK VALVE (FLAPPER)
DEFROST DUCTS 18 DORSAL AIR SCOOP
RIGHT HOT AIR DIST. DUCT 19 AIR PLENUM
8 VENT. AIR DIST. SYSTEM
20 PLENUM STATIC AIR DOOR
9 PILOT HOT AIR OUTLET
10 LEFT HOT AIR DIST. DUCT 21 CABIN VENTILATION FAN
11 CHECK VALVE ASSY (FLAPPER) 22 CABIN PRESSURE REGULATOR
12 HEAT EXCHANGER VALVE
23 CABIN PRESSURE SAFETY
VALVE

(Model 602P and 700P)
21-02-00
Page 21-21
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
PRECAUTIONS.
1. Maintenance personnel should thoroughly familiarize themselves with the airplane's environmen-
tal system prior to performing any checks, tests, or repairs on the system/components.
2. Ensure that all safety precautions by airframe/product manufacturer are adhered to when per-
forming checks, tests, or maintenance on the environmental system.
3. An Auxiliary Power Unit (APU) is recommended when electrical power is required. Ensure all
switches and equipment are turned OFF and all autopilot circuit breakers are pulled prior to con-
necting an Auxiliary Power Unit. The Master Battery and alternator switches must be left in the
OFF position until the Auxiliary Power Unit is disconnected to protect the voltage regulators and
system electrical equipment from voltage transients and possible damage.
4. Before disconnecting any electrical/electronic component, ensure electrical power is OFF.
5. Protect all disconnected ports, hoses, lines, tubing and leads as appropriate. Ensure all such
items are free from obstaiction/damage prior to connecting.
PRESSURIZATION. (Refer to Figure 21-1.)
The pressurization system on Model 601P, 602P and 700P will maintain an approximate 11,000 foot
cabin altitude when airplane altitude is 25,000 feet. The cabin pressure-vessel may be pressurized to a maximum
operating differential pressure of 4.25 pounds per square inch (psi) greater than atmosphere pressure. Aircraft
equipped with Option 262 (5.5 PSID Pressurization System) have a maximum operating differential pressure of
5.50 psi. These aircarft can maintain an approximate 8,000 foot cabin altitude when airplane altitude is 25,000
feet.
The bleed air from each engine's induction airbox provides a continuous supply of air for pressurization.
The exhaust driven turbocharger on each engine supplies sufficient air to the induction airboxes to be bled off for
cabin pressurization and ventilation requirements. The bleed air coming into the cabin will develop pressurization
by regulating its air flow from the pressure-vessel on the aft cabin bulkhead (fuselage station 204.00).
The pneumatic system provides a source of dry air to inflate the rubber seals around the cabin door and
emergency exit window to aid in sealing the pressure-vessel during pressurized flight.
COMPONENT MAINTENANCE.
FLOW CONTROL ASSEMBLY (601P). (Refer to Figure 21-2.)
A flow control assembly is located in the wing leading edge at the inboard side of each engine nacelle.
Each assembly consists of an electrically operated two position shut-off valve (bleed air valve) with a mount plate
assembly attached to one end and a sonic nozzle at the other. The mating flanges of the components are sealed
at the factory with sealant to prevent bleed air loss.
The components are non-repairable but a damaged component or malfunctioning shut off valve may be
individually replaced using RTV #102 sealant to reseal at mating flanges.
— NOTE —
Procedures for removal and installation of either left or right flow
control assembles are similar. Reference to left or right assembiy will
only be made when necessary to identify peculiarities.
21-11-01
Page 21-22
Issued: June 1,1995
2C9
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B380
C532
1. ENGINE AIR DISTRIBUTION BOX

2. DUCT
3. SONIC NOZZLE
4. FLEXIBLE DUCT
5. FLOW CONTROL
6. DIVERTER VALVE
7. OVERBOARD VENT
8. HEAT EXCHANGER
9. BLEED AIR CHECK VALVE
10. BOLT, WASHER, NUT (4 PLACES)
11. CLAMP
12. BOLT, WASHER (4 PLACES)
13. RELIEF VALVE
14. ACCESS DOOR
* SEAL MATING FLANGE WITH

PR820 SEALANT TO ABSOLUTE LEVEL
FAY SEAL WITH PR820

SEALANT TO ABSOLUTE LEVEL
Figure 21-2. Flow Control Assembly (601P)

21-11-01
Page 21-23
I
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
REMOVAL OF FLOW CONTROL ASSEMBLY (601P).
1. Remove power from airplane/master battery switcfi at "OFF" and open'circuit brealcer on instru-
ment panel for flow control assembly to be removed, "LEFT ENGINE BLEED AND CONTROL"
or "RIGHT ENGINE BLEED AND DUMP."
2. Remove upper hialf of engine cowling for left engine and lower fialf of engine cowling for rigfit
engine to gain access to flexible fiose connected to intal<e end of flow control assembly protrud-
ing tfirougli engine nacelle. Disconnect fiose from assembly duct.
3. Remove access panel on lower leading edge of wing between engine nacelle and fuselage.
4. Disconnect bleed air valve electrical connector and install dust caps.
5. Disconnect flexible tubing from sonic nozzle.
6. Remove fiardware securing flow control assembly to engine nacelle.
7. Remove assembly and fiardware from wing area.
8. Install dust protectors on open end of ducting in wing and engine nacelle.
— NOTE —
Remove only hardware necessary to facilitate removal of item to be
replaced. The replacement of the bleed valve assembly will require removal
of both the sonic nozzle and mount plate assembly.
9. Remove fiardware securing defective component(s). Carefully separate defective component(s)

from components to be retained for reinstallation using care hot to damage flanges.
10. Remove sealant from flange(s) of retained components.
INSTALLATION OF FLOW CONTROL ASSEMBLY (601P).
1. Thoroughly clean flanges of components to be mated and apply RTV 102 sealant evenly to mat-
ing surfaces.
— NOTE —
If mount plate assembly is being attached to the bleed air valve, the
longest portion of the plate must be positioned 90° from the bleed valve
control box with plate assembly tube angle pointed to the ground when
installed in the airplane. The bleed valve control will be installed in the air-
plane with the control box positioned toward the leading edge.
Ensure components are positioned correctly, as noted above, before seal-
ing and installing component attaching hardware to prevent having to
reposition and reseal components.
2. Attach flanges of components being mated using retained hardware.

3. Remove excess sealant from around mating flanges and allow to cure.
4. Ensure there are no foreign materials in openings of flow control assembly, then place assembly
in wing correctly positioned against engine nacelle, as mentioned earlier, and secure to nacelle
using retained hardware.
21-11-03
Page 21-24
Issued: June 1,1995 2C11

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
5. Remove dust protector from flexible tube inside wing and connect to the sonic nozzle.
6. Remove dust caps from bleed air valve electrical connectors and check for foreign materials.
- Connect valve and airplane connectors.
— CAUTION —
Because of variations in the internal wiring of earlier model shut-off valves,
when the bleed air valve is replaced, the "Bleed Air Valve/Switch" test pro-
cedure must be performed.
7. Perform "Bleed Air Valve/Switch" test per instructions contained'in Adjustment/Test of Flow
Control and Bleed Air Valve/Switch.
ADJUSTMENT/TEST OF FLOW CONTROL AND BLEED AIR VALVE/SWITCH ASSEMBLY (601P).
1. Test bleed air valve switch for operation.

2. If left valve is to be tested, remove upper half of left engine cowling. For right valve, remove lower
half of right engine cowling.
3. Disconnect lead air hose between airbox (on firewall) and flow control assembly duct on inboard
side of nacelle.
4. Apply power to airplane and ensure circuit breaker, for bleed air valve being tested, is closed.
5. Using a flashlight and mirror, determine position of butterfly inside bleed air valve looking through
tube opening in engine nacelle.
6. Observe when corresponding bleed air valve switch on pilot's console is positioned at "AIR
OFF", butterfly inside the valve is closed, and with switch positioned at "AIR ON" butterfly valve
is open.
— NOTE —
If switch indications are reversed, reworic of the airplane electrical harness
connector at the bleed air valve is required per Step No.'s 7 through 11. If
indications are okay proceed to Step 12.
7. Pull applicable bleed valve circuit breaker and remove power from airplane.
8. Remove access panel on lower leading edge of wing between engine nacelle and fuselage.
9. . Disconnect bleed air valve and airplane electrical connectors inside wing.
10. Exchange wires connected to pins "A" and "E" in airplane electrical hamess and reconnect elec-
trical connectors.
11. - Repeat Step No.'s 4 through 6 above to ensure valve and indications in switch correspond.
12. Remove power from airplane/master battery switch "OFF".
13. Reconnect bleed air hose between airbox and fitting on inboard side of nacelle so hose clears
exhaust tube by at least .50 inch. Ensure air hose fits over fitting squarely against nacelle then
tighten clamp. ' ,
14... Install upper half of engine cowling and access panel on underside of wing.
21-11-04
Page 21-25

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
FLOW CONTROL ASSEMBLY (602P AND 700P). (Refer to Figure 21-2.)
Tfie flow control assembly consists of a sonic nozzle mounted to tfie bottom inboard side of tfie engine
air distribution box, a flow control adapter assembly, and an electrically operated diverter valve (overboard dump
valve) located in the wing leading edge at the inboard side of each engine nacelle.
The diverter valve is operated by a switch on the pressurization console and is used to prevent contami-
nated air from entering the cabin by dumping the turbo bleed air overboard through a vent in the bottom of the
wing.
REMOVAL OF SONIC NOZZLE (602P AND 700P).
1. Remove lower engine cowling.

2. Remove bolts, nuts and washers (10) from flange of sonic nozzle (3).
3. Loosen clamp (11) at end of nozzle.
4. Exercising care, break seal at flange and extract nozzle from flex duct (4).
5. Clean sealant from flange and cover open ports.
INSTALLATION OF SONIC NOZZLE (602P AND 700P).
1. Clean flange of air box duct (2) and sonic nozzle (3) per Chapter 20.
2. Fay seal (with PR 820) flanges to absolute level per Chapter 20, .
3. Insert nozzle into flex duct (4), align flanges and install bolts. Torque per Chapter 20.
4. Tighten clamp (11) and install lower engine cowling.
5. Check for leakage (none allowed) at next engine run-up.
REMOVAL OF FLOW CONTROL ADAPTER/DIVERTER VALVE (602P AND 700P). (Refer to Figure 21-2.)
1. Auxiliary power disconnected and Master Battery switch OFF.

2. If flow control adapter is to be removed, remove lower engine cowling and remove clamp (11) at
side firewall.
3. Remove access cover (14).
4. Remove clamps (11) from inboard side and bottom of diverter valve and remove flexible ducts
(4).
5. Remove bolts (12) if adapter is being removed. If adapter is not being removed, remove bolts
(10).
6. Disconnect electrical plug and ground wire at connectors.
7. If adapter is being removed, exercise care when extracting to prevent damage to flexible duct in
engine compartmenL
8. If only the diverter valve is being removed, exercise care and break fay seal at adapter and valve
flanges and extract valve.
9. Clean sealant from flange (if required) and cover all open ports.
INSTALLATION OF FLOW CONTROL ADAPTER/DIVERTER VALVE (602P AND 700P).
1. Clean fay seal (with PR 820), flanges of adapter, and diverter valve per Chapter 20.
2. Position valve/adapter connecting flexible ducts (4) and install bolts (10) or (12). Torque per
Chapter 91.
3. Connect electrical plug and ground wire.
4. Run-up engine and check for proper operation of valve and leakage (none allowed).
5. Install access cover and lower engine cowling if removed.
21-11-09
Page 21-26
issued: June 1,1995 2C13
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
1. PRESSURIZATION STATIC PORT 18. GASKET .

2. PRESSURIZATION STATIC LINE 19. ELBOW WITH BLEED AIR CHECK VALVE
3. PRESSURIZATION STATIC DRAIN ATTATCHED
4. FLOW CONTROL ASSEMBLY 20. CLAMP
5. FILTER 2J. FLEXIBLE DUCT
6. OUTFLOW VALVE 22. T DUCT
7. HEATER ASSEMBLY 23. CLAMP (5 OR 6 PLACES)
8. CLAMP 24. SCREW
9. FLEXIBLE DUCT 25. MANIFOLD ASSEMBLY
10. BOLT, WASHER, GROMMET (6 PLACES) 26. CLAMP
11. HEAT EXCHANGER 27. IN-LINE FILTER.
12. RAM AIR DOOR 601P A/F 28. ' RAM AIR CHECK VALVE (FLAPPER VALVE)
13. CONTROL CABLE 0157 THRU 0212 29. BLEED AIR CHECK VALVE * .
14. CLAMP _
30.. RIVETS (4 PLACES) . . ' "
15. FLEXIBLE DUCT '
31. RIVETS (2 PLACES)
16. BOLT, WASHER, NUT (4 PLACES)
32. SONIC NOZZLE
17. ELBOW
33. DIVERTER VALVE
SEAL WITH PR820 SEALANT
TO ABSOLUTE LEVEL
Figure 21-3. Pressurization Systems Distribution Components :

21-11-09
' Page 21-27
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B373
M O D E L S 602P A N D 7 0 0 P
•
12 8
M O D E L 601P 11
e
Figure 21-3, Pressurization Systems Distribution Components (cont)
21-11-09
Page 21-28
Issued: June 1,1995
2C15
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
HEAT EXCHANGER., (Refer,to Figure 21-3.) .
The heat exchanger is a shrouded louvered device installed in the bleed air duct system of each wing
leading edge. The heat exchanger receives cooling ram air in-flight through a scoop at the wing root.
On airframe 0157 through 0212 manually operated doors in the air scoop allow the pilot to select the
desired heater mode.
REMOVAL OF HEAT EXCHANGER.
.. 1. Ensure power is removed from airplane/master battery switch "OFF".

2. Remove access panel on lower leading edge of wing between engine nacelle and fuselage, as
applicable.
3. Disconnect flexible ducting from both sides of heat exchanger. ,
4. Remove bolts, washers, and grommets securing heat exchanger and remove hardware and heat
exchanger from wing area.
5. Cap duct openings in wing and heat exchanger.
6. Check grommets for wear and deterioration. Replace, as required.
INSTALLATION OF HEAT EXCHANGER.
1. Remove dust protectors from bleed air ducting inside wing and openings in heat exchanger.
Ensure no foreign material is in heat exchanger.
2. Position heat exchanger inside wing in cavity provided and secure using retained hardware.
3. Install flexible ducting over heat exchanger inlet/outlet ports and secure with retained clamps.
4. Ensure inside wing area is free from foreign material. Install wing leading edge access cover.
BLEED AIR. CHECK V A L V E . (Refer to Figure 21 -3.)
The bleed air check valve is an all metal elbow fitting incorporating a flapper check valve. The valves are
located on the outer fuselage skin, one at each wing root.
REMOVAL O F BLEED AIR CHECK VALVE.
1. ' Remove applicable wing root leading edge fairing.

2. . Remove applicable aft seat and interior panels per Chapter 25 for access to elbow (17).
3. Disconnect flexible duct from elbow (19) and install dust covers.
4. Remove bolts and nuts (16) and gasket (18).
5. Drill out rivets (30) if elbow (19) is being removed. If only the check valve requires removal, drill
out rivets (31). .
— CAUTION —
The installed check valve requires sealant at the fuselage/elbow flange
mating surface to prevent air leaks. Care must be taken when separating
the elbow from fuselage to prevent damage to skin or valve.
21-11-14
Page 21-29
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
6. Exercising care, separate elbowA/alve from fuselage.
7. Clean sealant from flange/skin and cover all open ports.
INSTALLATION OF BLEED AIR CHECK VALVE.
— NOTE —
Left and right elbows are not interchangeable.
1. If new elbow (19) is being installed, position elbow on flexible duct (15) and back drill rivet and
bolt fioles. Ensure flapper valve is down with hinge at the top and that valve operates freely.
2. Clean elbow flange and skin. Fay seal elbow with PR 820 sealant to absolute level, per Chapter
20 and rivet elbow to skin. Rivets must be flush on interior skin.
3. If flapper valve is being installed, fay seal per step 2 and rivet flapper in place with flapper hinge
at top of opening. Ensure flapper seats over opening.
4. Position gasket (18) and elbows (17) and (19) and install bolts (16) and clamp (14). Torque per
Chapter 91.
5. Run-up applicable engine and check for leakage (none allowed).
6. Install wing root fairing.
7. Install interior panels and seat.
DORSAL RAM-AIR CHECK VALVE ASSEMBLY. (Refer to Figure 21-3.)
The ram-air check valve assembly is a duct tee fitting incorporating a flapper check valve and is located
in the ram-air intake ducting aft of the heater blower in the aft fuselage.
REMOVAL OF DORSAL RAM-AIR CHECK VALVE ASSEMBLY.
1. Open baggage compartment door and remove trim panel from rear of compartment.
2. Loosen three clamps securing check valve to flexible ducting and remove valve from ducting.
INSTALLATION OF DORSAL RAM-AIR CHECK VALVE ASSEMBLY.
— NOTE —
When installing ram-air check valve assembly ensure valve flapper is posi-
. tioned to allow ram-air/ambient air to enter system. If installed backward
air will not enter system and cabin will not pressurize.
1. Position valve assembly in ducting and secure with retained clamps (3 places).
2. Install trim panel at aft of baggage compartment.
21-11-18
Page 21-30
Issued: June 1,1995
2C17
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
( LEAKIEST.
CABIN LEAK TEST. (Refer to Figure 21-4, Test Set-Up.)
Equipment required:
A. Tester, Greer Model MD-1 or CLP-3, or equivalent.
B. Hose, locally fabricated, door seal valve to fuselage fitting.
0. Air Supply (not required if Model MD-1, or equivalent, used.)
D. Pressure Gauge (0 to 30 psi not required if Model MD-1 or equivalent, used.)
E. Pressure Regulator (not required if Model MD-1 or equivalent, used.)
2. Fuselage Preparation.
A. Apply electrical power to airplane/master battery switch "ON".
B. Actuate cabin dump valve switch. Observe switch for "NORMAL" in one mode and
"NORMAL/DUMP" in the other. Leave at "NORMAL/DUMP".
0. Actuate bleed valve switches. Obsen/e switch for "AIR ON" in one mode and "AIR OFF"
in the other. Leave at "AIR ON".
D. Remove power from airplane/master battery switch "OFF".
3. Remove the following panels:
A. Trim panels at fuselage station 176.88 (behind aft seat) and 204.00 (aft of rear cabin
shelf).
B. Trim and access panels at fuselage station 224.00 (baggage compartment).
C. Right access panel on pilot's console.
D. Left wing leading edge access panel.
E. Left and right engine nacelle upper cowling.
F. Open main landing gear doors per Chapter 32.
G. Nose compartment access door.
4. At fonward side of fuselage station 176.88 bulkhead, disconnect door seal outlet hose at valve
and pneumatic supply hose at fuselage. Connect a locally fabricated hose extension between
fuselage fitting and valve output hose. (Valve is now by-passed for remainder of test.)
5. At fonward side of fuselage station 204.00 bulkhead, disconnect hose from controller to outflow
valve at the valve and close bleed valve (turn knob clockwise) noting amount of turns required to
close same (at end of test valve should be opened same amount of turns).
— CAUTION —
Failure to cap cabin altimeter pressure port will damage instrument.
6 ' Plug cabin pressure port (marked C P . ) on cabin altimeter located in pilot's console.
7. Check static port on forward left side at fuselage station 83.00 (left and right for airplanes
equipped with alternate static system) and outflow and safety valves outflow ports behind fuse-
lage station 204.00 bulkheads are clear.
— NOTE —
The cabin pressurization check described herein requires a cabin pressur-
ization compressor, Greer Model MD-1 or CLP-3, or equivalent, to perform
test. Reference made regarding test equipment refers to Greer models.
Should different equipment be utilized, refer to manufacturer's operating
procedures.
8. Disconnect hose or remove cap at pressure port on fonA/ard side of fuselage station 54.25 bulk-
head and connect tester manometer line.
21-12-01
Page 21-31
2C18 issued: June 1,1995

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B374
CMIT WHEN USING GREER MODEL MD-1

CABIN PRESS. TESTER. : CONNECT DOOR
SEAL AIR SUPPLY DIRECTLY TO PORT
PROVIDED ON TESTER. USE TESTER
VIEW LOOKING AFT GAGE AND REGULATOR. '
AFT PRESSURE BLKHD

F.S. 176.88
OUTLET PORT
* SHOP AIR
DOOR SEAL PRESS. LINE

(DISCONNECT AT OUTLET
•PORT OF DOOR SEAL VALVE
AND CONNECT TO AIR SUPPLY)
NOTE:
DOOR SEAL PRESSURE
+1.0
NOT TO EXCEED 12 PSI
-0.0
Figure 21-4. Cabin Lealt Test Set-up

21-12-01
Page 21-32
issued: June 1,1995
2C19
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B375
CO^fVERSION CHART NO. 1

(LOW FLOW)
60° F:
80° INDICATED FLOW TO ACTUAL FLOW
100° F Q2= 35.306 ^ CQ^)
AIR TEMP EXAMPLE:
INDICATED FLOW 30 CFM
PRESS 10 PSI = 24.7. PSLA
TEMP 60O F = 520° R
ACTUAL FLOW 50 SCFM
10 8 6 4 CCMPRESSOR PRESSURE PSI
Figure 21-4. Cabin Leak Test Set-up (cont)

21-12-01
Page 21-33
issued: June 1,1995
2C20
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
9. Remove flexible fiose from bleed valve inlets at eacfi engine firewall and connect compressor air
hioses to valve inlet.
10. Disconnect pneumatic system air supply line inside wing at wing root and connect air supply to
wing root fitting. (If IVIodel MD-1, or equivalent, is used, air supply is provided by compressor and
external supply is not required.)
— NOTE —
All connections required to perform test procedures are complete. Cabin
closeup and safety inspections require conformance prior,to beginning
test.
11. If opened, close and secure emergency exit door. Ensure door pins are correctly engaged.
12. Close and secure main cabin doors. Cfiecl< door pin engagement loolcing ttirougfi copilot's win-
dow.
13. Install external safety straps around fuselage over main cabin and emergency exit doors.
14. Perform safety inspection, to include cfiecking: *
A. Windows and windsfiield attacfiments installed.
B. Cabin and emergency exit doors secured and safety straps installed.
C. Baggage compartment and main landing gear doors open.
D. All personnel clear from around fuselage pressurized vessel area.
15. Perform preliminary leak test (1 psi maximum).
A. Ensure safety inspection as previously described fias been accomplisfied.
B. Start compressor per manufacturer's operating procedures.
C. Apply air pressure to door seal regulated to 12 psi + 1.0/-0.0.
D. Adjust compressor flow valve as required to obtain 1 psig (2.03 in. Hg) cabin pressure
indicated by tfie compressor manometer. (Compressor attendant must remain at com-
pressor at all times.)
E. Inspect complete cabin stnjcture, bleed air system, fieater ducting, etc. for major leaks
and identify same.
F. Sfiut off compressor.
— NOTE —
If major leaks were detected temporarily terminate test and apply sealant at
leaks per Chapter 20. Repeat Preliminary Leak Check procedures to assure
leak(s) have been sealed.
16. Perfonn maximum differential pressure leak test.
CHART 2106 SEA LEVEL CONTROLLER, 4.25 PSID PRESSURIZATION SYSTEM,

MAXIMUM DIFFERENTIAL PRESSURE ALTITUDE
AIRPLANE ALTITUDE 8.500 10,500 11,900 13,100 14,200 15,400 16,900 18,800 20,000 21,200 23,000
CABIN ALTITUDE S.L 1 2 3 4 5 6 7 8 9 10
— NOTE —
Floor panels must be installed to perform leak tests exceeding 1 psL
A. Perform inspections noted in Step No. 14 above.
21-12-01
Page 21-34
Issued: June 1,1995 2C21
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
. ^ MAINTENANCE MANUAL
B. Start compressor per manufacturer's instnjctions.
— CAUTION —
During beginning of pressurization look through copilot's window and
ensure cabin and airplane altimeters, airspeed indicator, and airplane rate
of climb indicator are stable (unaffected by pressurization). If instruments
are showing indication, depressurize fuselage and perform static and/or
pitot checks per Chapter 34, as applicable.
C. Slowly adjust compressor flow so cabin rate of climb indicator in pilot's console does not exceed
1500ft/min.
D. Observe compressor manometer and adjust compressor flow valve to obtain 4.0 psig (8.12 in.
HQ).
E. Record leak flow rate indicated on compressor flowmeter. Record temperature indicated on com-
pressor temperature gauge.
F. Record pressure indicated on compressor/external supply pressure gauge.
G. Convert indicated flow (CFM) to standard flow (SCFM) using conversion ctiart.
H. If standard leak flow is in excess of 50 SCFM, inspect complete cabin structure, bleed air system,
heater/vent ducting for leak area. Identify leaks as major and minor (thiis will help in selecting
what areas must be sealed).
I. If standard leak flow is less than 50 SCFM, inspect complete airplane as in Step H above.
Sealing of leaks is not necessary unless they are major or produce excessive noise.
J. Increase cabin pressure until outflow valve actuates but do not exceed 4.50 psig (9.16 in. Hg).
— NOTE —
If valve does not relieve between 4.15 to 4.25 psig (8.45 to 8.65 in. Hg) the
valve must be replaced. If aircraft is equipped with Option 262, maximum
pressure is 5.80 psig and outflow must relieve between 5.40 and 5.50 psig
or be replaced.
K. Slowly depressurize cabin by reducing compressor flow.

L. Temporarily terminate test.
M. Disconnect static line at outflow valve and cap off line. Leave port on valve open to cabin.
N. Perform inspection noted in Step 14.
O. Start compressor per manufacturer's instructions and apply 12 psi pressure to door seals.
P. Slowly increase cabin pressure until safety valve relieves but do not exceed 4.50 psig (9.16 in.
Hg).
— NOTE —
, If valve does not relieve between 4.35 to 4.45 psig (8.86 to 9.06 in. Hg) the
valve must be replaced. If aircraft is equipped with Option 262, maximum
pressure is 5.80 psig and safety valve must relieve tyetween 5.60 and 5.70
psig or t}e replaced.
Q. Slowly depressurize cabin by reducing compressor flow.
21-12-01
Page 21-35

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CABIN L E A K TEST TERMINATION.
1. Shut off compressor per manufacturer's instructions. '
— WARNING —
The cabin will remain pressurized due to check valves in system. Do not
attempt to open cabin door until Step No. 's 2 and 3 have been performed.
2. Deflate door seals.

3. Disconnect manometer line to pressure fitting at fuselage station 54.25 bulkhead and wait for air
to stop coming from airplane at door, emergency exit, and cabin pressure fitting. Install cap or
connect hose at pressure port.
— WARNING —
If cabin door is opened prior to all pressure being relieved,- severe
injury could occur.
4. Remove safety strap at cabin door and open door.
— NOTE —
If leaks were detected that require sealing, apply sealant per Chapter 20
and repeat Final Leak Check procedures before continuing with test termi-
nation.
5. Remove safety strap at emergency exit.

6. At outflow valve:
A. Remove plug from static line and reconnect to valve.
B. Reconnect line to controller at valve.
0. Open bleed valve same amount of turns as noted during closing of valve.
21-12-02
Page 21-36
issued: June 1,1995
2C23
AEROSTAR AIRCRAFT
600/60l7601 P/602P/700P
MAINTENANCE MANUAL
CHART 2107. FIELD REPAIR LIMITATIONS - PRESSURIZATION COMPONENTS
COMPONENT .REPAIR
Cabin Controller a. Remove and replace cigarette filter.

b. Remove and clean poppet valve assembly witfi denatured alcofiol.
c. Repair electrical wiring between unit and aircraft.
d. Adjust selected versus actual cabin altitude.
e. Binding of outer ring on face of controller.
f. Adjust stops after step d above.
Outflow Valve a. Clean diapfiragm witti denatured alcofiol.

b. Replace cigarette filter.
c. Adjust isobaric valve.
Safety Dump Valve a. Adjust spring (back of unit).

b. Repair electrical wiring between aircraft and unit.
c. Clean diapfiragm with denatured alcohol.
— NOTE —
If heavy, smoking or excessively dusty conditions exist, the outflow and
dump valves may require cleaning more frequently than specified time
interval of 100 hours.
7. At door seal control valve:

A. Remove locally fabricated hose.
B. Reconnect hose to valve.
C. Reconnect pneumatic supply hose to fitting at fuselage.
8. Remove plug from cabin pressure (C.P.) port on cabin altimeter.
9. Remove compressor air hoses at bleed valve inlets at left and right engine firewalls and recon-
nect bleed valve hoses.
10. Disconnect air supply line to wing root fitting and reconnect pneumatic system air supply line.
11. Install trim and access panels removed in Step No. 3, and close main landing gear, doors per
Chapter 32.
CHAPTER SECTION SUBJECT 21-13-00 AND 21-14-00 NOT USED.
PNEUMATIC.
The pneumatic system provides dry air to operate the gyros, deice boots, and on the pressurized models,
the cabin door and emergency exit seals.
21-15-00
Page 21-37

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
DESCRIPTION.
The pneumatic system consists of two engine driven dry air pumps with inlet filters, two pressure regula-
tors or control valves, a manifold with check valves and an in-line filter. On A/C equipped for known icing and all
602P's, an ice shield is mounted in front of each inlet filter. The inlet filter must be protected from contamination
(fluids, etc.) when cleaning the engine.
The pressure regulators (Models 600 and 601 without surface deice) are spring loaded and regulate the
air presisure to the manifold and gyros to 3.5 psi.
The control valves (Model 601P, 602P, 700P and A/C with surface deice) are solenoid operated and reg-
ulate the air pressure to 5.7 psi. When the door seal switch is placed in the "INFLATE" mode the solenoid opens
a bypass in the control valve allowing 12.5 psi to enter the manifold to inflate the cabin door and emergency exit
seals. Refer to Figure 21-5 for the pneumatic system schematics.
The air from the manifold and in-line filter is routed under the cabin floor to an in-line pressure regulator
(601P, 602P, 700P and NC with deice) which is set at 4.75-5.25 in. Hg., then to the gyro pressure gauge, gyros
and overboard. On models 600 and 601 without deice, the air is directed to the gyro pressure gauge, gyros and
then vented inside the cabin. The gyro pressure gauge indicates pressure in inches of mercury (in. Hg.). The
gauge also has L and R red indicators that come into view when the air supply from either the L or R engine dri-
ven pump fails or drops below approximately 2.5 psi. This pressure is taken upstream of the check valves in the
manifold.
On 700P's vacuum is supplied to the outflow valve by means of a vacuum generator in order to reduce
cabin dive on takeoff.
On NC equipped for deice, pneumatic air for the boots is supplied from the manifold through a pressure
relief valve, duplex valve and a pressure switch. Refer to Chapter 30 for deice pneumatic system.
On pressurized models the inflatable door seals are controlled by an "INFLATE-DEFLATE" switch on the
pilot's console, a door seal valve, door seal pressure switch and a pressurization safety switch at the emergency
exit.
The air supply is tapped downstream of the in-line filter and fed into a pilot operated door seal control
valve and subsequently into the inflatable seals. The door seal control valve is comprised of a solenoid shutoff
valve, a check valve (for A/C equipped with surface deice, the check valve is replaced with a solenoid shut-off
valve) and a pressure switch set at 12 ± 0.5 psi. When the seal inflation mode "INFLATE" is selected, the control
valve is energized by the door seal control valve pressure switch and air is pumped into the seals until the control
valve is de-energized by the pressure switch allowing excess pumped air to discharge overboard and system
pressure to return to normal. A microswitch wired in series with the door seal control valve is mounted at the
emergency exit handle. This is to prevent inflation of the door seals in the event the emergency exit handle is not
in the fully closed position. The door seal switch located on the pilot's console will show "DEFLATE" regardless of
modes selected until the emergency exit handle has been properly secured.
Aircraft equipped with Option 253 (Electric-Pneumatic Door Seal System) have a miniture electric pres-
sure pump, filter, and check valve added to the pneumatic system to provide air to the door seals. The air sup-
plied by the electric pump tees into the pneumatic system just ahead of the door seal control valve. The pump is
located on the fonward side of the F.S.I 76.88 bulkhead. A mode switch on the center console can be used to dis-
able the electric pump and use the normal system.
COMPONENT MAINTENANCE.
ENGINE DRIVEN AIR PUMP. (Refer to Figure 21-7.)
The engine driven air pumps are attached at the aft end of the engine oil scavenge pump, mounted to the
air pump mount pad on the accessory case.
21-17-01
Page 21-38
Issued: June 1,1995
2D1
AEROSTAR AIRCRAFT
600/6017601P/602P/700P
MAINTENANCE MANUAL
REMOVAL OF ENGINE DRIVEN AIR PUMP.
1. Ensure power is removed from airplane; master battery switch "OFF."

2. Remove upper half of engine cowling for air pump being removed.
3. Disconnect inlet and outlet air supply hoses or ducts at pump and install dust protectors on all
openings.-
4. Remove nuts and washers securing pump to engine and carefully remove pump from engine so
as not to damage coupling and/or mounting pad studs.
5. Install protective plate over mounting pad.
INSTALLATION OF ENGINE DRIVEN AIR PUMP.
1. Remove protective plate from mounting pad.

2. Check air pump mounting pad gaskets for damage and replace gasket if required.
3. Place engine driven air pump on mounting pad engaging shaft coupling and secure with washers
and nuts. - „. . .
4. Remove dust protectors from air inlet and outlet openings and connect air hoses or ducts to
pump.
— NOTE —
Any time an air pump requires replacement, the pump inlet and door seal
in-line filters should be replaced unless they have recently been replaced
or show no evidence of contamination. Also, for pressurized airplanes, the
Pneumatic System Test-Pressurized Airplanes should be performed per
instructions contained in this chapter. These items should be accom-
plished to assure maximum pump life.
INSPECTION/CHECK OF ENGINE DRIVEN AIR PUMP.
1. Mounting pad gasket for damage; replace if required.

2. Mounting pad studs for security and thread condition. Secure or replace as required.
PNEUMATIC PRESSURE GAUGE.
The pneumatic pressure gauge is mounted in the instalment panel and provides a direct pressure read-
ing in inches of mercury from 3.5 to 6.5 with the green arc from 4.8 to 5.2 inches. ,
REMOVAUINSTALLATION OF PNEUMATIC PRESSURE GAUGE.
Refer to Chapter 39.
21-17-06
Page 21-39
2D2
Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
RH ENG CaiPT RH OTNG CABIN F.S. 176.38 LH WTNG LH ENG CQMPT
•ODEL 601P
KITHOUT SURF DEICE
MODEL 601P A N D 602P

WITH S U R F A C E DEICE
»CDrL 600. 601

w m U i T SURF DEICE
1. INLET FILTER
2. PUMP
3. REGULATOR/CONTROL VALVE
M O D E L 601P A N D 60ZP W I T H O R
4 MANIFOLD
WITHOUT SURF DEICE
5. IN-LINE FILTER
6. DOOR SEAL PRESSURE SWITCH (12 +/- 0.5 PSIG)
7. SOLENOID VALVE
8. DOOR SEAL PRESSURE
9. DOOR SEAL VALVE
10. PRESSURE RELIEF (22 PSIG)
11. DUPLEX DEICE VALVE
12. PRESSURE SWITCH (18 PSIG)
13. GYRO GAUGE
14. IN-LINE REGULATOR (4.75 - 5.25 IN. HG.)
15. VACUUM GENERATOR (700P)
Figure 21-5. Pneumatic System Schematics

21-17-06
Page 21-40
Issued: June 1,1995
2D3
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
Figure 21-5. Pneumatic System Schematics (cont)

(Model 601P, 602P and 700P)
21-17-06
Page 21-41
2D4 Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
Figure 21-6. Pneumatic System Components

21-17-06
Page 21-42
Issued: June 1,1995
2D5
A E R O S T A R AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE M A N U A L
o
B377
O P T I O N 253ONLY 26
2 8 - ^ - U /
700P ONLY
(TO VACUUM
GEN.)
o
1. CLAMP
2. F L E X I B L E HOSE
3. S C R E W (2 P L A C E S )
4. C O N T R O L VALVE
5. T I E - W R A P (2 P L A C E S )
6. P R E S S U R E R E G U L A T O R
7. CLAMP
8 O O O R S E A L INLET H O S E
9. M A I N C A B I N D O O R SEAL
10. O O O R S E A L INLET H O S E
11. E M E R G E N C Y EXIT S E A L
12 C L A M P (3 P L A C E S )
13 S C R E W (2 P L A C E S )
14. CONTROL VALVE
15. CLAMP
16. PRESSURE SWITCH
17. SWITCH MOUNT PLATE
18 S C R E W . W A S H E R . N U T (2 P L A C E S )
19. ACTUATOR
20 SWITCH
2 1 . C L A M P (5 P L A C E S )
22. FLEXIBLE HOSE (TYP.)"
23. IN-LINE P R E S S U R E R E G U L A T O R
24. V A C U U M G E N E R A T O R (700P ONLY)
25. P R E S S U R E R E G U L A T O R (700P ONLY)
26. P U M P
27 C H E C K V A L V E
28. MODE SWITCH RELAY
Figure 21-6. Pneumatic System Components (cont)

21-17-06
Page 21-43
Issued: June 1,1995
2D6
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CI 32
SPRING LOADED
CHECK VALVE
TO PRESSURE
SWITCH IN
WHEEL.WELL
.
—JZH 1 1
PNEUMATIC AIR
TO DOOR SEAL
1 r -
i 1
!1
•BLEED" HOLE FOR

"DEFLATE" MODE
DOOR SEAL VALVE SOLENOID
(ELECTRICALLY HELD CLOSED IN
THE "INFLATE" MODE. SPRING
LOADED OPEN IN THE "DEFLATE"
MODE).
VIEW E. PRESSURIZED AIRPLANE WITHOUT DEICE BOOTS
TO DOOR SEAL
"BLEED" HOLE FOR

"DEFLATE" M O D E "
7^ TO PRESSURE SWITCH IN
WHEEL WELL
L 1
r '
H. J
PNEUMATIC AIR
— J
DOOR SEAL VALVE SOLENOID • SOLENOID

(ELECTRICALLY HELD CLOSED (ENERGIZED DURING INFLATION CYCLE
WHEN DOOR SEAL IS IN THE ONLY. SPRING LOADED TO BLOCK
"INFLATE" MODE. SPRING PORT TO DOOR SEAL AFTER SEAL
LOADED OPEN WHEN IS INFLATED.)
"DEFLATE" IS SELECTED)
VIEW E. PRESSURIZED AIRPLANE WITH DEICE BOOTS
Figure 21-6. Pneumatic System Components (cont)

21-17-06
Page 21-44
Issued: June 1,19S5
2D7
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
LEFT H A N D INSTALLATION SHOWN-

RIGHT H A N D SIMILAR
1. E N G I N E D R I V E N A I R P U M P
2 . N U T . W A S H E R (4 P L A C E S )
3. FLEXIBLE H O S E (DUCT O N L A T E R M O D E L 6 0 0 A N D 6 0 2 P )
4. CLAMPS
5. W I N G N U T , WASHER
6. FILTER
7. B A F F L E - I N L E T FILTER ( U S E D O N M O D E L S 6 0 1 . 6 0 1 P NOTE
A N D 6 0 2 P IF E N G I N E I C I N G P R O T E C T I O N M O D I F I C A T I O N I S I N S T A L L E D ) """"^ ^""'''^'^ MOUNTED ON
THE F O R W A R D U P P E R ' ^ R / H SIDE O F
THE ENGINE.
Figure 21-7. Pneumatic System Air Pumps

21-17-06
Page 21-45
2Qg Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
. MAINTENANCE MANUAL ..
AIR PUMP INLET FILTER. (Refer to Figure 21-7.)
The air pump inlet filter is located on top of engine at the engine air driven pump inlet except for the 700P
which has the filter mounted on the fonward upper right-hand side of the engine. On A/C equipped for known icing
and all 602P's, an ice shield is mounted on the front of the air filter
— CAUTION —
Any time the engine or surrounding components are cleaned, serviced, or
maintenance is performed, adequate protection must be taken to prevent
cleaning solvents and fluids from contaminating the filter which could
cause pump failure. Remove and replace filter at any sign of contamina-
tion.
REMOVAL OF AIR PUMP INLET FILTER.
1. Remove upper half of engine cowling for filter being removed.

2. Remove wing nut and washer securing ice shield (if installed) and filter and remove from mount.
INSTALLATION OF AIR PUMP INLET FILTER.
1. Position air pump inlet filter and ice shield (if installed) on mount and secure with wing nut and
washer.
2. Install upper half of engine cowling.
PRESSURE REGULATOR (600, 601 ONLY). (Refer to Figure 21-6.)
The pressure regulators are located in the left-hand and right-hand wing leading edge, between the
engine nacelle and wing root on the aft intercostal inside the wing leading edge access panel.
REMOVAL OF PRESSURE REGULATOR.
1. Ensure power is removed; master battery switch "OFF."

2. Remove left or right access panel, as applicable, on lower leading edge of wing between nacelle
and fuselage.
3. Disconnect flexible hoses from pressure regulator outlet and remove the wrap securing valve to
support. Remove regulator from wing and install dust protectors on all openings.
21-17-11
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2D9
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
INSTALLATION OF PRESSURE REGULATOR.
1. • Remove dust protectors and attach pressure regulator at support using ty-rap.
2. Connect flexible hoses to regulator.
3. Ensure all foreign material is removed from inside wing cavity and install access panel.
CONTROL VALVE (601P, 602P AND 700P). (Refer to Figure 21-6.)
The control valves are located in the left-hand and right-hand wing leading edge between the engine
nacelle and wing root on^the aft intercostal, inside the wing leading edge access panel.
REMOVAL OF CONTROL VALVE.
1. Ensure power is removed from airplane; master battery switch "OFF" and open "RIGHT ENGINE
BLEED AND DUMP" and "SEAL PRESS" circuit breakers.
2. Remove left or right access panel, as applicable, on lower leading edge of wing between engine
nacelle and fuselage.
3. Disconnect flexible hose from inlet and outlet ports of control valve and install dust protectors on
openings.
4. Identify and disconnect electrical leads at control valve.
5. Remove screws securing control valve mounting bracket to intercostal and remove from wing
area.
INSTALLATION OF CONTROL VALVE.
1. Place control valve in position on intercostal and secure with screws.

2. Remove dust protectors and connect flexible hoses to inlet and outlet ports of control valve.
3. Connect electrical leads to control valve.
4. Perform Pneumatic System Test per instructions contained in this chapter.
PRESSURE REGULATOR (700P ONLY). (Refer to Figure 21-6.)
If this aircraft is not equipped with a deice system, a second pressure regulator has been installed to pre-
vent possible damage to the gyros during inflation of the cabin door seal. This regulator is located fonward of
fuselage station 204.00.
REMOVAL OF PRESSURE REGULATOR.
1. Ensure power is removed; master battery switch "OFF".

2. Remove left or right access panel, as applicable, on lower leading edge of wing between nacelle
and fuselage.
3. Disconnect flexible hoses from pressure regulator outlet and remove the wrap securing valve to
support. Remove regulator from wing and install dust protectors on all openings.
21-17-17
Page 21-47
.issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
INSTALLATION OF PRESSURE REGULATOR. -
1. Remove dust protectors and attach pressure regulator at support using ty-rap.
2. Connect flexible hoses to regulator. -
MANIFOLD ASSEMBLY. (Refer to Figure 21-6.)
.The pneumatic air distribution manifold assembly is a sealed assembly incorporating two check valves
which prevent system pressure loss should either engine driven air pump fail. The manifold is located behind the
"Royalite" trim panel at the aft of the cabin on the forward side of fuselage station 176.88 bulkhead.
REMOVAL OF MANIFOLD ASSEMBLY.
1. Ensure power is removed from airplane; master battery switch "OFF;" . ..

2. Remove "Royalite" trim panel at fuselage station 176.88.
3. Identify and disconnect flexible hoses from manifold and install dust covers over hose and mani-
fold openings.
4. Remove screws securing manifold to bulkhead and remove manifold.
— NOTE —
If engine deice is not installed on the airplane and the manifold Is to be
replaced, remove capped off hose at manifold and retain for reinstallation.
INSTALLATION OF MANIFOLD ASSEMBLY.
1. If removed, install capped off flexible hose on bottom right manifold assembly fitting.
2. Place manifold in position on right side of fuselage station 176.88 bulkhead and install screws
securing manifold to bulkhead.
3. Remove dust protectors from manifold and hoses and install hoses on manifold.
4. Install "Royalite" trim panel at fuselage station 176.88.
IN-LINE AIR FILTER. (Refer to Figure 21 -6.)
The pneumatic system in-line air filter is located at the aft of the cabin on the fonward side of fuselage sta-
tion 176.88 bulkhead.
REMOVAL OF IN-LINE AIR FILTER.
1. Ensure power is removed from airplane; master battery switch "OFF."

3. Remove clamps securing filter inlet and outlet hoses and remove filter and install dust covers on
hose openings.
21-17-23
Page 21-48
Issued: June 1,1995
2D11
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
INSTALLATION OF IN-LINE AIR FILTER.
1. Remove dust covers from fioses and place in-line filter in position at fuselage station 176.88
bulkfiead and connect fioses to filter inlet and outlet ports.
2. Install "Royalite" trim panel at fuselage station 176.88.
DOOR SEAL CONTROL VALVE. (Refer to Figure 21 -6.)
Tfie door seal control valve is comprised of a solenoid sliutoff valve, a cfieck valve, and a pressure
switcfi. Tfie sfiutoff and cfieck valve are contained in one unit located on forward side of aft cabin bulkfiead fuse-
lage station 176.88. The pressure switch is in the left wheel well on the forward bulkhead.
REMOVAL OF DOOR SEAL CONTROL VALVE.
1. Ensure power is removed/master battery switch " O F P and open "SEAL PRESS" circuit breaker.
— NOTE —
If the shutoff and check valve are to be removed proceed with Step No. 3. If
the pressure switch is to be removed omit Step No. 3 and proceed to Step
No. 4.
3. Shut off and check valve removal. •

A. Remove flexible hoses, 3 places, at valve and install dust protectors on openings.
B. Disconnect valve electrical leads.
C. Remove screws securing valve to bulkhead.
Pressure switch removal.
A. Place airplane on jacks per Chapter 7.
B. Disconnect pressure switch electrical lead on fonward side of fuselage station 176.88
bulkhead. •-
C. Open left main landing gear door per Chapter 32.
D. Carefully remove sealant from forward bulkhead inwheel well where switch electrical
lead goes through to cabin and pull lead from cabin.
E. Unscrew and remove switch from bulkhead.
F. Remove excess sealant from bulkhead where switch and electrical lead were sealed to
facilitate installation and resealing.
INSTALLATION OF DOOR SEAL CONTROL VALVE.
— NOTE —
If the shutoff and check valve is to be installed, perform Step No. 1, omit
Step No. 2, then proceed to Step No. 3. If pressure switch is to be installed,
omit Step No. 1 and perform Steps No. 2 and subsequent
21-17-27
Page 21-49
2Q^2 Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
1. Shutoff and check valve installation.
A. Position valve in place on fuselage station 176.88 bulkhead and secure with screws.
B. Connect valve electrical leads.
C. Remove dust protectors and connect flexible hoses to valve, (three places).
2. Pressure switch installation.
A. Apply sealant to switch threads per instructions in Chapter 20 and install switch into fit-
ting on fonward bulkhead in left wheel well. Tighten securely. Use care when tightening
switch so as not to damage switch housing.
B. Insert switch electrical lead through grommet in bulkhead and connect to electrical lead
in cabin.
C. Apply sealant at electrical lead grommet per instructions contained in Chapter 20.
3. Check pressure switch operation per instructions under Door Seal Pressure Switch Test.
4. Install trim panel at fuselage station 176.88.
5. Close main landing gear door per instructions in Chapter 32.
6. Remove airplane from jacks per Chapter 7.
INFLATABLE DOOR SEALS. (Refer to Figure 21-6.)
The cabin door inflatable seal is installed at the fuselage cabin door frame in a channel around the entire
periphery of the frame. The emergency exit inflatable seal is similarly installed at the emergency exit door on the
right side of the airplane.
— NOTE —
Removal and replacement of cabin and emergency exit door seals is simi-
lar, therefore the following procedures apply to both seals with differences
annotated when necessary.
REMOVAL OF INFLATABLE DOOR SEALS.
1. Open cabin door halves. Access to inflatable main cabin door seal in channel is now accessible
without removing door halves.
2. If emergency exit door seal is to be replaced, pull handle above exit door downward, retracting
pins (four places) and carefully separate door from airplane.
3. Remove trim panel forward of cabin door at lower left, if cabin door seal is to be removed.
Remove arm rest trim panel from right side of cabin if emergency door seal is to be removed.
— CAUTION —
Seal is cemented in place and take care when removing seal to prevent
damage to seal and/or structure.
4. Disconnect seal hose at connector and carefully pry seal from channel.
5. Carefully remove cement from airframe channel and check channel for gouges or sharp protru-
sions which could damage seal at installation.
21-17-29
Page 21-50
Issued: June 1,1995
2D13
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
INSTALLATION OF INFLATABLE DOOR SEALS.
1. Ensure airframe channel is clean and free from debris.

2. Clean mating surfaces of airframe channel and inflatable seal with denatured alcohol.
3. Apply cement to mating surfaces of channel and seal.
4. Insert seal filler tube through hole in channel and carefully work seal into channel using care not
to pull or stretch seal as excess seal will protrude when inserted at end of installation.
5. Connect seal filler tubes to pressurization connections.
6. Install removed trim panel.
7. If applicable, install emergency exit door ensuring pins engage window when handle is raised
and stowed in closed position.
8. Perform cabin leak test in accordance with procedures contained in this chapter.
IN-LINE PRESSURE REGULATOR. (Refer to Figure 21 -6.)
The in-line pressure regulator is located behind the instrument panel on the pilot's side of the airplane (on
airframes with wing boots).
REMOVAL OF IN-LINE PRESSURE REGULATOR.
1. Ensure power is removed/master battery switch "OFF".

2. Slide pilot seat aft as far as possible to facilitate regulator removal.
3. • Working in pilot's leg tunnel, identify and disconnect hoses, five places; at in-line pressure regulator.
Remove regulator from cabin and install dust protectors on all hose and regulator openings.
INSTALLATION OF IN-LINE PRESSURE REGULATOR.
1. Remove dust protectors from hoses and regulator.

2. Place regulator in position behind instrument panel and connect hoses to regulator.
3. Perform pneumatic system test in accordance with procedures contained in this chapter.
TESTS.
PNEUMATIC SYSTEM TEST (600, 601 ONLY). (Refer to Figure 21-8.)
1. Equipment required:
A. Pressure gauge (0-30 psi).
B. Hose cap. ~
2. Remove left and right wing leading edge access covers.
3. Ensure gyros are correctly installed and all lines secured.
4. Start right hand engine per flight manual instructions and run up to 1300 rpm.
5. Check gyro pressure gauge for.
A. Right hand red indicator out of view.
21-18-01
Page 21-51
2Q-f^ Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
C I 51 ONE W A Y CHECK
PRESSURE V A L V E (DUKES INC.
REGUbMOR 366-00 O R SUITABLE
\ SUBSTITUTE)
SHOP AIR
PNEUMATIC
FILTER
DOOR SEAL BULKHEAD
FITTING A N D W H E E L WELL
-TEST SETUP HOSE
PRESSURE S W .
EXISTING
EXISTING HOSE T O •T" FITTING
DOOR SEAL
PNEUMATIC AIR
INLET (DISCONNECT
HERE T O H O O K U P
SKETCH B TEST HARDWARE) FLOOR LEVEL PNEUMATIC FITTINGS
ONE W A Y
PRESSURE CHECK VALVE
0150
REGULATOR (DUKES INC. 3 6 6 - 0 0
OR SUITABLE
SUBSTITUTE)
DOOR SEAL
BULKHEAD FITTING
AND WHEEL WELL TEST SET-UP
PRESSURE SWITCH
HOSE
^ INLET
PNEUMATIC AIR
EXISTING
HOSE FROM
0
DOOR SEAL
VALVE
(DISCONNECTED)
3,
SKETCH A FLOOR LEVEL PNEUMATIC FITTINGS
Figure 21-8. Pneumatic System Test Set-up (Fuseiage Station 176.88)

21-18-01
Page 21-52
Issued: June 1,1995
2D15
AEROSTAR AIRCRAFT
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MAINTENANCE MANUAL
B379
1. M A N I F O L D ASSY
2. IN-LINE FILTER
3. D O O R S E A L V A L V E (601 P. 6 0 2 P A N D 7 0 0 P )
4. D O O R S E A L A I R S U P P L Y LINE •
VIEW LOOKING AFT AT F.S. 176.88 BLKHD
SKETCH C
Figure 21-8. Pneumatic System Test Set-up (cont)

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2D17
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B. Gyro pressure gauge indicator (needle) stable at liigli end of green arc (5.2 in. fig.).
— NOTE —
If Step No.'s 5-A and 5-B are acceptable, run engine to 1800 rpm and check
that indications are the same. If items are the same proceed to Step No. 7.
If Step No. 's 5-A and 5-B are not as noted, perform Step No. 6.
6. Cfieck tfie system fioses for leaks.

7. Adjust tfie pressure regulator in tfie wing (clockwise to increase, counterclockwise to decrease).
— NOTE —
If the gyro pressure gauge indicator needle is at 5.2 in. Hg. and the red
indicator remains in view, check that the hose connected to gauge "R"
port does not cover the vent hole at the port base. (Applicable for a gauge
with an external vent plug only.)
If both red indicators are out of view with only one engine running, this
indicates a faulty check valve in the manifold assembly (on F.S. 176.88
panel). Replace the manifold assembly.
— NOTE —
If adjustment does not correct problem, refer to Gyro System
Troubleshooting in this chapter.
8. Sfiut down rigfit engine and repeat Step No.'s 4 and 5 above for left-fiand engine.
9. Simultaneously, run botfi engines up to 1800 rpm and cfieck gyro pressure gauge for:
A. Botfi left-fiand and right-fiand indicators out of view.
B. Indicator needle stable at higti end of green arc (5.2 in. Hg.).
— NOTE —
If Step No. 9-B is not as noted, readjust both pressure regulators an identi-
cal amount to obtain 5.2 in. Hg. on pressure gauge.
10. Sfiut down engines and reinstall wing leading edge access covers.
PNEUMATIC SYSTEM TEST (601P AND 602P). (Refer to Figure 21-8.)
1. To perfonm a leak test of tfie main cabin door seal, emergency exit door seal and related under
cabin floor plumbing proceed as follows:
A. Remove panel cover at F.S. 176.88 bulkfiead.
B. Remove pneumatic hose going from door seal valve to fitting at floor level for under floor
door seal plumbing.
C. Connect test set-up (Figure 21-8, Sketch A) to fitting at floor level.
21-18-02
Page 21-55
2D1 8 > Issuesd: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
, MAINTENANCE MANUAL
D. Connect shop air to regulator. Adjust regulator so gauge downstream of one way check
valve reads 15 psi.
E. Remove shop air. One way valve will trap air in door seal and plumbing.
— CAUTION —
This test will inflate both the main cabin door seal and the emergency exit
seal. Do not attempt to close main cabin door or damage to seal will result.
— NOTE —
Door seals may be inflated with main cabin door open and/or emergency
exit removed without damaging seals.
F. Let sit for 15 minutes. There should be no leakage. If leakage is evident, source must be
located and eliminated.
G. Remove test set up, reconnect pneumatic pressure line and reinstall cover panel at F.S.
176.88 bulkhead.
2. To check the operation of the pneumatic door seal valve and wheel well pressure switch and to
check both for leaks proceed as follows:--
A. Remove cover panel at F.S. 176.88 bulkhead.
B. Remove pneumatic hose from T ' fitting just down stream of pneumatic filter going to
door seal valve.
C. Connect test set up (Figure 21 -8, Sketch B) to supply air directly into door seal valve.
D. With electrical power on aircraft and door seal " I N F L A T E / D E F L A T E " switch in
"INFLATE" mode, connect shop air to regulator. Adjust regulator so gauge downstream
of one-way check valve reads 12 to 14 psi. Door seal should inflate.
E. Remove shop air from regulator. One way check valve will trap air in door seal valve and
plumbing.
— CAUTION —
This test will inflate the main cabin door seal and the emergency exit door
seal. Do hot attempt to close main cabin door as damage to door seal will
result.
— NOTE —
Door seals may be inflated with main cabin door open and/or emergency
exit removed without damaging seals.
F. Test gauge should not drop below 12 psi.

G. Leak check solution in a squirt bottle can be used to spray on valve tubing, wheel well
bulkhead fitting and pressure switch in left hand wheel well to check for leaks.
— NOTE —
Test set up should be sprayed to check for leaks downstream of one way
check valve.
21-18-02
Page 21-56
Issued: June 1,1995
2D19
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
, ^ H. Repair leal<s as necessary to obtain an air tigtit system.
I. Remove test set up, reconnect pneumatic pressure lines and reinstall cover panel at F.S.
.176.88.
3. To perform an operational ctiecl< of tfie system utilizing tfie airplane's pneumatic pumps, proceed
as follows (Refer to Figure 21-8, Sketcfi C):
Ai Remove trim panel at fuselage station 176.88 bulkfiead and left and rigfit wing leading
edge access.
B. Disconnect flexible fiose between in-line filter and door seal valve on fuselage station
176.88 bulkfiead. Install low pressure test gauge (0-30 psi) in line, and cap downstream
end of tee fitting.
C. Ensure gyros are correctly installed and all lines are secured.
D. Start rigtlt fiand engine per fligfit manual instructions and run engine up to 1300 rpm.
E. Ensure door seal switcti in pilot's console indicates "DEFLATE" and ctieck test pressure
gauge for 5.7 ± .2 psig.
— NOTE —
If gauge does not Indicate a pressure of 5.7 ± .2 psig refer to Gyro System
Troubleshooting. If pressure is in excess of requirement, adjust pressure
regulator in wing counterclockwise to decrease.
F. Sfiut down rigfit fiand engine and repeat Step No.'s D and E for left fiand engine.
G. Simultaneously run botti engines to 1800 rpm. Test pressure gauge must remain at 5.7
± -2 psig.
H. Retard tfirottles to idle rpm.
I. Remove cap from end of tee fitting at test pressure gauge and reconnect fiose from door
seal valve and gyros with test gauge still in line.
J. Run right hand engine to 1300 rpm and check gyro pressure gauge in instrument panel
for:
(1) Right hand red indicator out of view.
(2) Indicator needle stable on high end of green arc (5.2 in. Hg).
K. Run right hand engine to 1800 rpm and check gyro pressure remains the same.
L. Retard right hand throttle to 1300 rpm and check the following:
(1) Seals inflate.
(2) Gyro pressure momentarily increases but returns to 5.2 in. Hg. after inflation of
seals and red indicator remains out of view.
(3) During seal inflation, test gauge momentarily indicates 16 ± 3 psig and returns to
5.7 ± .2 after inflation. ,
1^. Retard right hand throttle to idle rpm.
- N. Repeat Step No.'s K through M, for LH engine. v
O, Repeat Step No.'s K through M for both engines, simultaneously.
P. Simultaneously, run both engines to 1800 rpm and verify the following:
(1) Seals are inflated.
(2) , Red indicators on gyro pressure gauge are out of view and indicator needle is
stable at 5.2 in. Hg.
Q. Actuate door seal pressure switch to "DEFI_ATE" and observe seals deflate.
R. Shut down engines.
S. Remove test gauge and reconnect pneumatic pressure lines at fuselage station 176.88
and install trim panel. - .
T. Install wing leading edge access panels.
21-18-02
Page 21-57
AEROSTAR AIRCRAFT
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MAINTENANCE MANUAL
DOOR SEAL PRESSURE SWITCH TEST. (Refer to Figure 21-9.)
1. Test equipment.
A. Pressure gauge (0 to 30 psi, calibrated witfiin ± .25 psi).
B. Volt/Ofim meter.
C. Sfiut-off valve.
D. Bleed valve.
E. Air supply and regulator.
Test procedures.
A. Ensure electrical power is removed/master battery switcfi "OFF".
B. Remove trim panel from fuselage station 176.88.
C. Disconnect pressure switcfi electrical leads.
D. Disconnect door seal valve fiose to pressure switcfi at switcfi.
E. Witfi no air pressure applied, volt/otim meter sfiould indicate switcfi is closed.
F. Close manual bleed valve and open stiut-off valve. , ,
G. Slowly apply pressure to pressure switcfi (15 psig max.). Check switch opens at 12 ± .5
psig.
H. Close shut-off valve. IVIaintain system closed and check for no (zero) leakage at 15 psig
for five minutes.
1. Slowly open bleed valve to allow pressure to bleed off. Observe pressure switch closes
at 2 ± 1 psig below pressure at which switch opened in Step G above.
B381
3. BLEED VALVE
4. PRESSURE GAUGE
5. DOOR SEAL PRESSURE SIVITCH (F7-33-1)
6. VOLT/OHM METER
Figure 21-9. Door Seal Pressure Switch Test Set-Up
21-18-03
Page 21-58
Issued: June 1,1995
2D21
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
3. Test termination.
A. Remove air supply and disconnect test equipment.
B. Reconnect door seal valve hose to pressure switch
C. Connect pressure switch electrical leads.
D. Install trim panel at fuselage trim station 176.88. .
MANIFOLD ASSEMBLY TEST. (Refer to Figure 21-5.)
1. Remove pressure manifold by disconnecting pneumatic pump discharge lines and the pressure
line to the filter. If aircraft is equipped with surface deice, disconnect line to surface deice pres-
sure relief valve and cap port on manifold.
2. With a regulated source of air, connect a line to the filter side of the pressure manifold.
3. Slowly apply 20 psig of air to the pressure manifold.
4. Close off regulated air and check for leaks - a leak rate of .5 psig in 10 seconds is permitted.
5. If air flows through pressure manifold and out either of the pneumatic pump discharge sides of
the manifold, a diaphragm is ruptured and the unit must be replaced.
6. If unit passes leak test, reinstall in the aircraft by reconnecting the pneumatic pump discharge
and filter hoses. • , . '
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DISTRI-
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21-21-
02
Page
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
VENTILATION FAN BLOWER AND PLENUM BOX A S S E M B L Y .
The ventilation fan blower and plenum box assembly are located on the aft bulkhead of the cabin at fuse-
lage station 204.00. The airplane plenum box assembiy, if air conditioning is installed comes equipped with a fan
blower (24 volt electric motor) and evaporator unit with an access door in the lower front panel (See Figure 21-
10). The airplanes without air conditioning installed, do not have a front access door, evaporator unit, fan blower
or front air ducts on the front panel of the plenum box assembly. Later models do have the front air ducts.
The plenum box assembly (air conditioning installed) has four outlets for venting air to the cabin and
bleed air to the plenum box assembly. (See Figure 21-10). They are located at the lower left hand and right hand
side of the plenum box, and two air ducts on the upper front panel of the plenum box. These two air ducts convey
ventilating air to the overhead air duct located in the cabin from fuselage station 204.00 to fuselage station 90.82.
The left hand and right hand outlets convey bleed air into the plenum box assembly.
The left hand and right hand outlets are equipped with adapters to connect flexible hose to the left hand
and right hand bleed air inlets located at fuselage station 190.00. Two freon lines from the air conditioning unit
located at fuselage station 265.00 pass through the airplane to fuselage station 204.00 and connect midway
through the plenum box assembly on the left hand side to the evaporator unit.
The plenum box assembly (on earlier models without air conditioning) has one outlet for venting air to the
cabin. It is located at the lower right-hand side of the plenum box. Later models have two air ducts oh the upper
front panel of the plenum box. This outlet is equipped with an adapter to connect flexible hose to the right-hand
hot air distribution duct
There is a fixed inlet centered in the upper rear back panel of the plenum box which connects to a fixed
adapter on the aft cabin bulkhead at fuselage station 204.00. The ventilating air from the dorsal fin air scoop and
bleed air pass through this inlet to the plenum box.
The ventilation blower fan and plenum box assembly is designed to operate under the following three
modes:
Mode 1. Unpressurized ventilating.
Mode 2. Pressurized ventilating.
Mode 3. Air conditioning/pressurized and unpressurized ventilating.
Transition of the ventilating system within the ventilating fan blower and plenum box assembly to the
pressurized mode or vice versa, is automatic and does not require a change of environmental controls. A fixed
automatic drain is located at the left hand bottom side of the plenum box assembly (air conditioning installed).
REMOVAL OF PLENUM BOX ASSEMBLY. (Refer to Figure 21-10.)
— NOTE —
Removal procedures for the non-air conditioned plenum box assembly to
the aft bulkhead at fuselage station 204.00 are identical to the air condi-
• tioned plenum box assembly removal procedures.
1. Remove vinyl curtain located at fuselage station 204.00.

2. Remove screws from overhead duct attached to plenum box assembly, at fuselage station
204.00. (Refer to Chapter 25 for removal of overhead duct from cabin).
3. Remove screws from front panel of plenum box assembly and break RTV-102 sealant around
mating surfaces of panel to plenum box, Remove front panel.
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MAINTENANCE MANUAL
Figure 21-10. Vent Fan Blower and Plenum Box Assembly

21-22-01
Page 21-62
issued: June 1,1995 OC-I
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
8 FREON LINES FROM AIR COND. UNIT*

1. VENTILATION FAN BLOWER 9. FIXED INLET AND BULKHEAD ADAPTER
AND ELECT MOTOR • (4 SCREWS TYP.)
2. PLENUM BOX FRONT PANEL 10. FAN BLOWER DUCT
3. AIR CONDITIONING 11 TWO BOLTS. WASHERS AND'NUTS
(CONDENSER UNIT)* (NUT PLATES ON LATER MODEL
4. LOWER FRONT ACCESS DOOR* 602PS AND ALL 700PS)
5 L/H FLEXIBLE HOSE ADAPTER (TYP. BOTH SIDES)
6 R/H HOSE ADAPTER 12. ELECTRIC MOTOR LEADS
7. AUTOMATIC DRAIN* 13 PHILLIPS HEAD SCREWS (20 REQUIRED)
(SOLENOID OPERATED UP 14. AFT BULKHEAD BOLT ADAPTER
TO A / F 0456) (4 PLACES TYP.)
•ON AIR CONDITIONED MODELS ONLY
Figure 21-10. Vent Fan Blower and Plenum Box Assembly (cont)
21-22-01
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Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
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4. Disconnect plastic drain hose from automatic drain on bottom of plenum box by removing clamp.
5. Disconnect flexible hoses from left hand and right hand adapters on lower sides of plenum box
by removing clamps.
6. Remove screws from rear panel inlet and fixed adapter on aft bulkhead of cabin.
7. Remove bolts from rear panel of plenum box connected to mount adapters on aft bulkhead of
cabin.
8. Remove plenum box assembly from cabin.
INSTALLATION OF PLENUM BOX ASSEMBLY.
— NOTE —
The following procedures apply to the initial installation of the plenum box
assembly to the aft bulkhead of the cabin without fan blower or evaporator
unit installed In plenum box or removal of vinyl curtain or overhead air
duct in cabin.
Installation procedures for the non-air conditioned plenum box assembly

to the aft cabin bulkhead at fuselage station 204.00 are identical to the air
conditioned plenum box assembly installation procedures.
1. Center plenum box inlet on rear back panel to fixed adapter on the aft cabin bulkhead at fuselage
station 204.00.
2. Remove screws from front panel and remove panel to gain access to rear back panel of plenum
box.
3. Install screws into fixed adapter and inlet to aft bulkhead of cabin.
4. Install bolts through back panel of plenum box to bolt adapters on aft bulkhead of cabin.
5. Connect flexible hoses to left hand and right hand hose adapters on plenum box. Secure hoses
with clamps.
6. Connect plastic drain hose to automatic drain on bottom of plenum box. Secure with clamp.
7. Install fan blower and electric motor inside top of plenum box in horizontal position. Align four fan
blower duct holes to four bolt holes in top of plenum box.
8. Install washers and bolts through top of plenum box bolt holes and fan blower duct holes. Secure
bolts with nuts. (On later 602P's and 700P's, nutplates on top of the box replace the nuts.)
9. Route two electrical wire leads from fan blower motor through hole midway in right hand side of
plenum box. Secure wire leads to electrical connector on right hand aft bulkhead.
10. Align front panel screw holes to front of plenum box holes.
11. Install screws through holes in front panel and secure panel.
12. Apply an even coat of RTV-102 sealant to mating surfaces of front panel and plenum box.
13. Install vinyl curtain at fuselage station 204.00 and secure curtain. (Refer to Chapter 25 for instal-
lation of overhead duct procedures).
21-22-02
Page 21-64
Issued: June 1,1995
2E3
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
DUCTS.
RIGHT HAND DUCT ASSEMBLY (CABIN). (Refer to Figure 21-11.)
Tfie rigtlt fiand tfiermoplastic distribution duct assembly is located on tfie lower rigtit fiand cabin side from
fuselage station 190.00 to fuselage station 54.25 (approximately). Tfie rigfit fiand distribution duct assembly is
equipped with three adapters, one at fuselage station 190.00 for flexible hose connection from the heater and two
at fuselage station 54.25 for flexible hose connections to the pilot hot air outlet, and defrost blower. The right
hand distribution duct assembly has provisions for three WEMAC air valves along its top exterior surface. These
WEfvlAC air valves vent heated air and ventilation air into the cabin interior. After installation of the right hand dis-
tribution duct assembly it is covered over by cabin carpeting with outlets in the carpet for protrusions of the
WEMAC air valves. These valves are directional and air distribution may be vented accordingly.
REMOVAL OF RIGHT HAND DISTRIBUTION DUCT ASSEMBLY.
— NOTE —
Refer to Cfiapter 25, for removal of seats, carpeting and other furnishings
in the cabin prior to starting removal procedures on the right hand distrity
ution duct assembly.
1. Turn off all fans, switches and electrical power that furnish heat and vented air to the cabin.
2. Disconnect hose from duct assembly adapter at fuselage station 190.00 by removing hose clamp
and breaking sealant.
and breaking sealant from pilot hot air outlet.
and breaking sealant from defrost blower connection.
*5: Drill out pop rivets in plastic strip and plastic flange securing duct assembly to right hand ribs of
cabin. . _" . .
6. Remove the right hand distribution assembly from cabin.
INSTALLATION OF RIGHT HAND DISTRIBUTION DUCT ASSEMBLY.
— NOTE —
The following procedures apply to the initial-installation of the right hand
distribution duct assembly to the cabin interior, without cabin carpet over-
lay or removal of cabin seating.
1. Turn off all fans, switches, and electrical power that furnish heat and vented air to the cabin.
2. Align right hand distribution duct assembly along cabin wall between fuselage station 190.00 and
fuselage station 54.25 on the right hand side of the cabin.
3. Connect hose to duct assembly adapter at fuselage station 190.00 with hose clamp and sealant.
4. Connect hose to duct assembly adapter at fuselage station 54.25 with hose clamp and sealant to
pilot hot air outlet.
21-23-03
Rage 21-65
Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
2906
Figure 21-11. Right l-land Distribution Duct Assembly

21-23-03
Page 21-66
Issued: June 1,1995
2E5
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
2906
Figure 21-11. Right Hand Distribution Duct Assembly (cont)

21-23-03
Page 21-67
OCC Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
2907
TYPICAL C H E R R Y RIVET INSTALLATION
TYPICAL W E M A C AIR V A L V E A N D C O V E R
Figure 21-12. Left Hand Distribution Duct Assembly

21-23-03
Page 21-68
Issued: June 1,1995
2E7
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
2907
LEFT H A N D DISTRIBUTION DUCT A S S E M B L Y
Figure 21-12. Left Hand Distribution Duct Assembly (cont)

21-23-03
Page 21-69
Issued: June 1,1995
2E8
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
5. Connect hose to duct assembly adapter at fuselage station 54.25 vyith hose clamp and sealant to
defrost blower.
6. Rivet with pop rivets and washers the thermoplastic strip along top surface of duct assembly.
7. Align and drill holes through plastic strip into cabin ribs for pop riveting of distribution duct
assembly between fuselage station 190.00 and fuselage station 54.25 on the right hand side.
8. Rivet with pop rivets and washers, plastic strip to ribs of cabin fuselage. (Use two rivets and
washers per rib).
9. Align and drill holes through plastic flange on bottom side of distribution duct to cabin ribs for pop
riveting duct between fuselage station 190.00 and fuselage station 54.25 on the right hand side.
10. Rivet with pop rivets and washers, the duct flange to ribs of cabin (use one rivet and washer per
rib).
11. Apply an even coat of RTV-102 sealant to mating surfaces of plastic-strip and duct assembly.
12. Align and install three WEMAC air valves into duct assembly between fuselage station 190.00
and fuselage station 54.25.
13. Use four screws and washers per valve at pre-designated outlets in duct assembly, and secure
WEMAC air valves. (Refer to Chapter 25 this manual for installation of cabin carpeting and stain-
less steel collars on WEMAC air valves). ,
LEFT HAND DUCT ASSEMBLY (CABIN). (Refer to Figure 21-12.)
The left hand thermoplastic distribution duct assembly is located on the lower left hand cabin wall
between fuselage station 190.00 and fuselage station 111.00. The left hand distribution duct assembly is
equipped with one adapter at fuselage station 190.00 for a flexible hose connection. The left hand distribution
duct assembly has provisions for two or three WEMAC air valves along its top exterior surface. These WEMAC
air valves vent heated air and ventilation air into the cabin interior. After the left hand distribution duct assembly is
installed, it is covered over by cabin carpeting with outlets in the carpet for protrusions of the WEMAC air valves.
REMOVAL OF LEFT HAND DISTRIBUTION DUCT ASSEMBLY.
— NOTE —
Refer to Cfiapter 25, ttiis manual for removal of seats, carpeting and otfier
furnishings in the cabin prior to starting removal procedures on the left
hand distribution duct assembly.
and breai<ing sealant.
3. Drill out pop rivets in plastic strip and flange securing duct assembly to ribs of cabin.
4. Remove duct assembly from cabin.
21-23-05
Page 21-70
Issued: June 1,1995
2E9
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
INSTALLATION OF LEFT HAND DISTRIBUTION DUCT ASSEMBLY.
— NOTE —
The following procedures apply to the initial installation of the left hand
distribution duct assembly to the cabin wall without cabin carpet overlay
or removal of cabin seating.
2. Align duct assembly to cabin wall between fuselage station 190.00 arid fuselage station 111.00
(approximately) on the left hand side of the cabin.
3. Connect hose to duct assembly adapter at fuselage station 190.00 with hose clamp and sealant
to bleed air connection.
4. Align and drill holes through plastic strip into cabin ribs for pop riveting of duct assembly between
fuselage station 190.00 and fuselage station 111.00.
5. Rivet with pop rivets and washers the plastic strip to ribs of cabin (use two rivets and washers
perrib).-
6. Align and drill holes through plastic flange on bottom side of duct assembly to cabin ribs between
fuselage station 190.00 and fuselage station 111.00.
7. Rivet with pop rivets and washers the duct flange to ribs of cabin (use one rivet and washer per
rib).
8. Apply an even coat of RTV-102 sealant to mating surfaces of plastic strip and duct assembly.
9. Align and install two WEMAC air valves into duct assembly between fuselage station 190.00 and
fuselage station 111.00.
10. . Use four screws and washers per valve at pre-designated outlets in duct assembly and secure
WEMAC air valves. (Refer to Chapter 25 this manual for installation of cabin carpeting and stain-
less steel collars on WEMAC air valves).
RADIO FAN BLOWER ASSEMBLY. (Refer to Figure 21-13.)
The fan blower motor is controlled by the radio master switch, and operates continuously when radios are
turned on.
PRESSURIZATION CONTROL. (Refer to Figure 21-14.)
DESCRIPTION.
The pressurization console located between the pilot and copilot seats is fitted with one of two available
types of pressurization controller installations. A standard controller provides for cabin pressurization beginning at
5000 feet above sea level, and an optional controller permits pressurization starting at sea level. There are three
functional groups of pressurization cabin controls and directly related control units consisting of the following:
1. Pilot controls.
A. Cabin altitude selector.
B. Cabin rate of climb selector.
C. Door seal inflate/deflate switch.
D. Pressure dump selector switch.
E. Bleed air shutoff switch.
21-31-00
Page 21-71
^^•IQ issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B383
O F.S. 54.25 O
Figure 21-13. Fan Blower, (Instrument Panel Radios)

21-31-00
Page 21-72
Issued: June 1,1995
2E11
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B384
ma
o 7 5-
1. ACCESS COVER (2 PLACES) 9. DRÎDER

2. SCREV, WASHER, NUT (6 PLACES) 10. DISPLAY SCREENS
3. FLEXIBLE TUBING 11. HOLDER
4. CABIN ALTITUDE CONTROLLER 12. HOUSING
5. CLIP HALF (4 PLACES) 13. BLEED AIR SIVITQ-I ASSEMBLY
6. SWITCH GUARD (2. PLACES) 14. DOOR SEAL SWITCH ASSEMBLY
7. LIGHT CAPSULE 15. SAFETY VALVE SIVITCH ASSEMBLY
8. LAMP (2 PER CAPSULE)
Figure 21-14. Pressurization Controls

21-31-00
r Page 21-73
2E12 Issued:, June i, 1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
K.S. 204.00
PASSENGER CCMPAKIMENT (PRESSURIZED)
1. COrfTROLLER
2. STATIC PORT
3. S A F E T Y V A L V E (P + 4 . 3 5 + .10.-.00)
4. P R E S S U R E R E G U L A T O R V A L V E (P + 4 . 1 5 + . 1 0 , -.00)
5. S Q U A T S W I T C H M O U N T E D O NN L G .
6. PRESSURE D U M P SWITCH MOUNTED
O N PILOT C O N S O L E
7. C I G A R E T T E FILTER
NOTE:
IF A I R C R A F T E Q U I P P E D W I T H O P T I O N 2 6 2 , S A F E T Y V A L V E S E T A T 5 . 6 0 •
5.70 P S I A N D P R E S S U R E R E G U L A T O R V A L V E S E T A T 5.40 - 5.50 P S I .
NOTE
SCHEMATIC SHOWS PRESSURIZATION
S Y S T E M IN D I F F E R E N T I A L MODE
Figure 21-14. Pressurization Controls (cont)

21-31-00
Page 21-74
Issued: June 1,1995
2E13
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
2.- -Remote controls. .
A. Cabin pressure regulating valve (outflow), includes a negative pressure relief valve.
B. Cabin pressure safety valve (dump), includes a negative pressure relief valve.
C. Nose landing gear squat switcfi.
D. Aneroid switch for oxygen required light.
,, E. Door seal control valve/microswitch.
3. Monitoring instruments.
A. "Cabin rate of climb gauge.
B. Cabin altimeter/cabin differential pressure gauge, red lined at maximum operating pres-
sure differential.
C. Oxygen required warning light.
The cabin maximum operating differential pressure is controlled at 4.25 +.10/-.00 psi for the 601P or 4.25
+.00/-.01 psi for the 602P and 700P. The differential pressure safety relief valve will automatically relieve at 4.40
± .05 psi. If aircraft is equipped with Option 262, the cabin maximum operating differential pressure is controlled
at 5.40-5.50 psi and the differential pressure safety relief valve will automatically relieve at 5.60-5.70 psi.
The nose gear squat switch is incorporated with the dump valve to prevent inadvertent pressurization
with airplane on the ground.
PRESSURE REGULATING OUTFLOW VALVE AND SAFETY VALVE (601P, 602P AND 700P).
(Refer to Figure 21-15.)
The pressure regulating (outflow) and safety valves are located on the forward side of the fuselage sta-
tion 204.00 bulkhead. The outflow valve is on the left and the safety valve is on the right, looking forward.
— NOTE —
Removal and installation procedures for both valves are similar.
Differences will be noted where applicable.
REMOVAL OF PRESSURE REGULATING OUTFLOW VALVE AND SAFETY VALVE.
1. Remove electrical power/master battery switch "OFF" and open "LEFT BLEED AND CON-
TROL", "RIGHT BLEED AND DUMP", and "SEAL PRESS" circuit breakers.
2. Remove trim and access panels on fonvard side of fuselage station 204.00 bulkhead above hat
shelf.
— NOTE —
Removal of the oxygen bottle will be necessary to facilitate removal of the
valve. Refer to Chapter 35 for procedures.
3. If safety valve is being removed, disconnect valve solenoid electrical leads.

4. . Disconnect tubing from valve being removed (outflow valve tubing should be identified to facili-
tate reinstallation). Install dust protectors on tubing and valve ports.
5. Remove hardware from aft side of fuselage station 204.00 bulkhead securing valve. Remove
valve, gasket, and hardware from'airplane.
21-32-01
Page 21-75
2£'^4 Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
TO VACUUM -~.^'^'\K
GENERATOR ( 7 0 0 P ) ^ ' V
1. OUTFLOW PORT 7. CONTROLLER LINE

2. OUTFLOW TUBE 8. ELBOW FITTING
3. BOLT WASHER (6 PLACES) 9. PRESSURIZATION STATIC LINE
4. GASKET 10. BLEED VALVE
5. SOLENOID 11. FILTER
6. SAFETY VALVE 12. OUTFLOW VALVE
Figure 21-15. Outflow and Safety Valve
21-32-01
Page 21-76
Issued: June 1,1995
2E15
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
. MAINTENANCE MANUAL •
INSTALLATION OF PRESSURE REGULATING OUTFLOW VALVE AND SAFETY VALVE.
1. Position valve and gasket over opening on fonward side of fuselage station 204.00 bulkhead and
secure with bolts and washers from aft side of bulkhead. Torque to 20 inch-pounds.
2. Remove dust caps from valve port(s) and tubing. Connect tubing to valve using care not to dam-
age flexible tubing and fittings.
3. If safety valve is being installed, connect solenoid electrical leads.
4. Perform cabin leak test in accordance with instructions contained in this chapter.
5. Install oxygen bottle per instructions in Chapter 35.
6. Install trim and access panels.
ADJUSTMENTH-EST OF PRESSURE REGULATING OUTFLOW VALVE AND SAFETY VALVE.
1. Equipment required.
A. QED 5000-1 pitot-static system tester, or equivalent.
2. Safety valve static line vacuum check.
A. Open baggage compartment door. Remove trim and access panels at fuselage station
224.00.
B. Connect tester vacuum line to safety valve outflow port at upper right of fuselage station
204.00 bulkhead.
C. Apply vacuum to the static line per tester manufacturer instructions, at a rate not to
exceed 2000 feet per minute to a maximum of 8000 feet above local altitude.
D. Close off vacuum line and observe for a maximum altitude drop of 100 feet in one
minute.
— CAUTION —
Damage to the safety valve will occur if vacuum is relieved too rapidly or if
pressure is applied to the static port.
E. Relieve vacuum slowly, not to exceed 2000 feet per minute.

F. Disconnect tester from safety valve outflow port.
G. Install access and trim panels at fuselage station 224.00.
NOSE LANDING GEAR SQUAT SWITCH. (Refer to Figure 21-16.)
The squat switch is a subminiature single pole double throw-double break (SPDT-DB) environmentally
protected switch located on the upper scissor half of the nose landing gear.
21-33-00
Page 21-77
2E16 Issued: June 1,1995

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
REMOVAL OF NOSE LANDING GEAR S Q U A T SWITCH.
1. Remove external power/master battery switch "OFF" and open circuit breakers on instrument
panel labeled "LEFT B L E E D AND CONTROL","RIGHT B L E E D AND DUMP", and "SEAL
PRESS."
2. Disconnect electrical leads to nose landing gear switch.
3. For airframe 0001-0610.
A. Remove screws, washers, nuts, and spacers securing squat switch mount to nose land-
ing gear upper scissor.
B. Lift switch mount and attached switch from scissor. Remove screws, nuts, and retainer
securing switch.
— NOTE —
Use care when separating squat switch from mount as the actuator pin can
fall free from mount when switch is not attached.
C. Remove actuator pin from mount and inspect for damage. Replace as required.
4. For airframe 0611 and sutjsequent.
A. Remove screws, washers, and nuts securing squat switch to underside of nose landing
gear upper scissor.
B. Remove actuator pin from scissor and inspect for damage. Replace as required.
INSTALLATION OF NOSE LANDING GEAR SQUAT SWITCH.
1. For airframe 0001 -0610.

A. Ensure actuator pin is inserted into position in mount and attach switch to mount using ,
retained hardware and retainer. V
B. Secure mount to nose landing gear upper scissor using retained hardware.
2. For airframe 0611 and subsequent.
A. Install actuator pin through hole in upper scissor-half.
B. Attach switch to underside of upper scissor-half using retained hardware.
3. Connect electrical leads from switch to existing wiring.
4. Adjust squat switch to actuate at .37 to .50 inch from full strut extension.
5. Reset circuit breakers "LEFT BLEED AND CONTROL", "RIGHT BLEED AND DUMP", and
"SEAL PRESS" and apply power to the airplane.
6. Manually depress the nose landing gear squat switch actuator pin and listen for actuation of the
safety valve solenoid. Also observe pressure relief valve switch on pilot's console for "NORMAL"
and "DUMP" indication simultaneously when pin is depressed and "DUMP" when pin is released.
7. Remove electrical power from airplane/master battery switch O F F .
8. Verify that pin will hit striker and not bind.
21-33-02
Page 21-78
Issued: June 1,1995
2E17
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B386
SQUAT SIVITCH INSTALLATION

A/F 0001 THRU 0610
1. NOSE LANDING GEAR

2. UPPER SCISSOR ^
3. SCREW, WASHER, SPACER, NUT /
4. SCREW, NUT (4 PLACES) /'
5. SWITCH RETAINER
6. SQUAT SWITCH
7. ACTUATOR PIN
8. SWITCH MOUNT
Figure 21-16. Nose Landing Gear Squat Switch

21-33-02
Page 21-79
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B388
1. NOSE LANDING GEAR

2. UPPER SCISSOR
3. SCREW, WASHER, NUT
4. SQUAT SWITCH
5. ACTUATOR PIN
Figure 21-16. Nose Landing Gear Squat Switch (cont)

21-33-02
Page 21-80
Issued: June 1,1995
2E19
1
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CABIN ALTITUDE CONTROLLER. (Refer to Figure 21-14.)
Tfie cabin altitude controller is located in tfie lower left of tfie pilot's console.
REMOVAL OF CABIN ALTITUDE CONTROLLER.
1. Remove access covers from left and rigfit sides of pilot's console.
2. Disconnect tubing from controller and cap openings in tubing and controller.
3. Remove spiral wrap from electrical lead to controller. Identify and disconnect electrical leads to
aid reinstallation.
4. Remove fiardware securing controller and lift controller from console.
INSTALLATION OF CABIN ALTITUDE CONTROLLER.
1. Install new filter on controller.

2. Position controller in pilot's console and secure using retained attactiing hardware.
3. Connect electrical leads.
4. Remove dust caps from tubing and controller and carefully connect tubing to controller so as not
to damage tubing and connectors.
5. Install access covers on pilot's console.
RESETTING PROCEDURE OF CABIN ALTITUDE CONTROLLER.

\
Loosen both set screws on center l<nob but do not remove knob.
Rotate entire knob assembly so correct altitude is set in window. Retighten set screws.
3. Rotate outer ring to set altitude. Cabin altimeter and controller should now be correct.
— CAUTION —
Ensure the gap between the outer ring and the lace of the controller does
not change during resetting. Too small a gap will cause binding.
BLEED AIR, INFLATABLE DOOR SEAL AND SAFETY VALVE SWITCHES. (Refer to Figure 21-14.)
The bleed air (AIR ON/AIR OFF), inflatable door seal (INFLATE/DEFLATE) and safety valve (NOR-
N/1AL/DUMP) switches are located in the pilot's console. Guard covers are installed on the door seal and safety
valve switches to prevent inadvertent deactivation of pressure system.
REMOVAL OF BLEED AIR, INFLATABLE DOOR SEAL AND SAFETY VALVE SWITCHES.
1. Ensure power is removed from airplane/master battery switch OFF and the circuit breaker for the
switch being replaced is pulled (airframe 0190 and UP). "LEFT ENGINE BLEED AND CONTROL",
"RIGHT ENGINE BLEED AND DUMP" (also controls power to the safety valve switch), or "SEAL
PRESS", as applicable.
21-3.';-01
Page 21-81

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
C133
CABIN ALTITUDE
INDICATES 5000'
STEP 1
-CONTROLLER SET FOR
6000' CABIN
kit
STEP 2
STEPS SEE CAUTION^
NOTE
REFER T OTEXT F O R P R O C E D U R E
CAUTION
ENSURE THE G A P B E T W E E N T H E O U T E R RING A N D THE

FACE OF THE CONTROLLER DOES N O T C H A N G E DURING
RESETTING. T O O S M A L L A G A PW I L L C A U S E BINDING.
Figure 21-17. Cabin Altitude Controller Resetting Procedure

21-35-01
Page 21-82
issued: June 1,1995
2E21
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
2. Remove'access cover on left or'right side of pilot's console, to gain access to switch being
removed.
— NOTE —
Before the lighting capsule can be removed from either the door seal or
safety valve switch the switch guard must be raised to facilitate removal of
the capsule. ,
3. Pull capsule free from switch housing.

4. Loosen two screws in switch to free screw clamps. Push switch up from underside of console
enough to allow retaining clip halves or switch guard (door seal and dump switch only) to be
removed. Remove clip halves/guard.
5. Identify electrical leads to aid installation and disconnect leads from switch.
6. Pull switch from console.
INSTALLATION OF BLEED AIR INFLATABLE DOOR S E A L AND SAFETY VALVE SWITCHES.
— CAUTION —
Use care when soldering electrical leads to switch terminals to prevent
entry of flux and cleaner into compartment.
1. Connect and solder electrical leads to switch.

2. Insert switch through console side panel and up through mounting hole far enough to allow
retaining clip halves or switch guard to be installed. Install clip halves or switch guard.
3. With switch and clip halves/guard positioned flush in console, tighten screws in switch until screw
clamps contact underside of console securing switch.
4. Insert lighting capsule in switch housing.
— NOTE —
Because of variations in the internal wiring of earlier model bleed air shut-
off valves, when the bleed air switch is replaced, the Bleed Air
Valve/Switch test procedure must be performed.
5. Perform "Bleed Air Valve/Switch" test per instructions contained in Adjustment/Test of Flow
Control and Bleed Air Valve/Switch Assembly (601P).
HEATING.
All airplane models utilize a Janitrol combustion heater located in the aft fuselage.
The description section includes airplane model and airframe effectivity data, including heater operating
procedures for each model.
DESCRIPTION. (Refer to Schematic Figure 21-1.)
21-41-00
Page 21-83
2^22 Issued: June 1,1995

r
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
MODEL 600. /
A 25,000 BTU, gasoline powered Janitrol heater supplies heat as required for cabin comfort. The heater V?"
is located in the fuselage, aft of the baggage compartment and obtains its fuel supply from the airplane fuel sys-
tem fuselage tanl<. During continuous operation the heater fuel consumption is approximately 0.6 GPH. The
heater air supply comes from the inlet at the base of the dorsal fin and is directed to the floor air outlets.
1. Heater operation.
A. Open adjustable floor outlets (as many as possible, airframe 0213 and Subsequent). Pull
Air Knob fully out (airframe 0001 thru 0455).
— NOTE —
Never operate heater with less than two open outlets and Air Knob full out
(airframe 0001 thru 0455).
B. Heater Fan Switch - ON.

C. Cabin Heat Switch - PRESS ON momentarily.
D. Heater Temp Knob - PULL to desired temperature.
E. Floor Outlets - ADJUST to desired flow.
2. Heater shutdown.
A. Heater Fan Switch - OFF.
— NOTE —
Do not close floor outlets until heater has adequately cooled. For heater
shutdown after landing, allow at least three minutes for heater to cool
before turning off the battery master switch.
/ '
B. For ground operation the master battery switch must be ON or the airplane must be on i
external power. Operating the heater or cabin fan on battery only is not recommended y -
because of high current drain. The cabin FAN switch must be ON for all heater opera-
tion.
3. Heater protection.
A. The heater electrical system is protected by a circuit breaker located on the circuit break-
er panel.
B. A Duct Switch, located within the cabin right side floor duct, controls the temperature
within the ducts as selected by the pilot using the TEMPERATURE" Knob. This switch
has a maximum temperature setting to prevent damage to ducts. Under normal operation
this is the switch that controls the heater.
C. A Cycling Switch, mounted at the heater outlet is preset to cycle the heater off in case
the temperature exceeds the maximum normal heater operation temperature prior to the
duet switch reaching its pilot selected setting. After the temperature drops, the cycling
switch will automatically re-start the heater.
D. A Combustion Air P~rQSSure Switch senses pressure differential between the exhaust
stack and combustion -air inlet tube. The switch will open and de-energize the heater cir-
cuit if the combustion air flow drops below a predetermined sePing.
21-41-01
Page 21-84
Issued: June 1,1995 ^ 2E23

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
.. • . MAINTENANCE MANUAL
E. An Overheat Switch mounted on the heater case will turn off the heater if the tempera-
ture exceeds the maximum safe operating temperature. This is usually triggered by a hot
spot caused by low airflow through the heater. When the overheat switch turns off the
heater, a light (annunciator) identified as HEATER FAIL will illuminate.
— NOTE —
The heater fail light and automatic reset feature only apply to airframe 0356
and Subsequent. Earlier models have to be manually reset at the heater
unless they have been modified by the latest revision of Service Letter
SL600-45.
F. HEATER FAIL light will stay on until the temperature drops to a safe limit, at which time
the heater can be restarted by following the normal starting procedure and taking precau-
tions noted below.
— WARNING —
Prior to restarting the heater, ensure the following steps are followed
to prevent a fire hazard.
(1) Air Knob is full out (airframe 0001 thru 0455) and as many passenger floor out-
lets as possible are full open.
(2) The heater Temperature Knob is only out half of its full extension.
(3) Immediately shut off heater if HEATER FAIL annunciator comes on again after
attempting to restart. Do not operate heater again until it has been serviced by a
qualified repair station.
(4) After the heater has restarted, wait approximately 5 minutes and then, if desired,
the temperature knob may be pulled out for a higher temperature selection.
4. Windshield defrosting.
A. The windshield D E F R O S T control is attached to a butterfly valve in the windshield
defrost ducting. Pulling control fully out opens the butterfly valve to allow bleed or ram air
to be directed to the defroster outlet extending along the bottom of the windshield. The
defroster blower switch located next to the defrost control on the instrument panel acti-
vates the blower to provide maximum defrosting and additional cabin heat distribution
capability. Defrost air temperature is controlled by cabin air temp controls.
MODEL 601.
1. Model 601 utilizes a 35,000 BTU heater, for descnption of operation refer to Model 600 Heater
Description.
MODELS 601P, 602P AND 700P.
A 35,000 BTU, gasoline powered Janitrol heater supplies heat as required for cabin comfort. The heater
is located in the fuselage, aft of the baggage compartment and obtains its fuel supply from the airplane fuel sys-
tem fuselage tank. During continuous operation the heater fuel consumption is approximately 0.6 GPH. When
pressurized, the heater air supply comes from the bleed air only. For airframe 0456 and subsequent, in either
mode of operation, some air is also supplied by recirculation of cabin air through the plenum static air door. For
airframe 0157 thru 0212 some warm air can be obtained without operating the heater by closing the cooling ram
air supply to the bleed air heat exchanger.
1. Heater operation.
21-41-03
Page 21-85
Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
A. For all airplanes open adjustable floor outlets (as many as possible). For airframe 0157
tfiru 0212 pull air l<nob and proceed to next steps only if additional fieat is desired.
— NOTE —
Never operate heater with less than two open outlets.
B. Heater Fan Switcfi - ON.

C. Cabin Heat Switcfi - PRESS ON momentarily.
D. Heater Temperature Knob - PULL to desired temperature.
E. Floor Outlets - ADJUST to desired flow.
2. Heater stiutdown.
A. Heater Fan Switcfi - OFF.
B. Heater Temperature Knob - Pusli Full In.
C. Air Knob - Pusfi Full In (airframe 0157 tfim 0212).
— NOTE —
Do not close floor outlets until heater has adequately cooled. For heater
shut-down after landing, allow at least three minutes for heater to cool
before turning off the battery master switch.
D. For ground operation tfie master battery switcfi must be ON or the airplane must be on
external power. Operating the heater or cabin fan on battery only is not recommended
because of high current drain. The cabin FAN switch must be ON for heater operation
whether on the ground or in flight.
3. Heater protection.
A. The heater electrical system is protected by a circuit breaker located on the circuit break-
er panel.
B. A Duct Switch, located within the cabin right side floor duct, controls the temperature
within the ducts as selected by the pilot using the 'TEMPERATURE" Knob. This switch
has a maximum temperature setting to prevent damage to ducts. Under nomial operation
this is the switch that controls the heater.
C. A Cycling Switch, mounted at the heater outlet is preset to cycle the heater off in case
the temperature exceeds the maximum normal heater operation temperature prior to the
duct switch reaching its pilot selected setting. After the temperature drops, the cycling
switch will automatically re-start the heater.
D. A Combustion Air Pressure Switch senses pressure differential between the exhaust
stack and combustion air inlet tube. The switch will open and de-energize the heater cir-
cuit if the combustion airflow drops below a predetermined setting.
E. An Overheat Switch mounted on the heater case will turn off the heater if the tempera-
ture exceeds the maximum safe operating temperature. This is usually triggered by a hot
spot caused by low airflow through the heater. When the overheat switch tums off the
heater, a light (annunciator) identified as HEATER FAIL will illuminate.
— NOTE —
The heater fail light and automatic re-set feature only apply to airframe
0356 and UP. Earlier models have to be manually re-set at the heater
unless they have been modified by latest revision Service Letter SL600-45.
21-41-03
Page 21-86
Issued: June 1,1905 2F1

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
F. The HEATER FAIL light will stay on until the temperature drops to a safe limit, at which
time the heater can be restarted by following the normal starting procedure and taking
precautions noted below:
— WARNING —
Prior to re-starting the heater, ensure the following steps are followed to
prevent a fire hazard.
(1) As many passenger floor outlets as possible are full open.

(2) The heater temperature knob in only out half of its full extension.
(3) Immediately shut off heater if HEATER FAIL annunciator comes on again after
attempting a re-start. Do not operate heater again until it has been serviced by a
qualified repair station.
(4) After the heater has been restarted, wait approximately 5 minutes and then, if
desired, the temperature knob may be pulled out for a higher temperature selec-
tion.
INSPECTION OF HEATER AND HEATER COMPONENTS.
1. Inspect all fuel lines and fittings for fuel stains, indicating leakage, and replace lines or tighten fit-
tings as necessary.
2. Check heater for loose bolts, screws and wiring.
3. Inspect all electrical connections for corrosion. If corrosion is evident, clean affected compo-
nents, and wipe with a lightly oiled cloth.
DAILY INSPECTION.
1. Inspect the ventilating air inlet scoop, combustion air inlet scoop, exhaust outlet and fuel drain for
possible obstructions. Make sure that all of these openings are clear of any restrictions and that
no damage has occurred to air scoop protrusions.
2. Look in the area of the combustion heater exhaust tube for large or unusual accumulation of soot
on the aircraft skin. Soot accumulations indicate that the heater is operating at a 'luel rich" con-
dition. A "fuel rich" condition may be caused by incorrect fuel pressure to the heater, restriction
in the combustion air iiilet line, loss of performance by the combustion air blower, or partially
clogged fuel nozzle.
3. Perform an operational check as follows:
A. Place the HEATER SWITCH in the ON (or HEAT) position. The ventilating air blower
and combustion air blower should operate and the heater OVER T E M P light should illu-
minate.
B. Operate both the combustion air blower and ventilating air blower and check each for
unusual current draw, noise or vibrations.
— NOTE —
To proceed with the operational check, follow paragraph entitled Heater
System Operational Check. The above procedure should be repeated one
or more times.
21-41-05
Page 21-87
Issued: June 1,1995
2F2
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
100-HOUR INSPECTION.
The mandatory 100-Hour Inspection shall be conducted on new heaters or overhauled heaters with a
new combustion tube assembly upon accumulation of 500-heater operating hours or twenty-four months,
whichever occurs first, and thereafter at intervals not to exceed 100-heater operating hours or twenty-four
months, whichever occurs first. If an hour-meter is used on the heater assembly, it should be connected across
terminals number 2 and 5 on the heater terminal strip. If an hour-meter is not used, count one heater operating
hour for each two flight hours for normal aircraft operation. Consideration should be given for any excessive
ground operation of the heating system.
— NOTE —
The 100-Hour Inspection consists of the functional checks and inspections
listed below and the Pressure Decay Test.
1. Inspect ventilating air and combustion air inlets and exhaust outlet for restrictions and security at
the airplane sl<in line.
2. Inspect the drain line to make sure it is free of obstructions. Run a wire through it if necessary to
clear an obstruction.
3. Check all fuel lines for security at joints and shrouds, making sure that no evidence of leaks
exists. Also check for security of attachment of fuel lines at the various points in the airplane.
4. Inspect electrical wiring at the heater terminal block and components for loose connections, pos-
sible chafing of insulation, and security of attachment points.
5. Inspect the high-voltage cable connection at the spark plug to make sure it is tight. Also, exam-
ine the cable sheath for any possible indications of arcing, which would be evidenced by burning
or discoloration of the sheath.
6. Inspect the combustion air blower assembly for security of mounting and security of connecting
tubing and wiring. Tighten any loose electrical terminals and air tube connections.
7. Operate both the combustion and ventilating air blowers and check for unusual noise or vibra-
tions.
8. It is recommended that the condition of the spark plug be checked for operation as described in
paragraph titled "Spark Plug."
9. Evaluate the condition of the combustion chamber by performing a "Pressure Decay T e s f as
described in the latest revision of Janitrol Maintenance and Overhaul Manual P/N 24E25-1.
10. Following the 100-hour inspection, perfomi the "Preflight and/or Daily Inspection."
-^NOTE —
Janitrol Maintenance and Overhaul Manual P/N 24E25-1 can be obtained
from the Midland-Ross Corp., Janitrol Aero Division, 4200 Surface Road,
Columbus, OH 43228 (Phone: 614-276-3561).
OVERHAUL INSTRUCTIONS.
The heater assembly shall be overhauled after 1000 hours or whenever the pressure decay test require-
ment cannot be met. The heater should be removed from the aircraft, disassembled, all parts thoroughly inspect-
ed and necessary repairs and/or replacements made prior to reassembly. Detailed step-by-step instnjctions are
included in the Janitrol Maintenance and Overhaul Manual for a complete heater overhaul. In some instances,
however, inspections may reveal that it is unnecessary to remove certain parts. If so, those portions of the over-
haul procedures may be eliminated.
21-41-07
Page 21-88
Issued: June 1,1995
2F3
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
HEATER, BLOWER AND PLENUM ASSEMBLY. (Refer to Figure 21-18.)
Ttie heater, blower and plenum assemblies, hereinafter referred to as 'The Assembly", is located behind
the baggage compartment in the aft fuselage on the right side of the airplane.
REMOVAL OF HEATER, BLOWER AND PLENUM ASSEMBLY.
1. Remove external power/master battery switch "OFF" and open "CABIN HEATER" circuit breaker.
2. Open baggage compartment and remove trim panel from aft of compartment.
— CAUTION —
Use extreme care when performing maintenance in the aft fuselage com-
partment to prevent damage to stabilizer rods and fuselage skin.
— NOTE —
Removal instructions are for removing the assembly as a unit. Should the
individual assemblies need to be separated, refer to the appropriate proce-
dure.
3. Disconnect flexible tubing from ends of the assembly and install dust protectors on open end of
tubing and the assembly.
4. Disconnect combustion air blower flexible duct at heater elbow, lôdel 601P, 602P and 700P.
5. Loosen clamps securing cuff on heater exhaust shroud and slide cuff down to gain access to
exhaust extension screws.
6. Remove screws securing exhaust extension to heater exhaust.
7 Loosen screws at shroud outlet securing exhaust extension sufficiently to allow extension to be
separated from heater. Retighten screws to secure extension.
THIS S P A C E INTENTIONALLY LEFT BLANK
21-42-01
Page 21-89
Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
Figure 21-18. i-leater, Blower and Plenum Assemblies (Model 600 and 601)
21-42-01
Page 21-90
Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
Figure 21-18. Heater, Blower and Plenum Assemblies (cont) (Model 601P and 602P)
21-42-01
Page 21-91
2pg Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
2911
Figure 21-18. Heater, Blower and Plenum Assemblies (cont)

21-42-01
Page 21-92
Issued: June 1,1995
2F7
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
1. B L O W E R D E L A Y S W I T C H . S C R E W , W A S H E R (3 P L A C E S ) 12. GROMMET
2. PLENUM 13. GASKET
3. V - C L A M P (2 P E R U N I T ) 14. FUEL FEED, NOZZLE HOLDER, SCREW, WASHER
4. B O L T , W A S H E R (4 P L A C E S ) 15. GASKET
5. H O U S I N G , O N E P I E C E " B E L L E D " (601, 6 0 1 P , 6 0 2 P A N D 7 0 0 P ) 16. NOZZLE, FUEL SUPPLY
H O U S I N G , T W O P I E C E " N O N - B E L L E D " (600) 17. O-RING
6. BRACKET 18. COMBUSTION TUBE AND JACKET ASSY
7. F A N B L A D E (601, 6 0 1 P , 6 0 2 P A N D 700P) 19. ADAPTER, SCREW
S Q U I R R E L C A G E F A N (600) 20. E L B O W FITTING A N D T U B E
S E T S C R E W S (2 P L A C E S E A C H ) 21. COMBUSTION SWITCH
8. F A N M O T O R W / 0 B R U S H E S (601, 601P, 6 0 2 P A N D 700P) 22. I G N I T I O N A S S Y , S C R E W (4 P L A C E S )
F A N M O T O R W I T H B R U S H E S (600) 23. SPARK PLUG
C A P (600, 2 P L A C E S ) 24. L I M I T S W I T C H , S C R E W (2 P L A C E S )
B R U S H A N D S P R I N G A S S Y (600, 2 P U C E S ) 25. GASKET
9. FUEL BOX, SCREW (2 P L A C E S ) 26. C Y C L I N G S W I T C H , S C R E W (2 P L A C E S )
10. SOLENOID PLATE AND GASKET
11. ELBOW, WASHER, NUT 27. T E R M I N A L B O A R D , S C R E W (2 P L A C E S )
Figure 21-18. Heater, Blower and Plenum Assemblies (cont)
8. Disconnect fuel drain at tee fitting on bottom of fieater and move drain line out of way. Install
dust caps over openings.
9. Remove safety wire and loosen clamps securing tfie assembly to compartment wall and rotate
assembly to gain access to tenninal strip and fuel box.
10. Remove fuel box cover and disconnect tieater fuel inlet line at solenoid valve and install dust pro-
tectors. Loosely reinstall fuel box cover.
11. Identify relay terminal strip leads for reinstallation and disconnect leads from terminal strip.
12. Identify blower delay switcfi leads and disconnect at blower delay relays.
13. Support tfie assembly and remove previously loosened clamps supporting tfie assembly.
Remove assembly from airplane.
21-42-01
Page 21-93
2F8 Issued: June 1,1995

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
INSTALLATION OF HEATER, BLOWER AND PLENUM ASSEMBLY.
1. Position the assembly against wall in aft fuselage and loosely secure the assembly with two
mount clamps. Rotate the assembly as required to facilitate connecting fuel and electrical leads.
2. Connect electrical leads to appropriate tenninals of terminal strip, blower delay switch, and blow-
er delay relays identified during removal.
3. Remove fuel box cover, dust protectors, and connect heater fuel inlet line at solenoid valve.
Loosely install fuel box cover.
4. Position the assembly to align heater exhaust with heater exhaust extension. Loosen screws at
shroud outlet and insert exhaust extension over heater exhaust aligning holes in heater exhaust
and extension with bevel of extension facing aft. Install screws securing heater extension to
exhaust.
5. Slide cuff over heater exhaust shroud and secure with two clamps.
6. Tighten clamps securing the assembly and install safety wire securing clamp screws to mount-
brackets.
7. Remove dust covers and connect flexible ducting at heater inlet and outlet and combustion air
blower duct to heater elbow (Models 601P, 602P and 700P).
8. Remove dust caps and connect fuel drain line to tee fitting at bottom of heater.
9. Perform operational check of heater per instructions contained in this chapter and check for fuel
and air duct leaks.
HEATER SYSTEM OPERATIONAL CHECK.
— CAUTION —
Do not operate heater with less than two open outlets as an overtemp con-
dition may occur.
1. Open as many adjustable floor outlets as possible.
— CAUTION —
Ensure all switches and equipment are turned OFF and all autopilot circuit
breakers are pulled prior to connecting an auxiliary power unit as damage
to electrical equipment could result if high voltage was inadvertently
applied. Master battery and alternator switches must remain "OFF" as long
as auxiliary power unit is connected.
2. Apply external power and ensure "CABIN HEATER" circuit breaker is closed.
3. Pull out "TEMPERATURE" control knob and place "CABIN FAN" switch at "ON" allowing fan to
run for a few seconds.
— NOTE —
Heater will not operate unless the fan switch is ON.
4. Momentarily depress "CABIN HEAT' switch to ON.

5. Position "TEMPERATURE" and "DEFROST" control knobs to desired temperature.
6. Place defrost blower switch at "BLOWER" and check operation of blower motor. Turn switch
OFF.
21-42-03.
Page 21-94
Issued: June 1,1995 2 F9

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
7. Momentarily depress "CABIN HEAT" switch to O F F and "CABIN FAN" switch on or off as
desired.
— NOTE —
After shutting down the heater, leave electrical power on the airplane for at
least three minutes or until the blower delay switch has had time to func-
tion. Leave TEMPERATURE control knob out.
The combustion air fan circuitry includes a delay relay which keeps the fan
on until the heater has cooled and the combustion chamber is cooL
8. Position 'TEMPERATURE" control knob in or out as desired.
— CAUTION —
Ensure all switches are at the OFF position until external power is discon-
nected to protect the voltage regulators and electrical equipment from volt-
age transients.
9. Remove auxiliary power unit from the airplane.
HEATER PLENUIW ASSEMBLY. (Refer to Figure 21-18.)
The plenum assembly consists of a welded plenum incorporating a replaceable blower delay switch
attached to the heater assembly outlet.
REMOVAL OF HEATER PLENUM ASSEMBLY.
1. Remove heater assembly per instaictions contained in this chapter.

2. Identify leads for reinstallation and disconnect blower delay switch leads at blower and blower
delay relays.
— NOTE —
Before separating heater and plenum assembly mark a line across flanges
of components so that correct alignment can be maintained at reinstalla-
tion.
3. Remove V-clamp securing plenum assembly to heater. Separate plenum assembly and heater.
21-42-05
Page 21-95
Issued: June 1,1995
2F10
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
INSTALLATION OF HEATER PLENUM ASSEMBLY.
— NOTE —
If plenum assembly being installed is not the same one that was removed,
mark a line on flange at same point as on removed assembly so that cor-
rect component alignment can be maintained, and identify switch electrical
leads.
1. With plenum assembly and heater flange marks aligned secure components together using V-
clamp or fasteners.
2. Connect blower delay switch electrical leads to blower and blower delay relays.
3. Install heater assembly per instructions contained in this chapter.
HEATER BLOWER MOTOR ASSEMBLY. (Refer to Figure 21-18.)
The blower motor is 24 volt electrically operated, encased in a housing attached with a V-clamp to the
heater assembly inlet.
REMOVAL OF HEATER BLOWER MOTOR ASSEMBLY.
1. Remove heater, blower, and plenum assemblies per instructions contained in this chapter.
2. Disconnect blower motor electrical connector and install dust plugs over connectors.
— NOTE —
Before separating heater and blower motor assemblies mark a line across
flanges of components so that alignment can be retained at reinstallation.
If further disassembly of blower assembly is required, proceed with Step

No. 3. If not required, removal procedures are completed.
3. Remove fasteners or V-clamp securing blower assembly to heater and separate components.
4. Remove screws and nuts securing motor electrical connector to housing. Allow connector to slide
free from housing and remove connector gasket.
5. Remove screws and washers securing motor assembly bracket to housing. Carefully pull motor
assembly and attached bracket and fan free from housing so as not to damage components.
— NOTE —
Prior to removal of motor from bracket, scribe a line on case and bracket
so that correct alignment can be maintained to facilitate installation.
6. Loosen screw and washer securing motor assembly to bracket and separate motor from bracket.
7. Loosen set screws securing fan to motor shaft and slide fan free from shaft.
21-42-08
Page 21-96

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
INSTALLATION OF HEATER BLOWER MOTOR ASSEMBLY.
— NOTE —
If blower assembly has been completely disassembled proceed with Step
No. 1. If assembly was removed from the airplane as an assembly and no
further disassembly is required, omit Step No's 1. through 5. and proceed
with Step No. 6.
1; Apply a thin coat of petroleum base grease to motor assembly shaft prior to fan installation and
slide fan onto shaft. Tighten set screws.
— NOTE —
If same motor assembly and bracket are being installed, perform Step No.
2., omit Step No. 3. and proceed with Step No. 4. If new motor and/or brack-
et are being installed, omit Step No. 2. and proceed with Step No. 3.
2. Slide motor assembly into bracl<et aligning marks on bracket and motor case and tighten screw
securing motor assembly to bracket.
3. Slide motor assembly into bracket so large diameter of motor case is centered in bracket with
electrical lead positioned at bottom left (looking toward air exhaust area) of mounting bracket
screw. Tighten bracket screw. Insert bracket and motor assembly in housing and check, that with
bracket screws aligned, the electrical connector can be attached to housing without too much
lead slack or not enough slack. Remove and reposition motor assembly as necessary.
4. Insert motor assembly and bracket into housing and align bracket attach points with housing and
install screws and washers to secure bracket. Ensure fan does not contact housing.
5. Install gasket over electrical lead connector and insert connector through opening in housing.
Attach connector using retained screws and nuts.
— NOTE —
If blower motor assembly being installed is not the same one that was
removed, mark a line on flange at same point as the one on the removed
assembly so that correct component alignment can be maintained.
6. Position blower motor and heater assemblies mating flanges together and loosely install V-clamp
or secure with fasteners. Rotate assemblies to align scribe marks and secure clamp.
7. Remove dust plugs and connect blower motor electrical lead.
8. Install heater, blower, and plenum assemblies per instructions contained in this chapter.
21-42-09
Page 21-97
2P"J2 Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
INSPECTION/CHECK OF HEATER BLOWER MOTOR A S S E M B L Y .
1. At disassembly and 500 Flight Hours.

A. Blower wheel and sheet metal parts for cracks and damage. Repair or replace as
required.
B. Electrical leads for damage and broken insulation.
2. Inspection of motor brushes and commutator.
A. Remove brush cap at either brush location, noting position of brush inside of guide, and
carefully lift brush and spring assembly out of guide. Hold brush in same position as
removed so it can be installed in same position if replacement is not required.
B. Inspect brush for wear. If brush is worn to a length of 3/16 inch, it must be replaced.
C. Repeat Steps A. and B. for remaining brush and spring assembly.
D. Using shop air remove dust from commutator.
E. Looking through the brush guide, inspect commutator which should be smooth and medi-
um to dark brown in color
F. Observe commutator for groove{s) in brush track, gouged, scored, or shows signs of
having burned spots. If any of these conditions exist, motor will have to be replaced.
G. If commutator is okay and old brushes are good, reinstall old brushes in same position as
removed and secure with brush caps.
H. If new brushes are being installed, ensure brushes are positioned so curved end fits cur-
vature of commutator. Insert brushes into guide and install brush caps.
— NOTE —
After installing new brushes it is advisable to run-in the brushes. Continue
with Step I. if brush run-in is required.
I. Connect motor to a controlled voltage supply (rheostat in a 28 volt line). Operate the
motor at 1/2 its normal speed for first hour; gradually increase speed until motor is oper-
ating at approximately normal speed. Continue mn-in operation for at least two hours to
properly seat brushes before installing.
HEATER ASSEMBLY. (Refer to Figure 21-18.)
The heater is a fuel operated, 24 Vdc electrically controlled unit installed in the aft fuselage just aft of the
baggage compartment.
REMOVAL OF HEATER ASSEMBLY.
1. Remove heater, blower, and plenum assemblies per instructions contained in this chapter.
2. Remove heater blower motor assembly per instructions contained in this chapter.
3. Remove heater plenum assembly per instructions contained in this chapter.
— NOTE —
Various heater assembly component removals and spark plug adjustments
are contained in this chapter. Should complete disassembly of the heater
or a pressure decay test need to be performed, refer to the latest revision
of Janitrol Maintenance and Overhaul Manual P/N 24E25-1. Refer to the
Vendor Supplier information in the front of this manual for address and
telephone number. All screws and gaskets (both sides) must be coated
with Permatex-1372 Form-A-Gasket at installation on pressurized heater
installations.
21-42-12
Page 21-98

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
INSTALLATION OF HEATER ASSEMBLY.
1. Install heater plenum assembly per instructions contained in this chapter.

2. Install heater blower motor assembly per instructions contained in this chapter.
3. Install heater, blower, and plenum assemblies in airplane per instructions contained in this chap-
ter.
COMBUSTION AIR BLOWER ASSEMBLY. (Refer to Figure 21-19.)
The combustion air blower assembly is a 24 volt electrically operated motor assembly and housing locat-
ed aft of the baggage compartment above the heater assembly.
REMOVAL OF COMBUSTION AIR BLOWER ASSEMBLY.
1. Remove external power/master battery switch "OFF" and pull "CABIN HEATER" circuit breaker.
2. Open baggage compartment door and remove trim panel from aft of compartment.
— CAUTION —
Use extreme care when performing maintenance in the aft fuselage to pre-
vent damage to flight control rods and fuselage skin.
3. Disconnect flexible ducting at intake and outlet of blower and install protective covers.
4. Disconnect blower electrical leads at heater mounted terminal No. 6 and ground.
5. Remove screws, washers, retainer strap, and spacers securing blower assembly to mount.
Remove blower assembly and hardware.
— NOTE —
If further disassembly of blower assembly is required, proceed with next
step. If not required, removal procedures are completed.
6. Remove screws and washers securing outlet adapter to blower housing and separate adapter
from housing.
7. Remove screws securing blower housing halves and separate outer half from assembly.
8. Loosen set screw securing fan wheel to motor assembly shaft and pull wheel from shaft.
9. Remove nuts and washers securing inner half of blower assembly to motor assembly and sepa^
rate inner half of housing assembly and spacer from motor assembly.
INSTALLATION OF COMBUSTION AIR BLOWER ASSEMBLY.
— NOTE —
If blower assembly has been completely disassembled proceed with Step
No. 1. If assembly was removed as an assembly and no further disassem-
bly was required, omit Step No's 1. through 5, and proceed with Step 6.
21-42-16
Page 21-99
2|p-|4 Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B389
^1. COMBUSTION AIR BLOIVER ASSEMBLY

2. CLAMP
3. FLEXIBLE DUCT
4. BOLT, WASHER, SPACER (4 PLACES)
5. RETAINER STRAP
6. PAD
7. MOUNT
8. SCREW, WASHER (2 PLACES) O
9. OUTLET AD.ÊR
10. SCRBV, WASHER ( 3 PLACES) ^
11. INLET ADAPTER
12. SCREW (3 PLACES)
13. BLOWER HOUSING
14. SETSCRBV
15. FAN WIEEL
16. NUT, WASHER, WASHER (2 PLACES)
17. SPACER
18. MOTOR ASSEMBLY
19. CAP (2 PLACES)
20. BRUSH AND SPRING ASSEMBLY
Figure 21-19. Combustion Air Blower Assembly

21-42-16
Page 21-100
issued: June 1,19C:
2F15
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B390
Figure 21-19. Combustion Air Blower Assembly (cont)

21-42-16
Page 21-101
opiC Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
1. Slide spacer over motor assembly shaft with flat surface of spacer against motor housing.
2. Place inner half of housing over motor assembly shaft and attach studs and secure with nuts and
washers.
3. Apply a thin coat of petroleum base grease to motor assembly shaft prior to fan installation, and
slide fan wheel onto shaft. Ensure fan wheel clears housing and secure with set screw.
4. Fit outer blower housing to inner half and secure with screws. Ensure fan wheel clears housing.
5. Install outlet adapter to housing with screws and washers.
6. Position blower assembly on mount above heater and secure using screws, washers, pad,
retainer strap, and spacers.
7. Connect blower motor electrical leads to heater mounted terminal No. 6 and to ground.
8. Remove protective covers and connect flexible ducting to inlet and outlet of blower assembly.
9. Perform operational checl< of heater per instructions contained in this chapter.
10. Install baggage compartment aft trim panel.
INSPECTION/CHECK OF COMBUSTION AIR BLOWER ASSEMBLY.
1. At Disassembly or 500 Flight Hours.

A. Blower wheel and sheet metal parts for physical damage. Repair or replace as required.
B. Electrical leads for physical damage and broken insulation.
C. Brushes and commutator. (Refer to Inspection/Check for Heater Blower Motor
Assembly.)
D. Mount pads for security and deterioration. Replace as required.
HEATER SYSTEM RELAYS. (Refer to Figure 21 -20.)
The blower assembly, blower delay, and heater control relays are mounted aft of the baggage compart-
ment on the right side of the airplane adjacent to the combustion air blower assembly.
— NOTE —
Removal and replacement of the relays are similar and relays are inter-
changeable.
REMOVAL OF HEATER SYSTEM RELAYS.
1. Remove extemal power/master battery switch O F F and pull "CABIN HEATER" circuit breaker.
2. Open baggage compartment door and remove vinyl curtain from aft of compartment.
3. Identify and disconnect electrical leads at relay to be removed.
4. Remove screws, washers, nuts and spacers securing relay.
21-42-19
Page 21-102
Issued: June 1,1995
2F17
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B391
1. SCREW, SPACER, WASHER,

NUT (2 PLACES)
2. BLOUER DELAY RELAY
3. BLOIVER CONBUSTION RELAY
4. HEATER RELAY
Figure 21-20. Heater Relays

21-42-19
Page 21-103
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MAINTENANCE MANUAL
INSTALLATION OF HEATER SYSTEM RELAYS.
1. Place relay in position in aft fuselage and secure with screws, washers, spacers, and nuts.
2. Connect electrical leads to previously identified terminals.
3. Perform operational check of heater system per instruction contained in this chapter.
4. Install vinyl curtain aft of baggage compartment. Close compartment door.
SPARK PLUGS.
One of three types of plugs is used on the heater installed in the Aerostar.
The Type I plug has a center electrode and an attached ground electrode bail. The Type I plug is used on
the earlier Aerostar heaters (to A/F 0165).
The Type II plug has a center electrode but no attached ground electrode. The ground electrode is
attached to the combustion head of the heater. •
The Type III plug contains a center electrode. Jhis type plug is used on the heaters installed in later
model Aerostars.
REMOVAL OF SPARK PLUG.
1. Ensure electrical power is removed/master battery switch is OFF and open "CABIN HEATER"
circuit breaker.
2. Open baggage compartment door and remove vinyl curtain from aft of compartment.
3. Unscrew and remove high voltage lead connector at spark plug using care not to damage or foul
connector
4. For Model 600 airplane, remove grommet from around spark plug.
5. Using a 7/8 inch deep hex socket, unscrew and remove spark plug. Ensure gasket is still on
spark plug, if not retrieve from heater using a wire hook. (Refer to section titled Adjustment/Test
of Spark Plug Gap for adjustment and inspection criteria).
INSTALLATION OF SPARK PLUG.
— NOTE —
If a new spark plug is being installed, be sure to check spark plug gap per
section titled Adjustment/Test of Spark Plug Gap.
1. Install new spark plug gasket over plug threads. If gasket does not hold on threads place a small
amount of Aviation Permatex, or equivalent, on gasket so it will temporarily stick to plug shell.
2. Screw spark plug into heater using a deep socket. Torque plug to 336 inch-pounds.
3. For Model 600 airplanes, install grommet over spark plug into heater jacket opening.
4. Carefully insert spring connector on high voltage lead into spark plug shell; gently press down on
lead and start nut on threads. Torque nut to 240 inch-pounds.
5. Operate heater per instmctions contained in this section.
21-42-23
Page 21-104
Issued: June 1,1995
2F19
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
ADJUSTMENT/TEST OF SPARK PLUG. (Refer to Figure 21-21.)
1. ' Type I Sparl< Plug:

A. Tfie spark plug can be cfiecked visually for sparking across tfie gap prior to installing the
plug by the following nnethod:
(1) Disconnect the wire from the No. 3 terminal on the heater wiring side of the ter-
minal strip to de-energize the fuel solenoid valve.
(2) Connect the high voltage lead temporarily and lay the spark plug on the heater
jacket.
(3) Energize the heater system and check for spark between the spark plug and
ground electrode.
~ WARNING —
Be sure to plug the spark plug hole In the heater to prevent any possibility
of residual fuel blowing out and igniting.
Do not touch the spark plug while energized tjecause of dangerously high
voltage.
2. Type II Spark Plug:

A. Prior to installation, the spark plug can be checked visually for sparking across the gap
as follows:
(1) Install the spark plug in the special ground electrode fixture as shown in Figure
21-21 a. Screw the plug into the fixture until it is tight. Adjust the rod on the fix-
ture to obtain a gap of .156-.188 inch.
(3) Connect the high voltage lead temporarily and lay the spark plug in its special
ground electrode fixture on the heater jacket.
(4) Energize the heater system and check for spark between the spark plug and
ground electrode.
B. There are three methods for checking the spark plug gap for the Type II Plug. Methods I
and 11 are used when the heater is not disassembled. Method III is recommended when
the heater is being overhauled and before installation of the fuel nozzle.
(1) Method I:
(a) With a new gasket installed on the spark plug, measure the distance
between the spark plug seating surface and the end of the spark plug elec-
trode.
(b) Use a depth gauge to measure the distance between the ground electrode
in the heater to the spark plug seating surface in the heater jacket. Check
this measurement against the measurement obtained in the preceding
step. The difference should be between 0.156 to 0.188.
(c) Bend the ground electrode to obtain the required gap.
21-42-24
Page 21-105

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
C697
T Y P E I SPARK PLUG TYPE III S P A R K PLUG
385
BEND TO ADJUST .156- 188 G A P
0 . 0 5 0 T O 0.060 INCH
T -
^ 4
-10
B392 TYPE II S P A R K PLUG

(SHOWN INSTALLED)
1. S P A R K PLUG
2. S E A T I N G SURFACE
3. C O M B U S T I O N TUBE ASSEMBLY
4. GROUND ELECTRODE
5. J A C K E T ASSEMBLY
6. C O M B U S T I O N HEAD ASSEMBLY
7. MEASURE
8 GASKET
9 CENTER ELECTRODE
10. V E N T HOLES
Figure 21-21. Spark Plugs

21-42-24
Page 21-106
Issued: June 1,1995
2F21
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
C697
.. NOTE •
DIMENSION A VARIES WITH 1 IN. HEX S.A.E. 1112 SCREW STOCK
LENGTHOF SPARK PLUG. 0.640 DIA. DRILL CHAMFER 45"" x 1/16
0.125 DIA.
NEAR END ONLY
1010-1020 STEEL ROD THREAD 18 M.M. - 1.5 M.M. PITCH
3.00 INCH
. ADJUSTABLE S.A.E: SPARK PLUG STANDARD
GAP
0.3125 DIA. ROD, 0.50 LONG

1010-1020 STEEL ROD
DRILL AND TAP FOR 4-40 SCREW NOTE:
LOCATE 1/4 IN. EITHER END ALL DIMENSIONS
SCREW - MACHINE. RD HD, ARE IN INCHES
AN OR MS 4-40 - 1/4 IN. LONG •-DENOTES SILVER SOLDER
Figure 21-21 a. Ground Electrode Fixture
(2) IVIetiiod II:

(a) Locally fabricate the special tool, "Spark Gap Adjustment Tool," shown in
Chapter 91.
(b) Install the threaded end of the tool into the spark plug hole.
(c) Slide the tool rod into the combustion head until it contacts the ground
electrode.
(d) Check that the indicator ring on the rod lines up with the end of the tool.
Bend the ground electrode to obtain the required gap.
(3) Method III: '
(a) Use a 5/32 inch drill (0.156) or a piece of 5/32 rod to reach through the
opening in the combustion head to find the ground electrode.
(b) Move the drill along the spark side of the ground electrode. Movement
should be from the outer edge toward the center. The drill should just pass
through the spark plug gap opening.
(c) Bend the ground electrode (by reaching through the spark plug opening) as
necessary.
(d) If bending of the electrode is necessary, reinstall spark plug and recheck
gap per Step (b).
21-42-24
Page 21-107
2F22 Issued:June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
3. Type III Spark Plug:
A. If the spark plug appears to be in good condition, the outer surface of the ground elec-
trode sleeve may be wiped clean with a rag, the internal porcelain-may be blown clean
using shop air directed through the vent holes or through the open end.
B. After cleaning, the spark gap may be checked. The gap between the center electrode
disc and the ground electrode should be between .156 and .188 inch.
— NOTE-
NO regapping of this type of sparic plug is possible. Do not bend the center
electrode or the disc on top of the center electrode.
C. Prior to installation, the spark plug can be checked for sparking across the gap as fol-
lows:
(2) Connect the high voltage lead temporarily and lay the spark plug on the jacket.
(3) Energize the heater system and observe for sparking between the center and
ground electrodes.
CLEANING SPARK PLUG.
1. If the plug appears to be in good condition, except for a mild coating of oxide on the porcelain
and electrodes, it may be cleaned and reused.
2. Plug ceramic insert cavity at terminal end of plug with a piece of paper or cloth to keep cavity free
from cleaning abrasive.
3. Clean spark plug on a conventional spark plug cleaner holding plug far enough out of cleaner
nozzle opening to provide an effective job.
4. Remove plug from terminal end of plug and clean cavity thoroughly with a clean cloth and carbon
tetrachloride.
5. Ensure spark plug porcelain is white and electrodes are not eroded.
— NOTE —
If the spark plug fails to clean up properly and/or if the electrodes are badly
eroded, it should be replaced.
6. If plug is reusable, adjust the spark plug gap in accordance with procedures in section titled
Adjustment/Test of Spark Plug Gap.
FUEL FEED, NOZZLE HOLDER AND V A L V E ASSEMBLY. (Refer to Figure 21-18.)
The fuel feed, nozzle holder and valve assembly, hereafter referred to as fuel nozzle assembly is
installed at the inlet area of the heater assembly which is located aft of the baggage compartment.
21-42-26
Page 21-108
Issued: June 1,1995
2F23
AEROSTAR AIRCRAFT
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MAINTENANCE MANUAL
REMOVAL OF FUEL FEED, NOZZLE HOLDER AND VALVE ASSEMBLY,
1. Ensure electrical power is removed/master battery switch "OFF" and pull "CABIN HEATER" cir-
cuit breaker.
2. Remove heater, blower, and plenum assembly per instructions contained in this chapter.
3. Separate heater plenum assembly from heater assembly per instructions contained in this chap-
ter.
4. Remove screws securing fuel box cover and lift cover from fuel box.
5. Disconnect solenoid valve electrical lead from terminal strip and pull leads through grommet in
fuel box. (Remove union from solenoid if valve is to be replaced.)
6. Unscrew solenoid valve from elbow fitting and remove from fuel box.
7. Loosen nut on elbow fitting. Unscrew elbow fitting and separate fitting nut, washer, fuel box, and
gasket from heater. Discard gasket.
8. Remove screws and washer securing fuel feed and nozzle holder to combustion liner inlet
Separate holder and gasket from heater. Discard gasket.
9. If spray nozzle is damaged or clogged, carefully unscrew and remove nozzle from nozzle holder.
10. Clean and remove debris from nozzle and nozzle holder.
11. Remove dried Permatex from mating surfaces of combustion liner and nozzle holder, using care
not to damage component surfaces.
INSTALLATION OF FUEL FEED, NOZZLE HOLDER AND VALVE ASSEMBLY.
1. Install spray nozzle in fuel feed and nozzle holder. Torque spray nozzle 75 to 100 inch pounds.
2. Coat screws and both sides of new gasket with Pemriatex-1372 Form-A-Gasket.
3. Place gasket and nozzle holder in position on combustion liner and secure with screws and
washer, using care not to allow gasket sealant to contact spray nozzle opening.
4. Coat both sides of new gasket with PERMATEX-1372 Form-A-Gasket and position over opening
in heater jacket using care not to allow sealant to contact nozzle holder inlet.
5. Position fuel box on gasket and install washer, elbow fitting, and nut. Tighten fitting with inlet
opening pointing toward opening in end of fuel box (facing toward heater exhaust) and secure
nut.
6. Screw solenoid valve into elbow fitting and route electrical leads through grommet in fuel box and
connect ground lead to terminal strip.
7. If removed, install union in end of solenoid valve.
8. Install fuel box cover with retained screws.
9. Install heater plenum assembly on heater assembly per instmctions contained in this chapter
10. Install heater, blower, and plenum assembly per instructions contained in this chapter and per-
form operational check of heater
BLOWER DELAY SWITCH. (Refer to Figure 21-18.)
The blower delay switch is installed in the heater plenum assembly which is attached at the air outlet end
of the heater assembly located in the aft fuselage behind the baggage compartment.
21-42-29
Page 21-109

AEROSTAR AIRCRAFT
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MAINTENANCE MANUAL
REMOVAL OF BLOWER DELAY SWITCH.
1. Ensure electrical power is removed/master battery switch "OFF" and pull "CABIN DEFROST" cir-
cuit breaker.
2. Open baggage compartment door and remove trim panel at rear of compartment.
3. Identify and disconnect blower delay switch electrical leads at relays located above heater
assembly. Pull electrical leads free from ties. .
4. Remove screws and washers securing switch to plenum assembly.
5. Carefully pry switch free from plenum assembly using care not to damage plenum or switch.
6. Remove switch.
7. Clean sealant from switch, mating surface of plenum assembly, and (if same switch is to be rein-
stalled) remove sealant from switch flange.
INSTALLATION OF BLOWER DELAY SWITCH.
1. Apply RTV-102 sealant, or equivalent, to blower delay switch flange and switch mating flange on
plenum assembly.
— NOTE —
If new switch is installed identify electrical leads prior to installation.
2. Insert switch through hole in plenum assembly and secure with screws and washers.
3. Route and connect switch electrical leads to relays.
4. Perform operational check of heater system per instructions contained under Heating,
Description and Operation.
5. Install baggage compartment aft trim panel and close compartment door.
CYCLING SWITCH AND LIMIT (OVERHEAT) SWITCH. (Refer to Figure 21-18.)
The cycling and limit switches are installed on the heater assembly right side between the heater and
fuselage skin.
REMOVAL OF CYCLING SWITCH AND LIMIT (OVERHEAT) SWITCH.
cuit breaker.
2. Open baggage compartment door and remove compartment aft trim panel.
3. Identify and disconnect electrical leads from switch (cycling or limit) to be removed.
4. Remove screws and washers from switch being removed and remove switch and gaskets (limit
switch only) from heater assembly.
21-42-33
Page 21-110
Issued: June 1,1995
2G1
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
INSTALLATION OF CYCLING SWITCH AND LIMIT (OVERHEAT) SWITCH.-
1. Install switch arid gaskets (limit switch only) on heater assembly and secure with retained screws
and washers.
2. Attach electrical leads to switch at terminals identified dtiring removal.
3. Perform operational check of heater per instructions contained in this chapter.
4. Install baggage compartment aft trim panel and close compartment door.
COMBUSTION AIR PRESSURE SWITCH.
REMOVAL OF COMBUSTION AIR PRESSURE SWITCH.
1. Disconnect electrical leads from the terminals of the combustion air pressure switch and mark
them for proper reassembly.
2. Unscrew and remove the combustion air pressure switch from the fitting on the combustion air
inlet tube.
INSTALLATION OF COMBUSTION AIR PRESSURE SWITCH.
1. Screw the combustion air pressure switch on the threaded fitting of the combustion air inlet tube
and tighten it securely. Do not overtorque the switch, as this may change the setting.
2. Connect the electrical leads to their respective terminals.
3. Check for proper heater operation.
IGNITION A S S E M B L Y . (Refer to Figure 21-18.)
The ignition assembly consists of an ignition and/or vibrator assembly which are externally attached at
the fonward top end of the heater assembly in the aft fuselage.
REMOVAL OF IGNITION ASSEMBLY.
cuit breaker.
2. Disconnect primary wire from igniter to filter at ignitor.
3. Unscrew and disconnect high voltage ignition cable at spark plug using care not to damage or
foul connector.
4. Reriiove ignitor assembly attaching screws and lockwashers.
21-42-39
Page 21-111
2G2 Issued: June 1,1995

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL.
INSTALLATION OF IGNITION ASSEMBLY. ^ . .Z'
1. Position ignition assembly on heater mount brackets and secure with screws and iockwashers.
2. Carefully insert spring connector on high voltage lead into spark plug shell, press down gently
and start nut on threads. Torque nut to 240 inch pounds.
3. Connect primary wire from igniter to filter at igniter.
4. Operate heater per Heater System Operational Check instructions contained in this chapter.
CABIN HEAT DUCT SWITCH. (Refer to Figure 21-22.)
The duct switch is installed in the ventilating system ducting on the forward side of fuselage station
176.88. The duct switch may be adjusted manually from a high of 250 ± 10°F downward through a range of 146
±6°F.
REMOVAL OF CABIN HEAT DUCT SWITCH.
1. Remove electrical power/master battery switch "OFF" and pull "CAB HEATER" circuit breaker.
2. Remove trim panel at fuselage station 176.88.
3. Identify and disconnect electrical leads from duct switch.
4. Loosen duct switch cable attach screw and pull cable free from switch control lever.
5. Remove screws, washers, and nuts securing duct switch to ducting and remove switch.
21-42-42
Page 21-112
Issued: June 1,1995
2G3
AEROSTAR AIRCRAFT
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MAINTENANCE MANUAL
6393
5. HEAT DUCT SWITCH
Figure 21-22. Heat Duct Switch and Control

21-42-42
Page 21-113
r%r^ A Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL ^
INSTALLATION OF CABIN HEAT DUCT SWITCH. .. ^, --^^^
1. Slide cable through duct switch control lever and place switch in duct. Secure switch using
screw, washers, and nuts.
2. Ensure duct switch 'TEMPERATURE" control knob on instrument panel is pushed all the way in
and duct switch control lever is at "L" (low) position and secure cable with screw.
3. Connect electrical leads to duct switch.
4. Perform operational check of heater with duct switch set above ambient temperature to check
operation.
5. Install trim panel at fuselage station 176.88.
HEATER SYSTEM FUEL PUMP. (Refer to Figure 21-23.)
The heater system fuel pump is a 24 volt, electrically operated incorporating a replaceable filter. The fuel
pump is located beside the system fuel regulator and shutoff valve on the forward face of the fuselage station
224.00 bulkhead below the fuselage fuel tank.
REMOVAL OF HEATER SYSTEM FUEL PUMP.
1. Remove electrical power/master battery switch "OFF" and open "CABIN HEATER" circuit break-
er
— NOTE —
Defueling airplane is not necessary as the fuel regulator and shutoff valve
provides positive shutoff upstream of the fuel pump. However, mainte-
nance precautions noted in Chapter 28 should tie adhered to when per-
forming maintenance on the heater fuel system.
2. Place airplane on jacks per Chapter 7.

3. Open right main landing gear door per Chapter 32.
4. Disconnect strobe light power supply, if installed, and remove aft bulkhead access panel from
wheel well.
5. Disconnect heater fuel pump electrical lead.
6. Disconnect fuel lines at fuel pump and install protective caps on openings. Clean up any spilled
fuel.
7. Remove hardware securing fuel pump/electrical harness and remove from airplane.
— NOTE —
If a new fuel pump is to be installed remove elbow fitting and union from
pump and retain for installation on new pump.
If further disassembly of pump is required for maintenance or cleaning,

proceed with Fuel Pump Disassembly.
21-43-01
Page 21-114
Issued: June 1,1995
2G5
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
20
I
Figure 21-23. Fuel Pump Assembly and Fuel Pressure Regulator and Shutoff Valve
21-43-01
Page 21-115
Ofia Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B395
1. SCREIV, l\!ASHER (2 PLACES) 11. COVER

2. ELBOW FITTING (2 PLACES) 12. FILTER SCREEN
3. FUEL REGULATOR AND SHUTOFF VALVE 13. GASKET
4. SCREW, WASHER (2 PLACES) 14. SCREW (3 PLACES)
5. MOUNT BRACKET 15. SPRING COVER
6. AIRPLANE ELECTRICAL CONNECTOR 16. GASKET
7. BOLT, WASHER (2 PLACES) 17. SPRING
8. UNION 18. PLUNGER
9. ELBOW FITTING 19. PUMP BODY
10. FUEL PUMP ASSENBLY 20. INLET FUEL SUPPLY HOSE
Figure 21-23. Fuel Pump Assembly and Fuel Pressure Regulator and Shutoff Valve (cont)
21-43-01
Page 21-116
Issued: June 1,1995
2G7
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
FUEL PUMPDISASSEMBLY, .
— CAUTION —
The sealed (interrupter) end of the pump is filled with a special gas and
cannot be tampered with, as pump would become inoperative. The gas
seal is located in the center of the mounting bracket and no attempt should
be made to break the seal.
1. Hold pump securely and rotate cover counterclockwise to release cover from bayonet fittings.
2. Remove gasket from cover and remove filter screen.
3. Remove tfiree screws securing plunger spring cover to pump body. Remove cover, gasket, and
spring from pump cavity.
4. Carefully witfidraw plunger from pump cavity using care not to drop or damage plunger.
FUEL PUMP ASSEMBLY.
1. Insert plunger in pump tube witfi buffer spring end first. Slowly raise and lower plunger in tube to
ensure it moves freely witfiout a tendency to stick.
— NOTE —
When raising and lowering plunger in tube a click should be heard as
plunger approaches top of tube. If click cannot be heard, interrupter is not
functioning properly and pump assembly must be replaced.
2. Slide plunger spring over plunger.

3. Ensure gasket is not damaged and place in position on spring cover. Place gasket and cover in
pump cavity over plunger and spring and secure witfi tfiree screws.
4. Ensure cover gasket is not damaged and place in position on cover and install filter screen.
5. Place cover on pump body to engage pump bayonets. Rotate cover clockwise to fully engage
bayonets.
FUEL PUMP INSTALLATION.
1. Install elbow fitting at fuel pump "OUT' port so fitting is fiorizontal to pump witfi opening in fitting
facing outboard and install straigfit union at "IN" port.
2. Place fuel pump in position on fonward side of bulkfiead at fuselage station 224.00 and secure
pump and electrical fiarness using bolts and washers.
3. Remove dust caps and connect fuel lines to pump.
4. Connect fuel pump electrical connector.
5. Perform operational check of heater system per instructions contained in this chapter and check
fuel pump and fittings for leaks.
6. Install wheel well aft bulkhead access panel and connect strobe light power supply, if installed.
7. Close right main landing gear door per Chapter 32.
21-43-04
Page 21-117

AEROSTAR AIRCRAFT
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MAINTENANCE MANUAL
F U E L PUMP INSPECTION CHECK.
1. During disassembly check for:

A. All parts for damage.
B. Fuel pump electrical resistance. ^ ,
(1) Connect ohmmeter between electrical connector terminal and ground on pump
housing.
(2) Observe ohmmeter for a resistance reading of 19.0 to, 19.5 ohms. If resistance is
not within limits, replace pump assembly
FUEL PUMP PARTS CLEANING.
1. Wash plunger assembly in Stoddard solvent, or equivalent. If plunger assembly fails to become
thoroughly clean or any rough spots are present, dress surface carefully .with crocus cloth and
rinse thoroughly with solvent to remove all foreign material.
2. Dip pump body in clean solvent, shake lightly, and dry with compressed air
3. Check plunger tube in pump body for rough spots or foreign material. If not smooth, wrap a piece
of cloth around a wood dowel, dip cloth in solvent and swab tube until clean.
4. Rinse remaining parts in solvent and dry with compressed air. Use care when drying filter screen
to prevent damage to screen.
FUEL REGULATOR AND SHUTOFF V A L V E . (Refer to Figure 21 -22.)
The heater system fuel regulator and shutoff valve is 24 volts, electrically operated, and provides a preset
seven psi regulated fuel pressure regardless of fuel inlet pressure variations. The unit is located beside the fuel *
pump on the fonward face of the fuselage station 224.00 bulkhead below the fuselage fuel tank.
REMOVAL OF FUEL REGULATOR AND SHUTOFF VALVE.
1. Ensure fuselage fuel tank is empty of fuel and shutoff valves are in the OFF position. Refer to
Chapter 12 for defueling tanks and observe maintenance precautions noted.
2. Remove electrical power/master battery switch "OFF" and open "CAB HEATER", "L" and "R
FUEL SELECT", and "L" and "R FUEL BOOST" circuit breakers.
3. Place airplane on jacks per Chapter 7.
4. Open left main landing gear door per Chapter 32.
5. Remove left wheel well aft bulkhead access panel.
6. Disconnect fuel regulator electrical lead.
7. Disconnect fuel lines at fuel regulator and install protective caps on openings. Clean up any
spilled fuel.
8. Remove hardware securing fuel regulator and remove from airplane.
— NOTE —
If new regulator is to be installed, remove elbow fittings and mount bracket
from regulator and retain for installation on new regulator.
21-44-01
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600/601/601P/602P/700P
MAINTENANCE MANUAL
INSTALLATION OF FUEL REGULATOR AND SHUTOFF VALVE.
1. If removed, install elbow fittings and mount bracket on fuel regulator. Opening in fittings should
face forward, away from regulator.
2. Place regulator in position at fuselage station 224.00 and secure with screws and washers.
3.. Remove dust protectors and connect fuel lines to regulator.
4. Connect regulator electrical lead.
5. Perform operational check of heater per instructions contained in this chapter and check for fuel
leaks.
6. Install left wheel well aft bulkhead access panel.
7. Close left main landing gear door per Chapter 32.
ADJUSTMENT/TEST OF FUEL REGULATOR AND SHUTOFF VALVE.
1. Equipment requirements.
A. Supply regulator.
B. 0-30 psi gauge.
C. 0-60 psi gauge.
D. 2.5 inch fuel nozzle (Janitrol P/N D08D09).
E. 24 volt electrical power supply.
F. Gasoline or Stoddard solvent fuel supply.
2. Test setup (See Figure 21-24).
3. Test procedure.
— NOTE —
The fuel regulator and shutoff valve is adjustable but not considered eco-
nomically feasible to overhaul. The regulator contains age control compo-
nents that are subject to requirement of the latest revision of ANA Bulletin
4386.
A. Install regulator in test stand similar to that shown in Figure 21-24.

B. Adjust supply regulator to provide an inlet pressure of 20 to 30 psig and energize sole-
noid.
C. Using a screwdriver, adjust regulated outlet pressure to 7.5 psig. (Turn clockwise to
increase pressure; counterclockwise to decrease.)
D. Slowly adjust inlet pressure from 10 to 15 psig in steps, or continuous change, and
obsen/e outlet pressure remains between seven and eight psig.
E. Adjust supply regulator to provide an inlet pressure of 50 ± 3 psig. With solenoid ener-
gized outlet pressure should be seven to eight psig.
F. De-energize solenoid. Outlet pressure should drop to zero and flow from nozzle should
stop.
G. Repeat Steps E and F one more time.
— NOTE —
Any sign of regulator leakage is cause for rejection.
H. If satisfactory adjustment has been made, apply Glyptol or equivalent, to threads of

adjustment screw and in slot.
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AEROSTAR AIRCRAFT
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MAINTENANCE MANUAL
B396
1 2 3 4
5. ELECTRICAL POWER SUPPLY

6. FUEL NOZZLE
Figure 21-24. Regulator and Shutoff Valve Test Set-Up

WINDSHIELD DEFROST BLOWER ASSEMBLY. (Refer to Figure 21-25.)
The blower assembly consists of a 24 volt electrically operated motor assembly; blower housing, fan
wheel, adapter plate (used to secure assembly to bull<head), ducting adapter and attaching hardware. All but the
latter two items are provided by the vendor as a blower assembly. The blower assembly is located at the upper
right of the bulkhead at fuselage station 54.25 behind the instrument panel and protrudes through a cutout in the
bulkhead into the avionics compartmenL
REMOVAL OF WINDSHIELD DEFROST BLOWER ASSEMBLY.
1. Remove electrical power/master battery switch "OFF" and pull "DFRST BLWR" circuit breaker.
2. Disconnect flexible ducts at blower assembly and install dust protectors over openings.
3. Remove screw securing electrical lead clamp to blower housing. Reposition electrical lead to
facilitate blower assembly removal and reinstall screw.
4. Identify and disconnect blower assembly electrical leads.
5. Remove nose compartment access door. •
6. For pressurized airplanes, remove sealant from bolt heads securing pressurization cover and
remove bolts, washers, and nuts. Carefully pry pressurization cover from bulkhead and remove
cover.
7. Pull motor assembly electrical lead through forward side of bulkhead at upper right next to
assembly.
21-45-01
Page 21;20
Issued: June 1,1995 2G11
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B397
1. DEFROST BLOIVER ASSEMBLY 10. FAN UHEEL 4 J \

2. COVER (USED ON 601P, 602P AND 700P) 11. NUT (2 PLACES) ^
3. SCREW, WASHER (2 PLACES) 12. DOUBLER
4. OUTLET ADAPTER 13. SPACER
5. SCRBV, WASHER (3 PLACES) 14. NUT, WASHER, WASHER (2 PLACES)
6. INLET ADAPTER 15. MOTOR ASSEMBLY
7. SCRE}V(3 PLACES) 16. CAP (2 PLACES)
8. BLOK'ER HOUSING 17. BRUSH AND STRING ASSEMBLY (2 PLACES)
9. SET SCREW
Figure 21-25. Windshield Defrost Blower Assembly

21-45-01
Page 21-121
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MAINTENANCE MANUAL
8. Remove bolts and washers, from forward side of bulkhead, securing blower assembly and care-
fully remove assembly from under instrument panel so as not to damage electrical wiring or com-
ponents. (Same bolts secure ground wire and electrical lead clamp at two and four o'clock posi-
tions.)
— NOTE —
If further disassembly of the blower assembly is required, proceed with
Step No. 9. If disassembly is not required, removal procedures are com-
pleted.
9. Remove screws and washers securing outlet adapter to blower housing and separate adapter
from housing.
10. Remove screws securing blower housing halves and separate outer half from assembly.
11. Loosen set screw securing fan wheel to motor assembly shaft and pull wheel from shaft.
12. Remove nuts securing inner half of blower housing assembly and adapter plate to motor assem-
bly and separate housing, adapter and spacer from motor.
INSTALLATION O F WINDSHIELD DEFROST BLOWER ASSEMBLY.
— NOTE —
If blower assembly has been completely disassembled proceed with next
step. If assembly was removed from the airplane as an assembly and no
further disassembly was required, proceed with Step No. 8.
1. Slide spacer over motor assembly shaft with flat surface of spacer against motor housing.
2. Place adapter plate over motor assembly shaft and motor bolts with elongated portion of plate on
the opposite side of motor assembly electrical leads (plate must be installed with nut plates on
side away from motor).
3. Place inner blower housing half over motor assembly shaft and motor bolts to butt against
adapter plate with housing outlet opening parallel to motor assembly electrical leads.
4. Secure items installed in Step No's 2 and 3 with nuts on motor assembly bolts.
5. Apply a thin coat of petroleum based grease to motor assembly shaft, prior to fan installation,
and slide fan wheel onto shaft. Ensure wheel clears housing and attaching hardware then secure
wheel set screw.
6. Fit outer blower housing half to inner half and secure with screws. Ensure fan wheel clears hous-
ing.
7. . Install outlet adapter to housing with screws and washers.
8. Carefully place blower assembly in position against aft side of bulkhead (fuselage station 54.25)
with assembly outlet nozzle facing toward left side of airplane. Secure with bolts and washers
from forward side of bulkhead in avionics compartment, picking up ground wire and electrical
lead at two and four o'clock positions respectively (looking aft) and insert lead into cabin through
grommet in bulkhead.
9. For pressurized airplanes, install protective cover over blower motor on forward side of bulkhead
with sealant applied to mating surface of cover flange and bulkhead per instructions contained in
Chapter 20. After cover attaching hardware is secured, apply sealant to bolt heads to prevent
cabin pressure leakage.
10. Connect blower assembly electrical leads.
11. Attach electrical lead clamp to blower housing at six o'clock position using existing screw
(adapter to housing).
12. Remove dust protectors and attach flexible ducting to blower assembly.
13. Close "DFRST BLWR" circuit breaker, apply power to airplane, and activate blower motor switch
to "ON" (A/F prior to 0190, switch and circuit breaker are combined) and listen for motor oper-.l.on.
21-45-02
Page 21-122
Issued: June 1,1995
2G13
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
14. For pressurized airplanes, perform cabin leak test in accordance witfi instructions contained in
tfiis cfiapter.
COOLING.
Tfie air conditioning system consists of two major component installations, i.e., tfie equipment package
and tfie evaporator package.
Tfie equipment package comprises tfie compressor (on electrically driven installations), drive motor, con-
denser fan, coil (condenser), and receiver-dryer. Tfie evaporator package consists of an evaporator coil, blower,
blower drive motor, and expansion valve. On engine driven compressor installations, tfie compressor is located
on tfie rigtit-fiand side of tfie rigfit engine.
Wfien tfie air conditioner is turned off, it is recommended tfiat a minimum of tfiree minutes elapse before
it is turned on again: Tfiis allows tfie compressor head pressure to bleed off and bring the starting load to normal.
AIR CONDITIONING SYSTEM, DESCRIPTION AND OPERATION. (Refer to Figure 21-26.)
The air conditioning system is a recirculating, independent unit. It filters, dehumidifies and cools the air as
it passes through the evaporator. The unit is operated from controls on the right side of the instrument panel. The
master switch has three positions: A / C , O F F , and FAN. When the A/C position is selected the compressor drive
motor or magnetic clutch operates to drive the compressor through the V-belt, the condenser fan operates, and
power is provided to the blower fan switch. The two-position HI-LO fan switch operates the blower. The blower
may be operated to circulate air without using the air conditioning unit by placing the master switch at FAN and
selecting desired blower speed.
The air conditioning system uses Refrigerant 12 as the refrigerant. The refrigerant enters the compressor
as a vapor. The compressor pressurizes the heat-laden vapor until its pressure and heat reach a point that is
much hotter than the outside air and pumps the vapor to the condenser where it cools and changes to a liquid.
The liquid then passes to the receiver-dryer which functions to filter, remove any moisture, and ensure a steady
flow of liquid refrigerant into the evaporator through the expansion valve. The expansion valve is a temperature
controlled metering valve which regulates the flow of the liquid refrigerant to the evaporator to allow all the liquid
to evaporate and return to the compressor at a reduced pressure. From the evaporator, the refrigerant vapor
returns to the compressor where the process is repeated.
The following precautions must be adhered to when operating the air conditioning system:
1. Do not attempt a battery start of the engines with the air conditioner "ON."
2. When the air conditioner is to be utilized during taxi, both engines must be operated at 1300
RPM to provide sufficient voltage and alternator output to prevent draining of the batteries.
3. After fuming the air conditioning system "OFF," allow a minimum of three minutes for compres-
sor head pressure to "bleed-down" before turning air conditioner "ON."
4. In-flight operation of the air conditioner is limited to DAY-VFR only with both alternators operating
(later systems will not function unless both alternators are on line).
5. In the event of an engine or altemator failure, the air conditioner must be turned off.
6. Run the air conditioner occasionally in the winter to keep the oil moving.
SAFETY PRECAUTIONS.
1. The refrigerant used in the air conditioning system is R-12. This refrigerant is non-explosive, non-
flammable, non-corrosive, has practically no odor, and is heavier than air. Although R-12 is clas-
sified as a safe refrigerant, certain precautions must be observed to protect parts involved and
the person working on the unit.
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MAINTENANCE MANUAL
B398
Figure 21-26. Air Conditioning System

21-52-00
Page 21-124
Issued: June 1,1995
2G15
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
ELECTRICALLY DRIVEN C O M P R E S S O R INSTALLATION
8. EXHAUST DUCT
9. CONDENSER FAN
10. CONDENSER
11. COMPRESSOR SERVICE VALVES
12. FREON HOSE (SUCTION)
Figure 21-26. Air Conditioning System (cont)

21-52-00
Page 21-125
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
D138
ENGINE DRIVEN C O M P R E S S O R INSTALLATION
12-
3L_£:
1. OVERHEAD CABIN DUCT OUTLETS

2. EVAPORATOR ASSEMBLY
3. P L E N U M BOX*
4. B L O W E R FAN*
5. F R E O N LINES
6. COMPRESSOR
7. C O N D E N S E R A N D F A N
8. RECEIVER-DEHYDRATOR
9. P R E S S U R E SWITCHES
10. EVAPORATOR DRAIN*
11. S E R V I C E V A L V E S
12. ALTERNATOR •SEE DETAIL A O F ELECTRICALLY. DRIVEN
COMPRESSOR INSTALLATION.
Figure 21-26. Air Conditioning System ^cont)

21-52-00
Page 21-126
Issued: June 1,1995
2G17
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
D144
. ENGINE DRIVEN C O M P R E S S O R INSTALLATION SHELF
1 CONDENSER
2. AIR INLET
3. RECEIVER-DEHYDRATOR
4. BLOWER
5. AIR INLET DUCT
6. AIR EXHAUST
7. FREON LINES
Figure 21-26. Air Conditioning System (cont)

21-52-00
Page 21-127
2Q-^g Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
•449
• GAUGE PORT (TYPICAL)
Z22ZS
FRONT SEATED POSITION BACK SEATED POSITION
'CRACKED" POSITION
COMPRESSOR MOUNTED
SERVICE VALVE DETAILS
Figure 21-27. Compressor IMounted Service Vaives (Yorl< Compressor)
988
^ ^ : ^ M A N I F O L D G A U G E SET
PRESSURE
GAUGE
/ f ^ ^ ^ S ^ COMPOUND GAUGE
OPEN
VACUUM PUMP,
OUT SUCTION U N E
TO SCHRADER
VALVES
DISCHARGE LINE
Figure 21-28. Evacuation Hool<up

21-52-00
Page 21-128
Issued: June 1,1995
2G19
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
2. . Uquid R:12, at normal atmospheric pressure and temperature, evaporates so quickly that
to freeze anything that it contacts. Care must be tal<en to prevent any liquid refrigerant from com-
ing in contact with the skin and especially the eyes. R-12 is readily absorised by most types of oil.
Therefore, it is recommended that a bottle of clean mineral oil and weak solution of boric acid be
kept nearby when sen/icing the refrigerant system.
— CAUTION —
Always wear safety goggles when servicing any part of the refrigerant sys-
tem. Should any liquid refrigerant get into the eyes, use a few drops of
mineral oil to wash them out, then use a weak solution of boric acid to
wash eyes, and seek aid from a doctor immediately even though the irrita-
tion has ceased.
3. It is important to keep the system tightly sealed, because the refrigerant system is always under
pressure. Heat applied to any part would cause this pressure to build up excessively.
— WARNING —
To avoid explosion, never weld, use a blow torch, solder, steam clean,
bake airplane finish or use excess amounts of heat on, or in the immediate
area of any part of the air cooling system or refrigerant supply tank, while
they are closed to atmosphere with refrigerant or not Although R-12 gas,
under normal conditions, is nonpoisonous, the discharge of refrigerant
gas near an open flame can produce a very poisonous gas. This gas will
also attack all bright metal surfaces. This poisonous gas is also generated
in small quantities when a flame type leak detector is used.
4. When checking the system for leaks, the system should be allowed to operate from 10 to 15 min-
utes prior to checking.
— CAUTION —
The use of a flame-type leak detector is not recommended for use on air-
planes tjecause of fire hazard.
5. The use of the electronic leak detector H-10 is recommended; however, if the H-10 leak detector
is not available, leak detector solution conforming to N/IIL-L-25567 can be used to check each fit-
ting, hose connection and air conditioning component.
SERVICINGyTESTING.
SPECIAL SERVICING PROCEDURES.
— NOTE —
These procedures apply to all conditions of charging and testing. Follow
> all local, state, and federal procedures regarding the evaluation, charging,
and recycling of air conditioning systems in addition or in lieu of the pro-
cedures listed in this manual as applicable.
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AEROSTAR AIRCRAFT
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, MAINTENANCE MANUAL
1. Check all hose and fitting connections to be sure they are tight. This includes all factory or
assennbly line connections, as well as the connections you make.
2. Connect vacuum pump with hoses to both suction and discharge service valve ports. Turn both
compressor sen/ice valves approximately 4 turns clockwise from back seated position.
3. Pull vacuum on system for 20 minutes. Low pressure gauge should read about 20 inches of vac-
uum at 6000 feet altitude or 26 inches of vacuum at sea level within five minutes. For air condi-
tioning systems using a Sankyo compressor, the low pressure gauge should read about 23 inch-
es of vacuum at 6000 ft. altitude or 29 inches of vacuum at sea level within five minutes. If this is
not attained, you should suspect a leak, in which case, shut off vacuum pump, charge enough R-
12 into the system to show 30 psi on both gauges, and check for leak with Sherlock or Halide
Leak Detector.
— CAUTION-
DO not use electronic leak detector at this point.
4. After leaks are repaired, repeat Step 3 above.

5. After vacuum is obtained, shut off both valves on charging manifold. Then shut off vacuum pump.
Next, connect charging line from manifold to R-12 cylinder. Open cylinder valve and bleed charg-
ing line at manifold.
With R-12 cylinder valve open, and line bled, open low pressure (suction) line valve on manifold,
and charge unit until 70 psi is shown on both gauges, or until pressure stops rising.
6. You are now ready to operate and charge the system. Start the system and continue to charge
the unit until sight glass clears.
A. Observe glass carefully, and stop charging immediately as soon as bubbles disappear in
sight glass. This is important as overcharging electrically driven system can result in
damage to the drive motor.
B. Always charge with cylinder in upright position. If cylinder becomes very cold, indicating
too low a pressure to force vapor into system, heat cylinder by placing it in a container of
warm water.
7. When charging is finished, shut system off, and check every connection with Electronic Leak
Detector If any leak is detected, repair completely.
EVACUATION AND CHARGING PROCEDURES.
The evacuation and charging procedures given are factory recommended. If followed, these procedures
will give optimum results.
MATERIAL REQUIREMENTS.
The following equipment must be available to properly service the air conditioning system. •
1. Charging manifold and hoses.
2. Refrigerant can adapter.
3. 'R-12 refrigerant cans or R-12 cylinder
4. Vacuum pump capable of operating at at least 28 to 29 inches hg.
5. 1/4 inch open end wrench.
21-53-03
Page 21-130
Issued: June 1,1995
2G21
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CONNECTING THE MANIFOLD AND HOSE.
1. Remove caps from service ports.

2. Connect compound gauge (low pressure) fiose to suction port.
3. Connect higti pressure gauge fiose to discfiarge port.
4. Close valves on tfie charging manifold (turn clockwise).
CHART 2108. VACUUM/TEMPERATURE
System Vacuum Temperature °F
27.99 100
Compound Gauge 28.89 80
Reading in Inches 29.40 60
of fwlercury Vacuum 29.71 40
29.82 20
29.88 0
REFRIGERANT CYLINDER
Figure 21-29. Test Gauge and Manifold Set
21-53-04
Page 21-131

AEROSTAR AIRCRAFT
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MAINTENANCE MANUAL
1257
DIAGRAM D
Figure 21-30. Manifold Set Operation

21-53-04
Page 21-132
Issued: June 1,1995 OCÔ*^
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHECKING THE SYSTEM FOR LEAKS.
The following instructions should be used in conjunction with the instructions provided by the manufactur-
er of the leak check equipment.
— NOTE —
In cold weather (below AO'F) a fully charged system will show a static-pres-
sure of less than 40 PSI. Therefore all leak checking should be done at
temperatures above SOT.
1. Connect the manifold gauge set to the system. Add a 50 PSI charge to the system. If the gauge
readings with the system shut off is less than 50 PSI, add refrigerant until the minimum charge is
obtained.
2. Conduct the leak check with the system shut off. Pay special attention to fittings, elbows and
hose connections. Because R-12 is heavier than air, pay special attention to the underside of
hoses and fittings.
3. If a stubborn small leak should be encountered, the high side of the system might require leak
testing while the airflow to the condenser is restricted in order to raise the high side pressure
above normal. The low side is checked in the off position with the pressure equalized in both
sides of the system.
4. A small leakage at the compressor shaft seals is normal (about 1 oz. per year). Since many leak
detectors are sensitive enough to show this normal leakage, their sensitivity should be reduced
when checking the compressor shaft seals.
A shaft seal leak may reseal itself through continued running. If a shaft seal should begin leaking,
the system should be recharged and left in service for a few hours to give the seal an opportunity
to reseal itself.
5. If a fitting should show a leak, do not overtighten it. Disassemble the fitting, check for damage
and concentricity, then reassemble it, applying refrigerant oil liberally to all mating surfaces.
6. Rubber-neoprene hoses leak at a fairly high level through the pores in the hose itself. Since the
leakage is spread over the entire surface of the hose itself, it will not be detected by leak detector
equipment This should be kept in mind when checking systems which do not have very much
additional charge over that actually required to provide complete usage of the evaporator and, as
a result of leakage, may require additional charge added at periodic intervals to replace that lost
by normal leakage.
7. Compressor gaskets are made of a fiber-neoprene composition which has a wicking action. Do
not mistake this action for a leak as it is normal and should be expected.
INITIAL CHARGING OF THE SYSTEM.
Following repair of the system, it will be necessary to charge the system with refrigerant. This procedure
must be carefully and completely performed, as incorrect charging could result in poor system performance or
even component damage.
1. Check the compressor oil level. (Refer to Checking Compressor Oil Level.)
2. Remove protective caps from service valve stems.
3. Insure that manifold gauge hand valves are fully closed and that the hoses are tightly connected
to the service fittings on the manifold.
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MAINTENANCE MANUAL
4. Connect the high side gauge hose to the high side service fitting. (Discharge side on compres-
sor.)
5. Connect the low side gauge hose to the low side.service fitting. (Suction side on compressor.)
6. On the.Yorl< compressor, move both isolation valves on the compressor to their "mid-seated"
position.
7. Connect the vacuum pump to the center service hose.
, 8.. - Evacuate the system.
A. Open both hand valves on the gauge set and start the vacuum pump.
B. The low side gauge reading should reach 29" vacuum within a few minutes. Failure to
reach and/or hold this vacuum indicates-a leak. The leak must be repaired before pro-
ceeding.
C233
Figure 21-31. Charging Hookup
21-53-06
Page 21-134
Issued: June 1^ 1995
2H1
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
— NOTE —
Due to the drop in atmospheric pressure with an increase in altitude, the
normal vacuum reading will drop approximately 1" Hg for each 1000 ft. of
altitude above sea level. Example: If field elevation is 5000 ft. above sea
level, the normal gauge reading during evacuation will be 24" Hg vacuum.
C. Continue evacuating the system for at least 15 minutes after the normal vacuum reading
is reached; shut off both hand valves and disconnect the vacuum pump.
9. Purge the system.
A. Connect the R-12 can to the center service hose, open the can valve and purge the hose
of air by loosening the center sen/ice hose fitting at the gauge set for about 5 seconds
B. Open the high side hand valve and allow gaseous Freon (hold can upright) to slowly
flow into the system until the low side gauge reads about 5 PSI. Shut off the hand valve.
— NOTE —
Adding R-12 to the high side provides confirmation that the expansion
valve is not plugged or stuck closed. This is done ONL Y during the initial
charging process with the system shut off.
— CAUTION —
Never open the high side hand valve while the system is operating.
10. Evacuate the system a second time per step 8. This should effectively remove traces of moisture
from the system.
11. Add R-12 to the system by the following method:
A. Connect the center service hose to the refrigerant container and purge air from the hose
as done in step 9.
B. Open the high side valve and allow gaseous Freon (can held upright) to enter the system
until the high and low side pressures equalize within 10 PSI.
C. Close the high side hand valve.
— NOTE —
It may be necessary to heat the R-12 container during the charging
process to maintain adequate pressure in the container for charging. Use
warm (125°F) water only to heat the container and avoid splashing any
onto the charging hose connections.
12. Operate the system (after checking to insure that the high side hand valve is closed).
A. Check for bubbles in the sight glass. After 1-2 minutes of running, the sight glass should
be clear or only show occasional bubbles.
B. If there is a steady stream of bubbles in the sight glass, add gaseous R-12 (can held
: upright) to the low side of the system until the sight glass is clear.
13. Performance test the system. • •
21-53-06
Page 21-135
2H2 Issued: June 1,1995

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
. MAINTENANCE MANUAL
ADDING REFRIGERANT TO A SYSTEM WITH A L O W C H A R G E . . . . . .
A small loss of refrigerant (approx. 1 02. per year) is normal as tfie compressor seals will probably leak
tfiis amount. However tfiis leakage may be increased by several times if the air conditioning.system is not
periodically run in the winter.
A loss of any more than a few ounces of refrigerant a year would indicate a leak which should be
repaired before sen/icing the system. If a large amount of refrigerant has been lost, and/or there are indications of
oil loss from the system, the compressor oil level should be checked.
To add refrigerant to a system with a low charge:
1. Connect the manifold gauge set to the system and refrigerant supply. Purge the air from all three
service hoses. (Refer to step A under Initial Charging of the System.)
2. Stabilize the system by operating it on HIGH fan for 10 minutes.
3. Add R-12 to the system's low pressure side orily:
A. Insure that the service lines have been purged of air and that the refrigerant can is held
upright.
B. Open the low side hand valve.
— NOTE —
As the liquid R-12 in the can vaporizes, there will be less pressure avail-
able for charging the system. If necessary, the can may be heated by
immersing it in hot water (125°F maximum).
Charging with liquid refrigerant to the low side is not recommended.
C. Stop charging as soon as no bubbles are observed in the sight glass.
— CAUTION —
Never open the high side hand valve while the system is operating.
4. Performance test the system.
CHARGING THE SYSTEM WITH A CHARGING STAND.
1. Connect the manifold gauge set to the system.

2. Connect the charging stand to the center port of the manifold gauge set.
3. Insure that the hose from the charging stand to the center port is purged of air.
4. Open the high pressure control valve and close the low pressure control valve.
5. Open the refrigerant control valve on the charging stand and allow as much refrigerant to enter
the high side of the system as possible.
6. After completion of charging, close all valves on the charging stand.
7. On the York compressor, back seat the compressor service valves (fully counterclockwise).
8. Remove the manifold gauge set and hoses from the service valves using caution due to the
small amount of refrigerant remaining in the hoses.
9. Replace all access panels and install the engine cowling.
21-53-08
Page 21-13^^
Issued: Jun^ 1,1995 2H 3

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
411
1. COMPOUND GAUGE
2. VALVE, LOW PRESSURE CONTROL
3. VALVE. VACUUM CONTROL
4. CHARGING CYLINDER
5. BRACKET
6. SIGHT GLASS
7. HIGH PRESSURE GAUGE
8. HIGH PRESSURE CONTROL
9. REFRIG. CONTROL
10. CHARGING LINE HOSE HOLDER
11. BRACKET
12. LOW PRESSURE CHARGING LINE
13. HIGH PRESSURE CHARGING LINE
14. VACUUM PUMP
1 5. OIL FILL LOCATION
16. PLASTIC CAP
17. REFRIGERANT DRUM VALVE
18. VACUUM PUMP VALVE
19. VACUUM PUMP EXHAUST PORT
20. TOP CYLINDER VALVE
21. REFRIGERANT DRUM
22. WEB STRAP
23. REFRIG. DRUM REDUCER
24. CHARGING CYLINDER HOSE
25. VACUUM PUMP INTAKE HOSE 27. VACUUM PUMP POWER CORD
26. VACUUM PUMP SWITCH 28. HEATER PLUG
Figure 21-32. Charging Stand
PERFORMANCE TESTiNG SYSTEM.
A performance test of the system is recommended to verify that it has been properly repaired, senîced or
charged. The system should be given this test before initiating repairs, after repairs have been completed or fol-
lowing installation of a new unit. The performance test should be accomplished annually at the beginning of the
cooling season.
1. Visual Inspection.
A. Drive belts for security, condition, proper alignment and tension.
B. Mounting brackets for security and condition.
C. Hoses and wiring for proper routing, chafing, kinks or interference with other parts of the
aircraft.
D. Condenser and evaporator coils for cleanliness and restriction. Bent fins should be
combed straight.
E. Fans and blowers for proper operation at all speeds.
F. , Compressor oil level.
— NOTE —
Leaks can sometimes be visually detected by an oily spot on a hose or fit-
ting as oil is carried out of the system by escaping refrigerant.
G. Louvers and ducts for condition.

H. instrument panel placards and switch labels as specified in the Flight Manual
Supplement and other STC data for placement and legibility.
2. Connect a manifold gauge set to the system.
21-53-09
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AEROSTAR AIRCRAFT
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MAINTENANCE MANUAL
3. Stabilize the system by operating it on high fan for 10 minutes.
' 4. Check high side and low side pressures. Low side (suction) pressure should be 20-40 PSI while
high side (discharge) pressure will vary from 150-285 PSI depending on ambient temperature.
(See Chart 2109.)
CHART 2109. OAT VS. HIGH PRESSURE READING
OAT(°F) HIGH PRESSURE READING

80 165-185
90 190-210
100 220-250
Note: Individual systems may vary somewhat from these values.
5. Check sight glass for bubbles.

6. Measure evaporator performance. The air leaving the evaporator outlet should be approximately
20°F cooler than the air entering the evaporator when the fan is running on high. A poor tempera-
ture drop indicates a problem in the system while an excessive temperature drop can be caused
by inadequate airflow through the evaporator coil. Temperature drop will be less on days when
the relative humidity exceeds 70%.
7. Check amperage draw of total system and/or individual components. (Refer to Chart 2110.)
CHART 2110. NORMAL AMPERAGE DRAW OF ELECTRIC DRIVE

AIR CONDITIONING SYSTEM
System Component Amps
1.5 HP Compressor Drive Motor 40-45

Condenser Fan 14-16
Evaporator Blower (Dual) 10-12
8. Check relative temperatures of hoses. The high side hose should be uniformly wami along its
entire length. A sudden drop in the temperature of the hose indicates a restriction at that point.
The low side hose should be uniformly cool without frost build-up.
9. Measure condenser air temperature rise on condenser coils. The air flowing through the con-
denser should be wamried by 30-40''F. A higher temperature rise indicates questionable air flow
through the coil.
DISCHARGING T H E SYSTEM.
— NOTE —
Observe all safety precautions and suggestions recommended for the han-
dling of R-12.
21-53-10
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Issued: June 1,1995
2H5
AEROSTAR AIRCRAFT
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MAINTENANCE MANUAL
Discharging the system is required before replacing most components, except the York compressor
which has isolation valves. A manifold gauge set is.used to control the rate of discharge and minimize the loss of
refrigerant oil.
1. With the system not running, remove the protective caps from the test fittings on both the high
and low sides of the system.
2. Insure that both manifold hand valves, are closed. Then connect the manifold gauge set low and
high side hoses to the low and high side service fittings respectively.
3. Place the free end of the manifold gauge set center hose in a clean container.
4. Slowly open the valve on the low side of the manifold just enough to let the refrigerant flow out of
the center hose without excessive loss of refrigerant oil. Continue until both gauges register 0
PSI.
5. Measure the amount of oil collected in the container and add this amount of new refrigerant oil to
the compressor prior to recharging the system.
FLUSHING A CONTAMINATED SYSTEM.
Because the air conditioning system is a closed system and isolated from the environment, flushing
would be required only under unusual circumstances (such as excessive amounts of corrosion or the use of an
incorrect oil).
To flush the contaminated system:
1. Discharge the system. (Refer to Discharging the System.)
2. . Remove the receiver/dryer and replace with a union.
3. Remove the expansion valve and replace with a union.
4. Disconnect the lines to the compressor.
5. Using an appropriate fitting, connect a container of R-11 to the discharge hose removed from the
compressor.
— NOTE —
Methyl Alcohol can be used to flush the system in lieu of R-11, if desired.
6. Use a pump to circulate the R-11 for at least 15 minutes to ensure thorough cleaning of the lines,
or until clean R-11 flows from the suction hose.
7. Install a new receiver/dryer, expansion valve and compressor in the system.
8. Charge the system; then follow nonnal service procedures.
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AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL _^
COMPRESSOR, MOTOR AND CONDENSER ASSEMBLIES. (Refer to Figure 21 -26.)
The compressor, motor, and condenser assemblies are located on a shelf aft of the baggage compart-
ment on the left of the airplane. The components are secured to the shelf and in turn the shelf is attached to a
support system.
On later model 602P's and 700P's the compressor may be Installed on the outboard side of the right-
hand engine.
— NOTE —
The compressor fan (on some models, see above description), motor, and
condenser assemblies may be removed and installed as a unit, then indi-
vidual components can be removed as required by referring to the proce-
dures under the unit.
REMOVAL OF ASSEMBLIES.
Removal of the assemblies as a unit is as follows:

1. Ensure air conditioning circuit breaker is pulled.
2. Open baggage compartment and remove aft panel from compartment.
3. Discharge the air conditioning system per instructions contained in this section.
4. Disconnect hoses at compressor return port (condenser return port on engine mounted compres-
sor installations) and at outlet port of receiver-dryer Install protective caps on all openings.
— NOTE —
All open lines should be capped immediately to prevent dirt and moisture
from entering the system.
5. Disconnect exhaust duct at condenser

6. Disconnect motor electrical lead at connection adjacent to receiver-dryer (pallet mounted com-
pressor installation only).
7. Remove hardware, three places on both sides of shelf rail and remove assembly from compart-
ment.
— NOTE —
If component(s) require removal, refer to the instruction's for unit desired.
INSTALLATION OF ASSEMBLIES.
Installation of the assemblies as a unit is as follows:
1. With all components installed on shelf, place shelf in airplane aft compartment in position on sup-
port assembly aligning holes in shelf with holes in support. Install retained hardware, six places,
securing shelf to support.
2. . - Connect motor electrical lead at connection adjacent to receiver-dryer (pallet mounted compres-
sor installation only).
21-54-02
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Issued: June 1,1995
2H7
AEROSTAR AIRCRAFT
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MAINTENANCE MANUAL
3. Connect exhaust duct to condenser. '
4. Remove protective covers and connect hoses to receiver-dryeroutlet port and compressor return
port (condenser return port on engine mounted compressor installations).
5. Evacuate and charge system per instructions contained in this section.
6. Install aft panel in baggage compartment and close compartment access door.
COMPRESSOR REMOVAL.
— NOTE —
If the condenser and/or compressor motor (pallet mounted compressor
installation only) are to be removed, it is more feasible to remove all items
as a unit to facilitate maintenance. Refer to Compressor, Motor and
Condenser Assemblies in this section. The York compressor can be
removed with the system charged or discharged.
1. Ensure air conditioning circuit breaker is pulled.

2. Open baggage compartment and remove aft panel from compartment.
COMPRESSOR REMOVAL LEAVING SYSTEM CHARGED (YORK COMPRESSOR).
1. Fully close both service valves (clockwise) on compressor.

2. Remove bolts securing service valves at top of compressor and withdraw valves from compres-
sor.
— NOTE —
Compressor pressure will bleed off at the flanges of these valves when the
bolts are loosened.
COMPRESSOR REMOVAL WITH SYSTEM DISCHARGED (YORK OR SANKYO COMPRESSOR).
1. For pallet mounted compressors:

A. Depressurize air conditioning system per instructions in this section.
B. Remove suction and discharge lines from the sen/ice valves (or fittings) on compressor.
Install protective caps on all openings.
C. Loosen belt tensioner and remove belt from pulleys. ;
D. Position motor to gain access to motor mount bolts at base of mount and remove hard-
ware securing mount base.
E. Carefully position motor so that electrical leads will not be damaged and access to com-
pressor tie down bolts is obtained. Remove bolts and washers securing compressor to
mounting bracket and remove from airplane.
F. For York compressor remove bolt and washer securing pulley to compressor and with-
draw pulley from compressor shaft. Refer to Figure 21-36.
21-54-05
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AEROSTAR AIRCRAFT
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MAINTENANCE MANUAL
2. For engine mounted compressors: ••
A. Depressurize air conditioning system per instructions in tliis section.
B. Remove suction and discharge lines from the fittings on the rear of the compressor.
C. • Loosen belt tensioner bracl<et and remove belt from pulleys.
D. Remove bolts, nuts and washers from inboard compressor ears.
E. Remove pulley from compressor (if desired). Refer to Figure 21 -37.
COMPRESSOR INSTALLATION.
1. For pallet mounted compressors:

A. For York compressor install pulley over compressor shaft engaging key with pulley key-
way and secure to shaft with bolt and washer. For Sankyo compressor, install pulley per
Installation of Magnetic Clutch, Pulley and Coil (Sankyo Compressor).
B. Place compressor in position on shelf mounting bracket in aft compartment and secure
with retained hardware, four places. . •
C. Position compressor drive motor to locate holes of mount bracket and shelf and install
hardware to secure bracket.
D. Install compressor drive belt on pulleys and adjust per Replacement of Drive Belts.
— NOTE —
If a new belt is installed, reset tension after approximately one hour of
operation.
E. Check oil level in compressor per instnjctions in this section.

F. On York compressors, secure sen/ice valves to top of compressor or attach freon hoses
to valves as required, using teflon tape on threaded connectors. On Sankyo compressors
secure hoses to fittings.
G. Evacuate and charge the system per instructions in this section.
2. For engine mounted compressors:
A. Install pulley/magnetic clutch on compressor shaft per instmctions in this section.
B. Secure inboard compressor ears to compressor mounting bracket and belt tensioner
bracket.
C. Place belt over pulleys.
D. Tension belt per instructions in this section.
E. Attach freon lines to back of compressor.
F. Evacuate and charge the system per instmctions in this section.
21-54-06
Page 21-142
Issued: June 1,1995
2H9
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CLEANING, INSPECTION AND REPAIR.
1. Cleaning: . . .
A. Tiie air conditioning components should be wiped clean with a cloth and a stream of low
, . pressure dry air. - , -
2. 100 Hour Inspection Check:
A. Security of mounting.
B. Compressor and fan belt or belts for proper tension.
C. Sight gauge for proper refrigerant level.
D. Empty condensate tank (if installed).
E. Remove lint and grease from evaporator with a vacuum.
3. Repair and Servicing:
A. Repair to the air conditioning system is limited to the replacement of components.
CHECKING COMPRESSOR OIL LEVEL (YORK COMPRESSOR).
Check the compressor oil level only if a portion of the refrigerant system is being replaced or if there is a
leak in the system and the refrigerant is being replaced.
1. Operate air conditioning system for 15 minutes in temperatures of 60°F or above.
2. Turn off the air conditioner.
3. Discharge the refrigerant system in accordance with Discharge Procedures.
4. Remove either oil filler plug from the compressor, rotate the compressor until the keyway in the
shaft is pointing towards the head of the compressor. This places the throws of the crankshaft
into most favorable position for passage of the dipstick.
5. Insert the dipstick (refer to Figure 21-34) in the oil filler hole until it bottoms. The rod should show
from 7/8 inch to 1-1/8 inch of oil on the rod. The oil charge should be maintained between six
ounces and 10 ounces for best results.
6. If additional oil is needed in the compressor, add Sunisco 5 or Capella E refrigerant compressor
oil, or equivalent
7. Replace oil filler plug, evacuate and charge refrigerant system in accordance with Evacuating
and Charging Procedures:
8. Check compressor filler plug for leaks using the H-10 Leak Detector or Leak Tek MIL-L-25567.
— NOTE —
When inserting the oil fill plug, slip the sealing O-ring over the oil fill plug
threads in such a manner that the O-ring is not twisted.
If the plug should leak, do not attempt to stop the leak by overtightening
the oil check plug. The leak may be caused by dirt under the O-ring or on
the seat, a broken O-ring, or a damaged seat on the oil fill plug or oil fill
opening.
CHART 2111. YORK COMPRESSOR OIL CHARGE
Oil Charge in Ounces 6 8 10 12
Dipstick Reading in Inches 7/8 1 1-1/8 1-7/16
21-54-08
Page 21-143

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHECKING COMPRESSOR OIL LEVEL (SANKYO COMPRESSOR).
Whenever a system component has been replaced or there is an obvious leak, use the following proce-
dure to check the compressor oil level (after making necessary repairs):
1. Determine the compressor mounting angle by.positioning an angle protractor across the flat sur-
faces of the two front mounting ears.
— NOTE —
The outboard ears (4) on the engine mounted Sankyo compressor have
been removed. Use the upper inboard ear and the upper outboard ear
boss to determine the mounting angle.
2. Center the bubble and read the mounting angle to the closest degree.
3. ' Discharge the freon from the air conditioning system slowly until the low side gauge reads 0 psi.
(Refer to Connecting the Manifold and Hose and Discharging the System.)
4. Remove the oil filler plug.
5. Look through the oil filler plug hole and rotate the clutch front plate to position the internal parts
as shown in Figure 21-33.
A. If the compressor is mounted to the right (facing the pulley and clutch)(refer to Figure 21 -
35), center the parts as they are moving to the rear of the compressor (discharge stroke).
B. If the compressor is mounted to the left (facing the pulley and clutch)(refer to Figure 21-
35), center the parts as they are moving to the front of the compressor (suction stroke).
— NOTE —
This step is necessary to clear the dipstick of internal parts and to allow its
insertion to full depth.
0645
VIEW WHEN COMPRESSOR (TOP VIEW) VIEW WHEN COMPRESSOR

ANGLE RIGHT ANGLE LEFT"
ROD BALL
PISTON ROD
PISTON ROD
BALL SOCKET ON BALL SOCKET ON

PLANET PLATE PLANET PLATE
Figure 21-33. Positioning Sankyo Compressor Internal Parts
21-54-09
Page 21-144
Issued: June 1,1995
2H11
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
C645 ' ^
1/8" INCREMENTS
. . 1
SAIMKYO 1 1 y—~v ^
DIPSTICK \V y>y^
SANKYO ^ 415
P / N 32447 X
A N G L E — ^
FINGEfT^sA
YORK
DIPSTICK
^ \ .
ROBINAIRE
4-3/4 R \
L E F T H A N D M O U N T I N G : P / N 10545
C H E C K O I L WHEN N O NR O K S H A F T
K E Y IS D O W N .
1
RIGHT H A N D MOUNTING: 12 N O T C H ES,^''
i-i/2
C H E C K O I L WHEN N O NR O K S H A F T 1/8" A P A R T '"^
1
K E Y is UP.
Figure 21-34. Fabricated Dipsticks for Compressor Oil Check
1/8" INCREMENTS
SANKYO // V*—^ y —ri

DIPSTICK \A y>~?^
SANKYO '^•xc^^ 4.15

P / N 32447 /
•
A N G L E — ^
F I N G E R \
RING^^X*^
YORK \
\
DIPSTICK
ROBINAIRE
4-3/4 R
L E F T H A N D M O U N T I N G :
P / N 10545
C H E C K O I L W H E N N O N R O K S H A F T
K E Y IS D O W N .
1
RIGHT H A N D M O U N T I N G : 12 N O T C H E S ^
1-1/2
1/8" A P A R T
C H E C K O I L W H E N N O NR O K S H A F T 1
Figure 21-35. Sankyo Compressor Mounting Angle
21-54-09
Page 21-145
Issued: June 1,1995
2H12
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
6. Insert the dipstick to its stop position. (Refer to Figure 21-35.) The stop is the angle near the top
of the dipstick.
A. The point of the angle must be to the left if the mounting angle is to the right.
B. " The point of the angle must be to theright if the mounting angle is to. the left.
C. The bottom surface of the angle, in either case, must be flush with the surface of the oil
filler hole.
7. Remove the dipstick and count the increments of oil.
8. Use Chart 2112 to determine the correct oil level for the mounting angle of the compressor.
9. If the increments read on the dipstick do not match the table, add or subtract oil to the mid-range
value.
CHART 2112. SANKYO COMPRESSOR MOUNTING ANGLE/OIL LEVEL
Mounting Angle Degree Acceptable Oil Level

In Increments
0 4-6
10 6-8"
20 8-10
30 10-11
40 11-12
50 12-13
60 12-13
90 15-16
THIS SPACE INTENTIONALLY LEFT BLANK
21-54-09
Page 21-146
issued: June 1,1995
2H13
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
REPLACEMENT OF DRIVE BELTS.
1. To replace Polyflex belt:

A. For pallet mounted compressor installations, loosen motor mounting stud nuts and swing
motor towards compressor. For engine mounted compressor installations, loosen ten-
sioner bracket and swing compressor towards engine. Do not stretch or twist new belts
when installing on pulleys.
B: Be sure that the pulley grooves are clean and free of residue or foreign materials (such
as belt dressings).
— NOTE —
Do not apply belt dressings to Polyflex belts.
C. Check alignment of drive and driven pulley by placing a straightedge across the face of
both. Use Loctite on the set screw threads (pallet mounted compressor motor). Polyflex
belts cannot tolerate a misalignment of pulleys.
D. If frequent belt failures have been experienced, check pulley runout with a dial indicator.
Radial runout should not exceed .020".
E. Tighten motor mounting studs (pallet mounted compressor installations) or belt tensioner
bracket (engine mounted compressor installations) to maintain a belt tension of 30
pounds (35 pounds for engine mounted compressor installations). Use only AJBS28-1
Polyflex tension meter to check this tension.
F. When installing new belts:
(1) Set belt tension.
(2) After 1/2 hour operation, reset belt tension.
(3) After an additional 1/2 hour, reset belt tension.
(4) After an additional 5 hours of air conditioning operation, reset belt tension.
2. To replace 3/8" single v-belt:
A. For pallet mounted compressor installations, loosen motor mounting stud nuts and swing
motor towards compressor. For engine mounted compressor installations, loosen ten-
sioner bracket and swing compressor towards engine. Do not stretch or twist new belts
when installing them on the pulleys.
B. Be sure that the pulley grooves are clean and free from residue of previous belts or for-
eign material.
C. Check alignment of drive and driven pulley by placing a straightedge across the face of
both.
D. For pallet mounted compressor installations, adjust alignment of pulleys by loosening the
set screw on the motor pulley and sliding it on the motor's shaft. When reinstalling the
pulley, use only a self-locking (Nyloc) set screw or use Loctite on the threads.
E. For engine mounted compressor installations, align the compressor pulley with the aft
alternator pulley by using the (4) AN960-616L washers between the inboard upper com-
pressor ears and the mounting boss on the end of the compressor support bracket.
F. Tighten the motor mounting studs or belt tensioner bracket (on engine mounted com-
pressor installations). To maintain a belt tension of 30-35 pounds using the JBS 28 ten-
sion meter.
G. After one hour of operation, reset tension (for a new belt).
21-54-10
Page 21-147
2H1 4 Issued: June 1,1995

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
MAGNETIC CLUTCH (YORK COMPRESSOR).
MAGNETIC CLUTCH R E M O V A L (YORK COMPRESSOR).
1. Remove the self-locking capscrew and washer from the compressor shaft.
2. Insert a 4/8-11 VNC-2B bolt in the threaded portion of the hub and tighten. The pressure exerted
by the bolt on. the end of the compressor crankshaft will force off the rotor pulley assembly with-
out damage to the clutch or compressor
— CAUTION —
Do not use awheel puller on the outer flange of the pulley. This can dam-
age the pulley grooves or clutch bearings.
3. Remove the four bolts securing the field assembly against the compressor bosses and remove
the bolts, washers and field assembly.
MAGNETIC CLUTCH INSTALLATION (YORK COMPRESSOR).
1. Position the field assembly against the compressor bosses, with the electrical leads to the cylin-
der side of the compressor.
2. Secure the field assembly with four capscrews and Iockwashers, do not torque at this tihie.
3. Connect the electrical lead from the field assembly.
— NOTE —
The compressor shaft must t}e clean and free from burrs.
4. Slide the pulley assembly over the field assembly and onto the crankshaft. Now torque the field
assembly 85 to 120 inch-pounds. Then secure the pulley assembly with a washer and new self-
locking capscrew.
— NOTE —
If the clutch is not engaged while tightening the capscrew, insert a spanner
Into the holes provided in the armature face.
5. Spin the pulley by hand to check for any interference between the field and rotor pulley assem-
blies. A rubbing noise can be heard as the pulley rotates if there is interference. The rotor pulley
assembly must be removed and the mounting of the field assembly adjusted until the interfer-
ence is eliminated. . . , -
21-54-13
Page 21-148
Issued: June 1,1995
2H15
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
413
1. CAPSCREW
2. ROTOR PULLEY A S S Y .
3. CAPSCREWS & LOCKWASHERS
4.. FIELD A S S Y .
5. COMPRESSOR
Figure 21-36. Magnetic Clutch (York Compressor)
C745
1. H E X N U T
2. F R O N T PLATE
3. S H A F T K E Y
4. SHIMS
5. S N A P RINGS
6. R O T O R PULLEY
7. BEARING
8 CLIP
9 COIL
10 COMPRESSOR
11. COIL L E A D WIRE
12. KEYWAY
Figure 21-37. Magnetic Clutch Assembly (Sankyo Compressor)
21-54-13
Page 21-149
Issued:June 1,1995
2H16
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAGNETIC CLUTCH, PULLEY AND COIL (SANKYO COMPRESSOR).
REMOVAL OF MAGNETIC CLUTCH, PULLEY AND COIL (SANKYO COMPRESSOR). (Refer to Figure 21-37.)
1. Insert tfie two pins of tiie front plate spanner into any two tfireaded holes of the clutch front plate.
Hold clutch plate stationary and remove hex nut with 3/4 inch socket.
2. Remove clutch front plate using Sankyo puller 32416.
A. Align puller center bolts to compressor shaft and thumb tighten the three puller bolts into
the threaded holes.
B. Turn center bolt clockwise to remove front plate.
3. Remove shaft key by lightly tapping it loose with a slot screwdriver and hammer. Also, remove
shims.
4. Remove the external and internal snap rings by the bearing inner and outer races, respectively,
with snap ring pliers.
5. Remove rotor pulley assembly:
A. Insert the lip of the jaws into the snap ring groove.
B. Place rotor puller shaft protector over the exposed shaft.
C. Align thumb head bolt to puller jaws. Finger tighten.
D. Turn puller center bolt clockwise until rotor pulley is free.
6. Remove field coil.
A. Loosen coil lead wire from clip on top of compressor front housing.
B. Remove snap ring and field coil.
INSTALLATION OF MAGNETIC CLUTCH, PULLEY AND COIL (SANKYO COMPRESSOR).
1. Install field coil. Coil flange protrusion must match hole in front hosing to prevent coil movement
and correctly locate lead wire.
A. Install snap ring.
B. Position coil lead wire and secure it with clip on top of compressor front housing.
2. Replace rotor pulley:
A. Using a vise, clamp the compressor rear mounting ears, never the compressor body.
B. Align rotor assembly squarely on the front housing hub.
C. Using rotor installation set, place the ring part of the set into the bearing cavity. Make
certain the outer edge rests firmly on the rotor bearing outer race.
D. Place the tool set drive into the ring.
E. With a hammer, tap the end of the driver while guiding the rotor to prevent binding. Tap
until the rotor bottoms against the compressor front housing hub. Listen for a distinct
change of sound during the tapping process.
21-54-16
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2H17
AEROSTAR AIRCRAFT
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MAINTENANCE MANUAL
3. Install external and internal snap rings.
4. Replace front plate assembly.
A. Check that original clutch shims are in place on compressor shaft.
B. , Replace compressor shaft keyr
C. Align front plate keyway to compressor shaft key.
D. - Using shaft protector, tap front plate onto shaft until it has bottomed on the clutch shims.
Note distinct sound change.
5. Replace shaft hex nut and torque from 25 to 30 foot-pounds.
6. . Check air gap with feeler gauge (.016" to .031"). If air gap is not consistent around the circumfer-
ence, lightly pry up at the minimum variations. Lightly tap down at points of maximum variation.
—NOTE —
The air gap is determined by the spacer shims. When reinstalling or
installing a new clutch assembly, try the original shims first.
7. If the air gap does not meet the specifications in step 6, add or subtract stiims by repeating steps
4 and 5.
21-54-16
Page 21-151

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MAINTENANCE MANUAL
CHART 2113. TROUBLESHOOTING (AIR CONDITIONING SYSTEM)
Trouble/Symptoms Cause Remedy
Poor cooling. Refrigerant slightly low. 1. Leak test the system.:

1. Low side pressure 2. Add R-12.
slightly low. A. Repair leaks.
2. High side pressure B. Check compressor
too low. oil level..
3. Bubbles in sight glass. C. Evacuate, charge and
4. Evaporator air not cold. performance test system.
NOTE
1. The low side pressure should be 20-40 PSI.
2. The high side pressure should be 175-210 PSI.
Insufficient or no cooling. Condenser not functioning 1. Check condenser fan and

1. Low side pressure properly. ducting.
too high. 2. Check for obstructions
3. Bubbles may appear which could reduce air
in sight glass flow through the condenser.
occasionally.
5. Liquid line hot. Operate system if preceding
5. Evaporator air warm. remedies were utilized;
if still unsatisfactory, proceed
as follows:
3. Check for overcharge of

refrigerant:
A. Discharge refrigerant
until bubbles appear in
sight glass and both
gauge readings drop
below nomnal.
B. Add refrigerant until
bubbles disappear and
gauge readings are
normal.
Operate system; if still

unsatisfactory, proceed as
follows:
4. Remove, clean and flush

or replace condenser.
5. Performance test system.
21-54-16
Page 21-152
Issued: June 1,1995
2H19
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHART 2113. TROUBLESHOOTING (AIR CONDITIONING SYSTEM) (cont)
Trouble/Symptoms - Cause Remedy
Insufficient or no cooling. Thermostatic expansion 1. Check for sticking

1. Low side pressure valve stuck open. expansion valve or
too high: incorrect mounting of
2. High side pressure temperature sensing bulb:
slightly high. A. Operate system at
3. Evaporator air warm. . maximum cooling.
4. Evaporator and suction B. Spray liquid R-12 on
hose (to compressor) head of expansion
show considerable valve and/or temp,
moisture. sensing bulb.
C. Low side gauge should
show a vacuum reading.
2. If test shows expansion
valve operation is
satisfactory:
A. Clean surface of the
evaporator outlet pipe
and temp, sensing bulb,
then clamp bulb to pipe.
B. Performance test system.
3. If test shows expansion
valve to be defective,
replace valve.
Insufficient or no cooling. Large amount of air in 1. Discharge system.

1. Low side pressure is system. 2. Replace dehydrator and
high. and receiver.
2. High side pressure is 3. Evacuate, charge and
high. performance test the
3. Steady stream of tiny system.
bubbles in sight glass.
4. Evaporator air not cool.
21-54-16
Page 21-153

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
Insufficient cooling. Thiemnostatic expansion 1. Place finger on expansion

1. Low side gauge reading valve stuck closed or low valve inlet. If too cold to
.0 PSI or vacuum. side restriction. touch, proceed as follows.
2. Higfi side pressure 2. Proceed with steps
too low. 1A through 2B in
3. Evaporator air cool, remedy column for
but not sufficiently 'Ihermostatic expansion
cold. valve stuck open."
4. Expansion valve inlet 3. If expansion valve inlet
pipe surface sfiows surface shows frost or
considerable moisture heavy moisture:
or frost. A. Discharge system.
B. Disconnect inlet line
from expansion valve.
Inspect, clean and
reinstall screen.
C. Reconnect inlet line.
4. Proceed with step 3
of remedy column for
Ihermostatic expansion
valve stuck open."
5. After performing steps 3
and/or 4, proceed as
follows:
A Insure that temp.
. sensing bulb is
properly mounted on
evaporator outlet pipe.
B. Evacuate, charge and
performance test the
system.
21-54-16
Page 21-154
Issued: June 1,1995
2H21
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
Insufficient cooling - Restriction on high side 1. Discharge system.

1. Low side pressure of system. 2. Replace the liquid lines,
too low. receiver/dehydrator or
2. High side pressure other obstnjcted
too low. components.
3. Evacuate, charge and
— NOTE — component test the
A normal or high reading system.
of the high side pressure
gauge under these conditions
indicates that the system is
overcharged or that an
incorrect condenser or
receiver/dehydrator has been
installed.
3. Evaporator air only

slightly cool.
4. Liquid line and
receiver/dehydrator
are cool to the touch
and show frost or
considerable moisture.
Insufficient cooling. Refrigerant excessively low. 1. Leak test system.

1. Low side pressure low. 2. Discharge system.
2. High side pressure 3. Repair leaks.
too low. 4. Check compressor oil
3. No liquid or bubbles level.
in sight glass. 5. Evacuate, charge, and
4. Evaporator air warm. performance test system.
Insufficient cooling. Compressor malfunction. 1. Check compressor drive

1. Low side pressure motor and belt.
too high. 2. If motor and belt are in
2. High side pressure good condition and
too low. compressor is turning
3. No bubbles in at correct RPM,
sight glass. replace compressor.
4. Evaporator air not
cold.
21-54-16
Page 21-155

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
Insufficient cooling. Air in system. 1. Leak test system,

1. Low side pressure giving special attention
normal. to tfie compressor
2. Higfi side pressure seal area.
sligfitly fiigfi or 2. Discfiarge system.
normal. 3. Repair leaks.
3. Tiny bubbles in 4. Replace receiver/
sigfit glass. defiydrator.
4. Evaporator air 5. Cfieck compressor oil
not cold. level to insure no loss.
6. Evacuate, cfiarge and
performance test tfie
system.
Insufficient cooling. Moisture in ttie system. 1. Discharge system.

(May occur only during 2. Replace the receiver/
tfie fiottest part of dryer.
tfie day.) 3. Evacuate, charge and
1. Low side pressure is performance test the
normal but drops to a system.
vacuum during testing.
2. Higfi side pressure
is normal, but it
drops wiien low side
sfiows vacuum.
3. Tiny bubbles in
sigfit glass.
4. Evaporator air is
sufficiently cold
until low side
pressure sfiows
vacuum, tfien it -
becomes warm.
Noisy compressor. Loose, torn or Align or replace belL

misaligned belt.
Foreign material or Remove and replace

damaged part in compressor.
compressor.
Compressor loose on Tighten compressor.

bracket.
Noisy fan. Fan striking fiousing. Align fan travel.
Fan sfiaft bearings out. Replace bearings.
21-54-16
Page 21-156
Issued: June 1,1995 2H23
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
GRID 2H24
INTENTIONALLY LEFT BLANK
2H24
CHAPTER
AUTO FLIGHT
211
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHAPTER 22 - AUTOFLIGHT
CHAPTER
SECTION GRID
22-00-00 GENERAL 213
22-10-00 AUTOPILOT 213
22-10-01 Non-Aerostar A.F.C.S. Equipment Contacts 213

22-10-02 Piper A.F.C.S. Equipment 214
22 - ContTEffec.
Page -1
Issued: June 1,1995
212
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
GENERAL.
Due to the wide variety of A.F.C.S. (Automated Flight Control System) options, it is mandatory to follow
the service literature published by the individual manufacturer of the A.F.C.S. equipment installed in any particu-
lar airplane. This includes mechanical service such as: Adjusting bridle cable tension, servo removal and instal-
lation, servo clutch adjustments, etc.
AUTOPILOT.
NON-AEROSTAR A.F.C.S. EQUIPMENT CONTACTS.
Refer to the following list of AutoPilot/Flight Director manufacturers to obtain service direction, parts sup-
port and service literature.
Bendix/King Radio Corporation Collins General Aviation Division

400 North Rodgers Road 400 Collins Road N.E.
Olathe, KS 66061 Cedar Rapids, lA 52498
(913) 782-0400 (319) 395-3625
Edo Corporation - Avionics Division Global Navigation

Box 610 8216-154th Avenue N.E.
Mineral Wells, TX 76067 Redmond, WA 98052
(817) 325-2517 (206) 861-6200
Sperry Flight Systems/Avionics Div. Piper Aircraft Corporation

5353 W. Bell 2926 Piper Drive
Glendale, AZ 85308 Vero Beach, FL 32960
(602) 436-4512 (407) 567-4361
22-10-01
Page 22-01
Issued: June 1,1995
213
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
PIPER A.F.C.S. EQUIPMENT.
In the case of early models, Piper AutoPilot equipment bears the Piper name, and the appropriate Piper
AutoPilot/Flight Director Service l\/lanual shall be used.
— NOTE —
If a Roll Axis-only AutoPilot is installed, or if no AutoPilot is installed, con-
sult tfie Piper Pitch Trim Service Manual for manual electric pitch trim ser-
vice information.
The following is a complete listing of Piper A.F.C.S. equipment service literature. It is imperative to cor-
rectly identify the AutoPilot system by "faceplate" model name, in order to consult the appropriate service manual.
Each manual identifies the revision level and revision status as called out on the Master Parts Price List -
Aerofiche published monthly by Piper. Consult the aircraft's parts catalog for replacement parts.
NAME PART NO.
AutoControl l/ll & AltiMatic l/ll 753 798

AutoControl III and AltiMatic III and IIIB 753 723
AutoControl IIIB and AltiMatic IIIB-1 761 502
AltiMatic NIC 761 602
AltiMatic V and V-1 761 525
AltiMatic V F/D and V F/D-1 761 526
AltiMatic X F . D . / A . P . / & X A . P . 761 668
AutoFlite 753 720
AutoFlite II 761 481
Piper Pitch Trim (Manual-Electric) 757 771
— END —
22-10-02
Page 22-02
Issued: June 1,1995
214
CHAPTER
215
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHAPTER 23 - COMMUNICATIONS
CHAPTER
SECTION GRID
23-00-00 COMMUNICATIONS 219

23-01-00 Description 219
23-02-00 Troubleshiooting 219
23-03-00 Precautions 2114
23-04-00 System Test 2114
23-10-00 SPEECH COMMUNICATION 2114

23-11-00 VHF Communications System (Collins) 2114
23-11-01 VHF-251 Transceiver 2116
23-11-02 Removal of VHF-251 Transceiver 2116
23-11-03 Installation of VHF-251 Transceiver 2116
23-11-04 Operational Test, (VHF) 2116
23-11-05 PWC-150 Power Converter 2118
23-11-06 Removal of PWC-150 Power Converter 2118
23-11-07 Installation of PWC-150 Power Converter 2118
23-11 -08 Power Converter Voltage Test 2118
23-11-09 COMM-1 Antenna 2118
23-11-10 Removal of COMM-1 Antenna 2118
23-11 -11 Installation of COMM-1 Antenna 2120
23-11-12 COMM-1 Antenna Operational Cfieck 2120
23-11-13 COMM-2 Antenna 2120
23-11-14 Removal of COMM-2 Antenna 2120
23-11 -15 Installation of COMM-2 Antenna 2120
23-11 -16 COMM-2 Antenna Operational Cfieck 2120
23-12-00 HF Communications System 2122
23-12-01 Description 2122
23-12-02 SB-10HF System (Pantronics) 2122
23-12-03 Troublesfiooting 2123
23-12-04 SB-10 Transceiver 2J2
23-12-05 Removal of SB-10 Transceiver (A/F 0001-0422) 2J2
23-12-06 Removal of SB-10 Transceiver (A/F 0423 and Up) 2J2
23-12-07 Installation of SB-10 Transceiver (A/F 0001-0422) 2J2
23-12-08 Installation of SB-10 Transceiver (A/F 0423 and Up) 2J2
23-12-09 SB-10 Transceiver Operational Ctieck (Fixed Antenna) 2J9
23-12-10 SB-10 Control Head 2J9
23-12-11 Removalof SB-10 Control Head 2J9
23-12-12 Installationof SB-10 Control Head 2J9
23-12-13 Control Head Operational Cfieck 2J9
23-12-14 SB-10-RL28 Antenna Load Unit 2J9
23-12-15 Removal of SB-10-RL28 Antenna Load Unit 2J9
23-12-16 Installationof SB-10-RL28 Antenna Load Unit 2J10
23-12-17 Antenna Load Unit, Tuning and Adjustment 2J10
23 - ContTEffec.
Page -1
216 Issued: June 1,1995

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHAPTER 23 - COMMUNICATIONS (cont)
CHAPTER
SECTION GRID
23-10-00 S P E E C H COMMUNICATION (cont) —

23-12-00 HF Communications (cont) —-
23-12-18 HF Fixed Antenna 2J10
23-12-19 Removal of HF Fixed Antenna 2J10
23-12-20 Installation of HF Fixed Antenna 2J11
23-12-21 Fixed Antenna Operational Check 2J11
23-12-22 HF Trailing Wire Antenna 2J12
23-12-23 Removal of HF Trailing Wire Antenna 2J12
23-12-24 Installation of HF Trailing Wire Antenna 2J12
23-12-25 Trailing Wire Antenna Operational Check .2J12
23-13-00 ASB-100AHF System, (Sun Air) 2J13
23-13-01 Description 2J13
23-13-02 Tuning Antenna Coupler and ASB-100A Components 2J14
23-13-03 Troubleshooting ASB-100A System 2J14
23-13-04 SCU-10 Control Unit 2J18
23-13-05 Removal of SCU-10 Control Unit 2J18
23-13-06 Installationof SCU-10 Control Unit 2J18
23-13-07 RE-1000 Receiver/Exciter 2J18
23-13-08 Removal of RE-1000 Receiver/Exciter 2J18
23-13-09 Installation of RE-1000 Receiver/Exciter 2J18
23-13-10 PA-1010 Power Amp/Power Supply 2J19
23-13-11 Removal of PA-1010 Power Amp/Power Supply 2J19
23-13-12 Installationof PA-1010 Power Amp/Power Supply 2J19
23-13-13 CU-110 Antenna Controller 2J19
23-13-14 Removal of CU-110 Antenna Coupler 2J19
23-13-15 Installation of CU-110 Antenna Coupler 2J19
23-13-16 Antenna 2J22
23-13-17 Removal of Antenna 2J22
23-13-18 Installation of Antenna 2J22
23-13-19 Operational Test 2J22
23-14-00 Emergency Locator Transmitter (ELT) 2J24
23-14-01 Removal of ELT 2J24
23-14-02 Inspection of ELT 2J24
23-14-03 Battery Pack Replacement 2K2
23-14-04 Installation of ELT 2K2
23-14-05 Testing ELT 2K3
23-14-06 Inadvertent Activation 2K4
23-14-07 ELT Fixed Antenna 2K4
23-14-08 Removal of ELT Fixed Antenna 2K4
23-14-09 Inspection of ELT Antenna 2K4
23-14-10 Installation of ELT Fixed Antenna 2K5
23 - ContTEffec.
Page - 2
Issued: June 1,1995
217
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHAPTER 23 - COMMUNICATIONS (cont)
CHAPTER
SECTION GRID
23-10-00 SPEECH COMMUNICATION (cent) —

23-15-00 Microphone Switch 2K5
23-15-01 Troubleshooting 2K5
23-15-02 Removal of Microphone Switch 2K5
23-15-03 Installation of Microphone Switch 2K6
23-50-00 AUDIO INTEGRATING SYSTEM 2K7

23-51-00 Description 2K7
23-52-00 Troubleshooting 2K7
23-53-00 AMR-350 Audio/Marker Panel 2K11
23-53-01 Removal of AMR-350 Audio/Marker Panel 2K11
23-53-02 Installation of AMR-350 Audio/Marker Panel 2K11
23-53-03 Operational Test of AMR-350 Audio/Marker Panel 2K11
23-54-00 , Audio Switching Panel . 2K11
23-54-01 Removal of KMA-20/AMR-350H Audio Switching
Panel (HF) 2K11
23-54-02 Installation of KMA-20/AMR-350H Audio Switching
Panel (HF) 2K13
23-54-03 KMA-20 and AMR-350H Operational Check (HF) 2K13
23-55-00 Removal of Headphones and Microphones 2K13
23-56-00 Cabin Loud Speaker . 2K13
23-56-01 Removal of Cabin Loud Speaker 2K13
23-56-02 Installation of Cabin Loud Speaker 2K13
23-60-00 STATIC DISCHARGING 2K14

23-61-00 Description 2K14
23-62-00 Static Wicks 2K14
23-62-01 Removal of ESD-3 Static Discharge Wicks . 2K14
23-62-02 Installation of ESD-3 Static Discharge Wicks 2K14
23 - ContyEffec.
Page-3
2|g Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
COMMUNICATIONS.
The communication system consists primarily of a VHF air-to-air and air-to-ground system. However,
some airplanes are also equipped with HF. The VHF is used mainly for the shorter ranges, while the HF system
is utilized for medium and long range use.
DESCRIPTION.
The VHF system is composed of two identical transceivers, designated COM-1 and COf^-2. Each is con-
nected to its remotely mounted power supply, which furnishes the input voltage to the transceiver. An audio
switching panel is provided for system selection, as well as choice of speal<er or headphone audio. Individual
fuselage mounted antennas complete the VHF installation.
The HF system, in those airplanes so equipped, is comprised of a single, remotely mounted transceiver.
A panel mounted control unit provides all of the functional audio output interfaces with the VHF system at the
audio switching panel where system selection and choice of speaker or headphones can be made. Two different
antenna configurations are provided for the HF system; a fixed antenna, or an electric reel trailing wire type.
The airplane is also equipped with a static-discharging system composed of ESD-3 Static Dischargers.
Use of these devices minimizes receiver noise on the HF, VHF and navigation systems during periods of static
electricity build-up.
TROUBLESHOOTING.
Refer to VHF Chart 2301 for Troubleshooting procedures.
23-02-00
Page 23-01
2IQ Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHART 2301. TROUBLESHOOTING (COLLINS VHF)
Unable to energize VHF VHF circuit breaker OFF, Reset VHF circuit breaker,
transceiver (Collins). Com-1/Com-2. Com-1/Com-2.
Radio master switch OFF. Turn radio master switch ON.
Battery circuit breaker Reset circuit breaker

OFF.
Master battery switch OFF. Turn master battery switch O N .
Transceiver not secured Check for proper mating of con-

- in its mounting tray. nectors at rear of transceiver.
Ensure tumlock is tight.
Loose terminal lugs at Tighten lugs at TB-1. See Figure

TB-1, lugs 1, 2 and 3, 23-5.
PWC-150 power con-
verter.
Loose or broken conductor Check power input circuit,

in 14 volt input power point-to-point. Plug P-1, trans-
circuit to transceiver. ceiver, pins 10, 11, 22, 23, 24
and 25. See Figure 23-1 and 2.
Replace/repair as required.
No output voltage at. Replace power converter

PWC-150 power converter
lug 3. See Figure 23-5.
Power input OK. Unable Transceiver tuned to in- Retune to correct frequency.
to perfomri operational correct frequency.
check.
Loose, broken or corroded Check connectors at trans-
connectors on RF transceiver and antenna. Repair/
mission line to an- replace.
tenna.
Open circuit in trans- Check pins 5 and 9 at plug P-1,

mitter keying line. transceiver See Figure 23-2.
Repair or replace as required.
23-02-00
Page 23-02
Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
^ MAINTENANCE MANUAL
CHART 2301. TROUBLESHOOTING (COLLINS VHF) (cont)
Power input OK. Unable Loose or broken audio Repair/replace as required.

to perform operational connectors/cables at
cfieck. (cont) AMR-350 audio panel.
See Figure 23-1.
Defective push to talk Repair/replace.

switch.
Defective microphone or Repair/replace.

frayed, worn cord.
Defective antenna. Check antenna for loose mount-

ing, cracked or damaged base.
Bent, broken or damaged radi-
ating element.
Defective transceiver. Check for weak or no sidetone;

"XMIT" indicator out or dim.
Replace transceiver.
RF output OK. No audio Loose or broken audio Check, tighten connectors.

at cabin speakers, head connectors at audio
phone audio OK. panel.
Defective isolation Replace audio panel.

amplifier in audio panel.
No headphone audio. Loose or broken audio Check/tighten connectors.

connectors at audio
panel.
Check antenna RF path Replace/repair as required.

from transceiver plug
P-2, to antenna.
Volume control too low. Increase volume control.
No squelch. Defective transceiver. Replace transceiver.
23-02-00
Page 23-03
Issued: June 1,1995
2111
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE.MANUAL
B400
LEFT SPEAKER RIGHT SPEAKER J]PHO.

iQPHO.
1j)mc.
MIC.
PI d 15 7 8 11 17 12 13 18
AMR-350
(AUDIO/HARKER
PANEL) P2 11 To]
P3 CNTR
VHF-251 HO. 1
(com 1) J V
PI 10 11 25 22 23 6 5 13 9|
PWC 150 NO. 1 TBI 12 3

(POWER
CONVERTER)
P5 CNTR
VHF251 NO. 2
(com 2)
P6 25 2f 10 11 23 22 6 5 13 9
• PWC 150 HO. 2 TB3 1 2 5

(POWER
CONVERTER)
Sn.lSW
PUSH TYPE C. BIWS •

t
TO AVIONICS BUS
DETAIL O
Figure 23-1. VHF Interconnecting Diagram (CoMins)

23-02-00
Page 23-04
Issued: June 1,1995
2112
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B401
VHF-2511 1/VHF-250( 1
COMMUNICATIONS -DETAILO
I
TRANSCEIVER
2
NOT CONNECTED
3
4
MICROPHONE 5
AUDIO GROUND 6
27.5 V DIMMER 7 AIRCRAFT /JX
IS.75 V DIMMER 8 DIMMER ^
KEYLINE 9
SWITCHED C O M M POWER 10
COMM + 1 3 . 7 5 V DC 1 1
SPEAKER 12
COMM AUDIO 500-OHMS 13
(
14
NOT C O N N E C T E D
15
ACC TEST 16
- 1 1 7
7 18 AUXILIARY
AUX AUDIO ' 1 AUDIO
3 19
INPUTS
4 20 CBl
AUDIO GROUND 21 7.5 A
COMM POWER IN 22 •H3.75/

23 • 2 7 . 5 V OC
COMM POWER IN AIRCRAFT
POWER GROUND 24 GROUND POWER '
POWER GROUND 25
J
NOTES
(£) A C C IS BROUGHT OUT TO P I - 1 6 FOR T E S T I N G P U R P O S E S O N L Y .
(?) THE P W C - 1 5 0 POWER C O N V E R T E R IS C O N N E C T E D IN SERIES WITH THE PI-IO
TO P I - 1 1 J U M P E R WHEN INSTALLED IN A 28 V SYSTEM.
P/0 PI P/D P/0

7.5 A
TBI iTBl
••27.5 V DC- 23
PA) PWC-150
POWER
10
CONVERTER
22
II
(D WIRES CARRYING • 1 3 . 7 5 / ^ f 2 7 . 5 V OC INCLUDING POWER G R O U N D M U S T B E 20

AWG OR L A R G E R , A L L OTHERS MUST B E 24 AWG OR L A R G E R .
<4) PI-7 A N D P I - 8 A R E NOT U S E D (NO I N T E R N A L C O N N E C T I O N ) IN T H E V H F - 2 5 1 t 1.
FOR 13.75 V LIGHTING GROUND P I - 7 AND C O N N E C T P l - B TO LIGHTING B U S .
FOR 27.5 V LIGHTING C O N N E C T P l - 7 TO L I G H T I N G BUS AND L E A V E P l - 8 O P E N .
Figure 23-2. VHF 250/251 Communications Transceiver Interconnect Wiring Diagram

23-02^0
Page 23-05
2|-^2 Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
PRECAUTIONS.
1. Operating and maintenance personnel should be aware of the potential electrical shock hazard
that exists in the output stage of the HF transceiver. When in the transmitting mode, high RF
potentials are present at the antenna. Personnel should keep a minimum distance of several feet
from exposed portions of the antenna and RF terminals.
2. The Auxiliary Power Unit must be switched "ON" and the voltage allowed to stabilize at 24 to 28
volts DC before installing the external power plug in the tail receptacle. Since power will be auto-
matically supplied to the bus, the more delicate electrical components will be protected from
external power supply voltage spikes by ensuring that the radio master switch is "OFF" as long
as external power is connected.
3. Only authorized personnel should install or remove components or perform maintenance on the
communication system.
SYSTEM TEST.
1. Refer to the section titled Operational Test (VHF).

A. Perfomri Com-1 operational test with tower or station in vicinity.
B. Repeat Step A for Com-2.
2. Refer to one of the following sections (as applicable) for the HF Operational Test: SB-10
Transceiver Operational Check (Fixed Antenna), Trailing Wire Antenna Operational Check, or
Operational Check (Fixed Antenna).
A. Perform HF operational test.
SPEECH COMMUNICATIONS.
VHF COMMUNICATIONS SYSTEM (COLLINS).
The VHF system provides air-to-air and air-to-ground voice communications in the frequency range of
118 to 136 MHZ, and is composed of two transceivers, power supplies, and antennas. An audio switching panel
integrates the receiver outlets and system selection, also allowing for choice of speaker or headphone audio.
The two transceivers, Com-1 and Com-2, are centrally located on the radio stack, and contain all of the
controls necessary for operation of the system. See Figure 23-4 for appearance and location of indicators and
controls.
A power converter furnishes the operating voltage for the system. It is composed of two independent volt-
age reducing regulators which provide 13.75 V DC for the transceivers from the airplane's 28 V DC power bus.
The two power converters are located in the nose section and are mounted above the center shelf on the fonward
side of fuselage station 54.25 bulkhead. Each unit is connected by wiring to its respective transceiver
The antennas provided with the system are ANT-251 communication antennas. Each is connected to its
respective transceiver through 50-ohm coaxial transmission line. Com-1 antenna is fuselage mounted above the
aft portion of the cabin, while Com-2 antenna is fuselage mounted above the baggage compartment.
23-11-00
Page 23-06
Issued: June 1,1995
2114
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B402
1. AMR-350 AUDIO PANEL

2. CCM-NAV 1 TRANSCEIVERS
3. CCM-NAV 2 TRANSCEIVERS
4. CCM-1 ANTENNA
5. COM-2 ANTENNA
6. PWC-150 POIVER CONVERTIER
Figure 23-3 VHF System Locator

23-11-00
Page 23-07
Issued: June 1,1995
2115
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
An audio switciiing panel located above the transceivers on the radio stacl< provides .switch selection of
Com-1 and Com-2 VHF, as well as speaker or headphone audio. The audio panel also contains components
which are not specifically used in the communications system, and is therefore dual purpose. See Figure 23-4,
Detail B.
The operating frequency may be recalled from memory by using the recall function of the transceiver, or
a new frequency may be selected. Othenwise, the last frequency in use will be the one the transceiver is tuned to
and will appear at the electronic display on the transceiver front panel.
When the transceiver is in the transmit mode, the RF output can be monitored by observing the "XMIT'
indicator light on the transceiver panel. Light intensity corresponds to microphone audio level, and is therefore a
relative indication of modulation percentage. During periods of transmission, sidetone will be audible in head-
phones as an additional transmission indicator.
VHF 251 TRANSCEIVER.
REMOVAL OF VHF 251 TRANSCEIVER. (Refer to Figure 23-4.)
1. Com-1 and Com-2 O F F , Radio (faster switch O F F .

2. Master Battery OFF/Auxiliary Power disconnected.
3. Twist front panel tumlock to unlocked position.
4. Grasp unit by frequency selector knobs and carefully withdraw from mounting tray.
INSTALLATION OF VHF 251 TRANSCEIVER.
1. Com-1 and Com-2 O F F , Radio Master switch O F F .

2. Battery Master OFF/Auxiliary Power Unit disconnected.
3. Verify turnlock is in upward, unlocked position.
4. Carefully insert unit in its mounting tray. To insert, place thumbs on bottom comers and gently
apply pressure until rear connectors are fully mated.
5. Twist tumlock to locked position.
OPERATIONAL TEST (VHF).
1. Radio Master switch ON, Battery Master Ofvl/APU connected.

2. Select Com-1 at audio switching panel.
3. Select Headphones or Speaker.
4. Com-1 transceivers ON. •
5. Check squelch by pulling out Off-Vol-Tst control. Receiver noise will be audible, set volume as
desired.
6. Push Off-Vol-Tst control in. Receiver noise will cease as squelch activates.
7. Select operating frequency of a known station in vicinity.
8. Contact station and obtain signal check. Sidetone should be audible during transmission.
9. Verify that "XMIT" indicator on transceiver panel illuminates and fluctuates in intensity while
speaking during signal check.
10. Repeat Steps 7 through 9 with several other stations on different frequencies if possible.
11. Com-1 transceiver O F F .
12. Repeat Steps 1 through 10 for Com-2.
13. Tum equipment OFF, Radio Master OFF, Battery Master/APU OFF.
23-11-04
Page 23-08
Issued: June 1,1995
2116
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B403
-DETAIL©
8 8 99« C 8
DETAILO
CCM-1
COM-2-
o ELECTRONIC
AMBIENT
LIGHT
SENSOR
DISPLAY"
I t ' *
-TRANSMIT
INDICATOR
STORE/SELECT/
RECALL - • MHZ
CONTROL FREQUENCY
CQNTROL
-KHZ "
ON/OFF ^ V FREQUENCY
VOL/SQUELCH-
CONTROL
TEST
o
-TURNLOCK
LIGHTS
OUTER MIDDLE INNER / AMBIENT LIGHT SENSOR TURN LOCK
COLLINS AUDIO /MARKER
COM 1/COM 2/EXT SPEAKER HIGH L

O W TEST
AUTO COMl COM2 NAV1 NAV2 ADF DME MKR
9 § §PHO§
NE MARKER
Figure 23-4. VHF Transceivers and Audio Switching Panel

23-11-04
Page 23-09
Issued: June 1,1995
2117
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
PWC-150 POWER CONVERTER.
REMOVAL OF PWC-150 POWER CONVERTER. (Refer to Figure 23-5.)
1. Com-1 and Com-2 O F F .

2. Battery Master OFF/Auxiiiary Power Unit disconnected.
3. Remove nose section access door.
4. Locate power converter mounted on fonward side of fuselage station 54.25 bulktiead.
5. Remove connecting wires at TB-1 and TB-2, lugs 1, 2 and 3.
6. Remove unit.
7. Replace access door.
INSTALLATION OF PWC-150 POWER CONVERTER. (Refer to Figure 23-5.)
1. Com-1 and Com-2 O F F .

4. Install power converter on forward side of fuselage station 54.25 bulkhead.
5. Connect wires at TB-1 and TB-2, lugs 1, 2 and 3.
POWER CONVERTER VOLTAGE TEST. (Refer to Figure 23-5.)

2. Locate power converter mounted on forward side of fuselage station 54.25 bulkhead.
3. Radio Master Switch ON, Battery Master/APU ON, Com-1 ON.
4. At power converter, verify 28 VDC is present between lugs 1 and 2, TB-1 and 2.
5. At Power Converter, verify 14 VDC is present between lugs 3 and 2, TB-1 and 2.
6. Com-1 transceiver OFF. Repeat Steps 3, 4, and 5 for Com-2.
7. Tum Com-2 transceiver OFF, Radio Master OFF, Battery Master/APU OFF.
8. Replace access door
COM-1 ANTENNA.
REMOVAL OF COM-1 ANTENNA. (Refer to Figure 23-6.)
1. Com-1 and Com-2 O F F , Radio Master OFF.

3. Locate Com-1 antenna above cabin.
4. Remove screws securing antenna mounting plate.
5. Lift antenna assembly off fuselage and disconnect coax transmission line.
6. Rerhove antenna.
23-11-10
Page 23-10
Issued: June 1,1995 2118
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B404
/ \
. PWC-150 POIVER CONVERTER

DETAILO
BULKHEAD 54.25-
o
I 2
TBI COMM
1 •»2avoc
2 GROUND
3 +14 V DC ( 0 - 5 A ) ,
NAV-2 I 2
T B 2 NAV
DETAIL©, 1 +28vbc
TB-2 2 GROUND
3 +14 V OC ( 0 - 2 A )
PWC-150 POWER CONVERTER
Figure 23-5. PWC-150 Power Converter Locator

23-11-10
Page 23-11
Issued: June 1,1995
2119
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
INSTALLATION OF COM-1 ANTENNA. (Refer to Figure 23-6.) I - ^17 1
1. Com-1 and Com-2 OFF, Radio f^/laster OFF.

3. Locate Com-1 antenna placement above cabin.
4. • Connect coax transmission line.
5. Install antenna. Verify mating surfaces are clean. Clean ligfitly, as required to obtain adequate
bond between antenna mounting plate and fuselage.
COM-1 ANTENNA OPERATIONAL CHECK.
1. Perform operational test per tfie section titled Operational Test (VHF) after any re-installation of
antenna.
COM-2 ANTENNA.
REMOVAL OF COM-2 ANTENNA. (Refer to Figure 23-7.)
1. Com-1 and Com-2 OFF, Radio Master OFF.

2. Battery Master Off/Auxiliary Power Unit disconnected.
3. Locate Com-2 antenna above baggage compartment, fonward section.
4. Open baggage compartment access door.
5. Antenna cable connector is visible top center forward area. Disconnect cable connector, remove
bolts securing antenna.
6. Remove antenna.
7. Close baggage compartment access door.
INSTALLATION OF COM-2 ANTENNA. (Refer to Figure 23-7.)
1. Com-1 and Com-2 OFF, Radio Master OFF.

2. Battery Master Off/Auxiliary Power Unit disconnected. .
3. Locate Com-2 antenna placement above baggage compartment.
5. Verify mating surfaces are clean. Install antenna and connect coax line.
COM-2 ANTENNA OPERATIONAL CHECK.
1. Perform operational test per tfie section titled Operational Test (VHF) after any re-installation of
antenna.
23-11-16
Page 23-12
Issued: June 1,1995
2120
AERdSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B405
Figure 23-6. VHF Com-1 Antenna
B406
Figure 23-7. VHF Com-2 Antenna
23-11-06
Page 23-13
212'! Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
HF COMMUNICATIONS SYSTEM.
DESCRIPTION.
The HF system provides air-to-air and air-to-ground voice communications in the frequency range of 2.8
to 18 MHz. The HF system makes possible reliable medium and long range communications, depending on the
time of day and various other propagation factors. The HF system consists of a single-sideband (SSB) and com-
patible amplitude modulated (AM) transceiver, control head, and an antenna coupler working into a fixed or trail-
ing wire antenna. An audio switching panel is provided for selection of desired Com system and choice of speak-
er or headphone audio.
SB-10 PANTRONICS HF SYSTEM.
The SB 10 transceiver contains the transmitting and receiving elements of the system, and features 10
crystal controlled channels with temperature control for frequency stability. The transceiver contains an integral
power supply. Either of two operating modes may be used, SSB or compatible AM. In the SSB Mode, only upper
sideband may be selected. Transmitter power output is a nominal 100 watts SSB or 50 watts on AM. A warm-up
time of 10-20 minutes is recommended to allow the crystal controlled circuits to reach operating temperature and
the frequency to stabilize. The SB 10-CH control head is a panel mounted unit where all of the operating controls
and related functions are located for centralized operation of the system, as follows:
1. The microphone amplifier provides impedance matching between the mike and succeeding cir-
cuits, also increasing audio power to required level for the operation of the loudspeakers.
2. The channel selector control is a 10-position rotary switch, enabling remote channel selection.
Any 10 frequencies in the 2.8 to 18 MHz HF range may be chosen.
3. The ON-OFF-VOL control energizes the system by rotating knob clockwise. Increased rotation
sets audio to desired level.
4. The clarifier control is used to improve audio response. Rotating the control causes the received
frequency to shift slightly, thus improving audio voice quality. A range of at least ±150 Hz is pos-
sible by use of this feature.
5. A relative power output meter completes the control head functions. Observing meter during
transmission gives an indication of RF Power output as well as modulation level.
The KMA-20 Audio Panel/Marker Beacon provides integration of the audio system. Since the unit con-
tains components not specifically related to the HF System, it serves a dual purpose. Later airplanes were
equipped with an AMR-350 H Audio Panel instead of the KMA-20. Both types provide similar functions.
The Antenna Load Unit is used to tune the fixed wire antenna in order to achieve maximum power output,
resulting in optimum HF performance. The load unit is made up of variable inductance and capacitance forming a
"Pi" network which is commonly used to properly tune a fixed, mobile antenna. Once the load unit is properly
tuned or matched to a particular antenna, it will not require any other attention during normal operations. The
transceiver RF output is fed through the load unit to the fixed wire antenna which is installed between the right
wing tip and the vertical stabilizer.
After selection of the HF System at the audio switching panel, power is applied to the transceiver at the
control head. The operational mode, SSB or AM, and the desired channel are selected at this time. Allowing 10-
20 minutes for equipment warm-up renders the system operational. After contact with a station is made, transmit-
ter power output can be monitored by observing the relative power meter at the control head. Received informa-
tion is routed to the audio switching panel, thence to either the cabin speakers or headphones.
23-12-02
Page 23-14
Issued: June 1,1995
2122
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
TROUBLESHOOTING.
Refer to HF Chart 2302 Troubleshooting Procedures.
CHART 2302. TROUBLESHOOTING (HF)
Trouble • Cause Remedy
Unable to energize HF. HF circuit breaker OFF. Reset HF circuit breaker.

transceiver.
Radio master switch OFF. Turn master switch ON.
Battery circuit breaker Reset circuit breaker.

OFF.
Blown fuse at SB-10 Check fuse, replace.

transceiver.
Loose plug at SB-10. Tighten plug.
Loose plug at control Tighten plug.

head.
. Loose or broken conductor Repair/replace.

at pin 1, transceiver, or
at pin 25, control head.
Open circuit in battery Repair/replace.

A, (28 volts).
Check pins 2, 5 and 6 at
transceiver.
Power input OK. Unable Jumper loose, broken or Repair/replace jumper.

to perfomn operational missing at pins 28 and
check. 29, SB-10 transceiver.
Open circuit in keying Repair/replace conductor.

line. Check pin 7,
(SB-10) and pins 7 and
8 (control head).
Loose, broken or corroded Repair/replace connector.

RF connector at SB-10
and/or at antenna load
box.
23-12-03
Page 23-15
Issued: June 1,1995
2123
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHART 2302. TROUBLESHOOTING (HF) (cont)
Power input OK. Unable • No rotary switch input at Check channel selector switch at
to perform operational antenna load box. Check control unit, check for open cir-
check, (cent) pins 33, 34, 35 and 36 at cuit or loose plug at both control
control head and pins 1, unit and antenna load box.
3, 5 and 7 at antenna Repair/replace as required.
load box.
No A (28 volts) in- Repair/replace as required. See

put at antenna load box. Figure 23-8.
Check for open circuit,
pin 11, at load box.
Blown fuse F-101 at Replace fuse.

-
antenna load box.
Defective mike amplifier Replace.

LM-270 in control uniL
Defective push-to-talk Replace.

switch.
Defective microphone or Repair/replace.

-
frayed, worn cord.
Loose audio connectors Tighten connectors.

at KI\/1A-20 or AMR-350H
audio panel.
Defect in antenna system. Repair/replace as required.

Check transmission line
from feed-thru insulator
at load box to antenna.
- Check for cracked or
broken insulators and
tension unit inspect
entire antenna.
Defective SB-10 trans- Replace transceiver.

• ceiver.
RF output OK. Head- Loose or broken audio Check/tighten connectors.

phone audio OK. No audio connectors at KMA-20
at cabin speakers. or KMA-350H audio panel
(as applicable).
Defective isolation amp Replace audio panel.

in audio panel.
23-12-C:
Page 23 16
Issued: J u n e l , 1995
2124
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHART 2302. TROUBLESHOOTING (HF) (cont)
Trouble , . Cause Remedy
No headphone or speak- Loose or broken audio Check/tighten connectors.

er audio. connectors at KMA-20
or KMA-350H audio panel
(as applicable).
Antenna system components. Repair/replace as required.
Antenna components OK, Replace transceiver.

defective receiver.
Defective reel IN-OUT Replace switch.

switch.
Defective clutch or Repair/replace as required.

motor in reel assembly.
SB-10 transceiver normal, Reel circuit breaker OFF. Reset circuit breaker.
unable to operate reel
antenna. Limit switches in reel Adjust micro switches for
assembly maladjusted. proper closure. Refer to
the latest revision of
Pantronics SB-10 Instaiction
Manual, Section III, page 18.
SB-10 transceiver normal, RF connection at fair- Repair/replace as required.

unable to tune antenna, lead loose, broken or
(trailing wire type). corroded.
RF connection at SB-10 Repair/replace connector.

.transceiver loose,
broken or corroded.
RF connections at thermo- Repair/replace as required.

couple loose, broken or
corroded.
Defective thermocouple. Replace thermocouple.
Defective DC line from Check out line for shorted or

. . . thermocouple to tuning . open condition.
meter.
Defective tuning meter. Replace meter.
23-12-03
Page 23-17
Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
SB-10 TRANSCEIVER.
REMOVAL OF SB-10 TRANSCEIVER, A/F 0001-0422. (Refer to Figure 23-10, Detail G.)
1. HF OFF, Radio Master Switch OFF.

2. Battery Master,OFF/Auxiliary,Power Unit disconnected.
3. -Open nose section access door. ..
4. Locate SB-10 transceiver mounted on nose compartment floor fonward of fuselage station 54.25
bulkhead.
5. Disconnect plug at rear of unit.
6. Disconnect antenna coax cable.
7. Release transceiver from mounting tray.
8. Remove unit and replace access door.
REMOVAL OF SB-10 TRANSCEIVER, A/F 0423 and UP. (Refer to Figure 23-10, Detail K.)
1. Repeat Steps 1 and 2.

3. Locate SB-10 transceiver mounted above floor between fuselage station 224.0 bulkhead and
fuselage station 240 bulkhead, and removeplastic cover if so equipped.
4. Repeat Steps 5, 6, and 7.
5. Remove unit and close access door.
INSTALLATION OF SB-10 TRANSCEIVER, A/F 0001-0422. (Refer to Figure 23-10, Detail G.)

3. Open nose section access door.
4. Locate SB-10 transceiver placement forward of fuselage station 54.25 bulkhead.
5. Install transceiver on mounting tray.
6. Connect antenna coax cable.
7. Connect plug at rear of unit.
INSTALLATION OF SB-10 TRANSCEIVER, MF 0423 and UP. (Refer to Figure 23-10, Detail K.)
1. Repeat Steps 1 and 2.

2. " Open baggage compartment access door.
3. Place SB-10 transceiver placement above floor between fuselage station 224.00 bulkhead and
fuselage station 240.00 bulkhead.
4. Repeat Steps 5, 6, and 7.
5. Replace plastic trim cover if so equipped.
23-12-08
Page 23-18
Issued: June 1,1995 2J2
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
2912
CANNON DPX-32-
NOTE
FOLLOWING PAGE.
Figure 23-8. SB-10 Transceiver Interconnecting Diagram

23-12-08
Page 23-19
2J3 Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
2912
W P 57-50360
HF1-22 28
• HF2-22 • 27
HF3-22S- 1
2
•HF4-22 — 29
•HF5-20- 1"
• HF6-22 • J
-HF7-22- 7
-HF8-22- 5
-HF9-22- 9
-HF10-22- 25
•HF11-20- 15 SB-10
•HF12-20- 16 CONTROL HEAD
-HF13-20- 17
•HF14-20- 18
-HFI5-22: 2'J
•HF16-22' 26
0
0
23
22
30
33
5ti
35
3C
32
-HF21-22 • HF2II-20N—1
•HF22-22S-J
HF25-20-
HF17-20-
•HF18-20-
•HF19-20-
• HF20-20-
Figure 23-8. SB-10 Transceiver Interconnecting Diagram (cont)

23-12-08
Page 23-20
Issued: June 1,1995
2J4
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
2913
CANNON DPX-52-3'<i AMP 57-30360
17 -HFl-22- - 28
19 -HF2-22- . 27
12 -HF3-22S- . 1
11 "T • 2
9 -HFH-22- • 29
26 -HF5-20- • in
1 -HF5-22- • 3
7 -HF7-22- - 7
3 5 s
8 -HF9-22- 9
1 -HrlO-22- Of
25
13 -HFn-20- 15 i
11 -HF12-20- 16 o
2 15 17 OQ
-HF13-20- CO
23 -HFlU-20- 18
16 -HF15-22- 21
18 HF16-22 26
28 HF 8
JunPER
29 9 15 o - -HF26A12—I 23
2 -HF26B16- 22
5 -HF26D16- 30
6 -HF26E16- 32
32 -HF23-22-
HF21-20N
UG 9 5 9 / U
BNC CONN K2;212-3-l (REF.)
ATP
26-190-32
-HF21-22-
-'HF22-22S-
I
TO INSTL. LIGHT RHEOSTAT< HF25-20-
RG-8/U
-HF36-
NOTE
FOLLOWING PAGE.
Figure 23^9. SB-10 Transceiver Interconnecting and HF Reel.Diagrams

23-12-08
Page 23-21
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
2913
HF REEL
-HFJOAIS-
rHFJ7-20N-
•OUT-
«S25011-')
LIGHT (REF.)
TYPE 327 ( R E F . ) ^
11 •f555059-27
-Lo
'2
IN- o3 o'
I _ _ J
r-HF33-18-l
r-HF32-2CN-
/ 1 3 « 6 8 2 "1
ER-28
Figure 23-9 SB-10 Transceiver Interconnecting and HF Reel Diagrams (cont)

23-12-08
Page 23-22
issued: June 1,1995
2J6
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
-^ • . • *
Figure 23-10. HF Locator •

23-12-08
Page 23-23
Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
o B408
FRONT
SB10-2B
TRANSCEIVER
o o F.S.
F.S.
224.00 o o 240'. 00
TRANSCEIVER LOCATION, A/F 0423 § UP
RF TERMINAL.
DRAG SOCK
ANT. LEAD WIRE FROM THERM.

TO RF TERMINALS" LONG MAX.
.TO TUNING
METER
LINE LINE
TO SBIO
©-
TRANSC THERflOCOUPLE
-RG-8U COAX TRANS,
LINE TO SBIO TRANSCEIVER
FAIRLEAD (REF.)
Figure 23-10. HF Locator (cont)

23-12-08
Page 23-24
Issued: June 1,1995
2J8
' AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
SB-10 TRANSCEIVER OPERATIONAL CHECK (FIXED ANTENNA). .
1. HFON..
2. Select.HF at audio switching panel.
3. Select headphones or speaker at audio switching panel.
4. HF transceiver ON. Allow 10-20 minute warm-up.
5. Set frequency selector to desired channel.
6. Contact station and obtain signal check.
7. Observe relative power meter while speaking. Note that pointer fluctuates on voice peaks, indi-
cating nomial modulation. Sidetone should be audible. Optimize audio by means of clarifier.
8. Contact several other stations on different channels for Com check if possible.
9. Turn equipment O F F .
SB-10 CONTROL HEAD.
REMOVAL OF SB-10 CONTROL HEAD.
1. HF O F F , Radio Master Switch OFF.

3. Release control head by removing screw fasteners.
4. Withdraw unit from instrument panel and disconnect plug at rear.
5. Remove control head.
INSTALLATION OF SB-10 CONTROL HEAD.
1. HF O F F , Radio Master Switch OFF.

3. Position control head at instrument panel.
5. Install control head.
CONTROL HEAD OPERATIONAL CHECK.
Perform operational test per the section titled SB-10 Transceiver Operational Check (Fixed Antenna).
SB-10-RL28 ANTENNA LOAD UNIT.
REMOVAL OF SB-10-RL28 ANTENNA LOAD UNIT. (Refer to Figure 23-10, Detail B.)
1. HFOFF. . , . : , .
3. Open baggage compartment door.
.4. Locate RL-28 antenna load unit mounted on upper right side fuselage between fuselage station
240.00 bulkhead and fuselage station 265.00 bulkhead.
5. Disconnect RG-8 transmission line.
23-12-15
Page:23-25
2JQ Issued: June4,.1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
6. Remove feed wire from fixed antenna at RF feed-through insulator terminal on load unit.
7. Disconnect plug at front of load unit.
8. Remove antenna load unit and close baggage compartnient door.
INSTALLATION OF SB-10-RL28 ANTENNA LOAD UNIT. (Refer to Figure 23-10, Detail B.)
1. HFOFF.
3. Open baggage compartment door.
4. Locate RL-28 antenna load unit placement, upper right side fuselage between fuselage station
240.00 bulkhead and fuselage station 265.00 bulkhead. Install load unit.
5. Connect antenna feed wire to RF feed-through insulator terminal on front.of load unit.
6. Connect RG-8 transmission line.
7. Close baggage compartment door.
ANTENNA LOAD UNIT, TUNING AND ADJUSTMENT.
Refer to the latest revision of Pantronics Instruction Book, Pancom DX-RL antenna loading units, loading
procedure.
HF FIXED ANTENNA.
REMOVAL OF HF FIXED ANTENNA. (Refer to Figure 23-10, Details B, C & E.)
1. HFOFF.
3. Remove right wing tip.
4. Untie knot at end of antenna and release clamp securing wire.
5. Thread wire free of wing insulator
6. Release tension unit at vertical stabilizer.
7. Open baggage compartment door, locate antenna load unit mounted aft of fuselage station
240.00, upper right side fuselage.
8. Release clamp securing antenna wire and disconnect from load unit at RF feed-through terminal.
9. Thread antenna wire out of fuselage insulator and remove antenna.
10. Close baggage compartment door
23-12-19
Page 23-26
issued: June 1,1995
2J10
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
INSTALLATION OF HF FIXED ANTENNA. (Refer to Figure 23-10, Details B, C &.E.)
1. HFOFF. - ' '• • <

3. Open baggage compartment door and locate antenna load unit mounted aft of fuselage station
240.00, upper right side fuselage. - '
4. Feed end of shorter antenna section through fuselage insulator.
5. Connect end of wire to antenna load unit RF feed-through terminal.
6. Secure antenna wire to clamp, leaving slack loop on load unit side.
8. Attach tension unit to vertical stabilizer.
9. Feed end of antenna through wing insulator. Position strain insulator to achieve total antenna
length of 29 feet.
10. Tie knot in end of antenna after routing through insulator and secure with clamp. Coat knot and
wire end with RTV (or equivalent).
11. Reinstall wing tip.
12. Re-tension antenna by adjusting tension unit.
13. It may be necessary to re-tune the system.
FIXED ANTENNA OPERATIONAL CHECK.
Perform operational test per the section titled SB-10 Transceiver Operational Check (Fixed Antenna).
. 23-12-21
. Page 23-27
2J11 issued: June 1,1995

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
HF TRAILING WIRE ANTENNA.
REMOVAL OF HF TRAILING WIRE ANTENNA. (Refer to Figure 23-10, Detail J.)
1. HFOFF.
3. ' Open baggage compartment door and locate ER-28 reel assembly mounted in lower aft fuselage
at fuselage station 347.50.
4. Remove clamps fielding fairlead tube. Break seal at doubler plate.
5. Disconnect antenna lead wire (6 incfi lengtfi) from fairlead RF temninal.
6. Disconnect ER-28 power plug at reel assembly.
7. Release ER-28 reel assembly from mounting plate.
8. Remove reel assembly and fairlead togetfier. Nylon drag sock will collapse to pass tfirougfi fair-
lead fiole in fuselage.
INSTALLATION O F HF TRAILING WIRE ANTENNA. (Refer to Figure 23-10, DetailJ.)
1. HFOFF.
3. Open baggage compartment door and locate ER-28 reel assembly placement in lower aft fuse-
lage at fuselage station 347.50.
4. Install reel assembly to mounting plate.
5. Install fairlead tube after applying sealer at doubler plate. (PR 1422 sealant or equivalent.)
6. Connect antenna lead wire (6 incfi lengtfi) to fairlead RF terminal.
7. Connect ER-28 power plug to reel assembly.
TRAILING WIRE ANTENNA OPERATIONAL C H E C K .
— NOTE —
Normally It is not practical to attempt transmission while the airplane is on
the ground. This is due to antenna tyeing fully reeled in, therefore transmit-
ter would not be correctly loaded into antenna. In order to perform a nor-
mal operational check a test flight should Ije obtained.
1. After airplane is airborne select HF at audio switcfiing panel and speaker or fieadptione audio.
2. Apply power to SB-10 transceiver and allow 5-10 minute warm-up.
3. Set mode switcfi to AM and select desired channel.
4. Begin extending antenna and key transmitter while observing tuning meter.
23-12-25
Page 23-28
Issued: June 1,1995 2J "I 2
AEROSTAR AIRCRAFT
600/601/601 P/602P/7a0P
MAINTENANCE MANUAL
5. While antenna is "extending" tuning meter will go towards a "max" reading, transmitter keyed.
6. Going beyond this length will cause meter reading to decrease. Find point of maximum reading
by adjusting antenna length as required. Antenna is now tuned for selected channel. Any other
channel can be tuned similarly.
7. Select transmission mode if other than AM.
8. Contact station and obtain Com check. •
9. Obsen/e that relative power meter shows output with pointer fluctuating on voice peaks, indicat-
ing normal modulation. Side tone will be audible.
10. Repeat Steps 3 through 9 on several other Channels if possible. Note antenna must be tuned to
each channel in use as per Steps 4, 5, and 6. .
11. When test is completed, retract antenna and turn equipment OFF.
ASB-100A HF SYSTEM (SUNAIR).
The ASB-100A Communications Equipment is a lightweight, 10-Channel, single sideband (SSB) and
compatible amplitude modulated (AM) transceiver designed for medium and long range communications in the 2-
18 MHz frequency range.
The system consists of three units; the RE 1000 Receiver/Exciter, the PA-101 OA Power Amplifier/Power
Supply, and the SCU-10 Control Unit.
Operation of the system, power output and antenna requirements are similar to that of the older SB-10
Pantronics System.
DESCRIPTION.
The SCU-10 Control Unit is panel mounted for remote operation of the ASB-100A System. The controls
located in this unit are as follows:
1. The RF Gain control, volume control and ON-OFF switch are all on one knob. The RF gain con-
trol provides the operator with a means for adjusting the receiver sensitivity to the desired level,
while the volume control is used to adjust the audio level. The 2-section on-off switch, operated
by the volume control shaft, controls the on-off power relay located in the Power Amplifier/Power
Supply Unit, while the other switch section is used for the panel lights.
2. A clarifier control provides the operator with a means to obtain natural voice quality audio.
3. The mode selector is used to select the mode of operation desired, upper sideband (USB), lower
sideband (LSB) or compatible Amplitude Modulation (AM). Only upper sideband may be selected
for normal operation.
4. The meter in the Control Unit provides the operator with a means of checking the operation of the
transmitter and fixed antenna system and can also be used as a tuning indicator for a trailing
wire antenna. The meter indicates relative transmitter power output.
RE-1000 Receiver/Exciter - This unit contains the complete receiver section and the exciter portion of the
transmitter Channeling of this unit is controlled by a rotary solenoid remotely controlled by the SCU-10 control
unit. The microphone and headphone jacks and intercabling connectors are located on the front of the unit. The
sidetone potentiometer for adjusting the sidetone output level is accessible from the front of the unit.
23-13-01
Page 23-29
2J13 issued: June 1,1995

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
PA-1010A Power Amplifier/Power Supply - This unit contains the amplifier driver, power amplifier and
power supply for the system. Channeling of this unit is accomplished by means of a rotary solenoid that is con-
trolled by the rotary in the receiver/exciter unit. All connections for inter-unit cabling, the 28V fuse and the Hi-Lo
power switch are located on the front of the unit.
CU-110 Antenna Coupler - This unit provides an optimum impedance match between the transmitter
power output stage and the antenna. Pre-tuning to each channel is required, after which the unit will need little or
no attention.
Antenna requirements - The ASB-100A system can be used with either a fixed antenna system or a trail-
ing wire antenna. A fixed antenna installation consists of the antenna, either bare wire or an anti-precipitation
type, with an antenna coupler tuned to the fixed antenna. A trailing wire antenna can be either manually or electri-
cally operated.
TUNING ANTENNA COUPLER AND ASB-100A COIVIPONENTS.
Refer to the latest revisions of Sun Air Operation and maintenance manual P/N 99398 for the ASB-100A
Transceiver and Sun Air Instruction Manual P/N 99694 for the CU-110 Antenna Coupler for tuning and mainte-
nance procedures.
TROUBLESHOOTING ASB-100A SYSTEM.
Refer to Chart 2303 for troubleshooting procedures.
23-13-23
Page 23-30
Issued: June 1,1995
2J14
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHART 2303. TROUBLESHOOTING (ASB-100A)
Trouble Cause Rerfiedy
Unable to energize HF HF circuit breaker OFF. Reset C/B.

system.
Radio master switch OFF. Turn radio master ON.
Battery master switch OFF. Turn battery master ON.
Loose plug at PA-101 OA Tighten plug.

power amp/power supply.
Defective connection, Check wiring point-to-point.

loose, broken or corroded Repair/replace.
wire in cabling.
Blown fuse in power Replace.

supply.
Power input OK, unable Faulty meter in control Replace.

to perform operational unit.
ctieck.
Defective component in Isolate faulty unit and replace.
receiver/exciter, power
amp control unit.
Loose plugs or defective Check out wiring, repair/

wiring in the inter-unit replace.
cabling.
Open or bad RF connection Check all antenna coax connec-

in antenna circuit. tions, lead-in and antenna.
Very low sensitivity and Open RF gain wire in re- Locate break, repair/replace.
no RF gain control. ceiver or control unit.
Volume at maximum and Open volume control wire Locate break, repair/replace.
unable to control. in receiver or control
unit.
Clarifier does not Open clarifier wires in Locate break, repair/replace.

function. receiver or control
unit
Defective component in Isolate faulty unit and replace.

receiver or control
unit.
23-13-03
Page 23-31
2J15 lssued:.June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHART 2303. TROUBLESHOOTING (ASB-100A) (cont)
Dead receiver, no audio Defective relay(s) in Check, clean contacts or replace

output. receiver. unit.
No A.G.C. voltage due to

Replace receiver.
defective component.
Receiver oscillator in-

Replace receiver.
operative due to faulty
component.
No power input to receiver Check out power circuit point-

due to open circuit in to-point. Locate break or bad
wiring. connection, repair or replace
as required.
Channels off frequency. Defective crystal oven. Repair/replace.
No voltage to oven. Find open wire and repair/

replace.
Faulty component in Replace unit

receiver/exciter unit.
One or more channels OFF Defective crystal. Replace.

frequency.
Wrong crystals. Use only proper Sunair crystals.
Misaligned exciter. • Replace unit.
Good exciter output in Defective microphone. Replace mike.

AM, but no output in SSB
with modulation present. Defective gain pot. Replace receiver/exciter unit.
Defective component in Replace receiver/exciter unit

mike amplifier.
No power output, filaments Blown fuse in power Replace fuse.

dark in P.A. supply.
Defective K-2 relay in Repair/replace unit.

power supply.
Open filaments in tube(s) Replace tube(s).

VI, V2 and V3 in power
amplifier.
23-13-03
Page 23-32
Issued: June 1,1995 2J16
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHART 2303. TROUBLESHOOTING {ASB-100A) (cont)
" Trouble - Cause Remedy
No power output, filaments Defective P.A. tube(s). Replace tube(s).

lit.
Break or bad connection Check all RF connections. Re-'
in antenna circuit. pair as required.
Ledex rotary switch motor Check motor circuit or replace

not-running. unit
Defective component in Replace unit.

power amp.
Low power output. . Weak tube(s) in P.A. Test tubes and repair or replace
unit
Hi-Low switch in Low Switch to Hi position.

position.
Driver and/or final coils Re-tune tank circuits or replace

detuned. unit.
Faulty component in P.A. Replace unit.
Dirty or corroded switch Clean contacts..

contacts in antenna
coupler
Coil taps in wrong Re-tune antenna coupler per

position in antenna the latest revision of
coupler Sunair Instmction Manual
P/N 99694.
*-
•.J
23-13-03
Page 23-33
2J17 Issued: June 1,i995

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
SCU-10 CONTROL UNIT.
REMOVAL OF SCU-10 CONTROL UNIT. (Refer to Figure 23-12.)
1. HF OFF, Radio Master Switcfi O F F .

2. Battery Master OFF/APU disconnected.
3. At instrument panel "radio stack," release control unit by unlocking ttie zeus fasteners.
4. Witfidraw unit from instrument panel and disconnect plug at rear.
5. Remove control unit.
INSTALLATION OF SCU-10 CONTROL UNIT.

3. Position control unit at instrument panel.
5. Install control unit.
RE-1000 RECEIVER/EXCITER.
REMOVAL OF RE-1000 RECEIVER/EXCITER. (Refer to Figure 23-12.)

3. Open baggage compartment door and locate tfie RE-1000 Receiver/Exciter-unit mounted on tfie
baggage compartment fonward bulkfiead above floor.
4. Disconnect tfie two coaxial cables going to tfie PA-1010 Power Amp unit.
5. Disconnect tfie plug at tfie front of tfie unit.
6. Release thumb screw lock and remove unit from mounting tray.
INSTALLATION OF RE-1000 RECEIVER/EXCITER.
1. HF OFF, Radio Master Switch O F F .

3. Locate placement of RE-1000 Receiver/Exciter unit on the baggage compartment forward bulk-
head above floor.
4. Place unit in mounting tray, tighten thumb screw lock.
5. Connect coaxial cables two from PA 1010 Power Amp and install plug at front of unit.
23-13-09
Page 23-34
Issued: June 1,1995
2J18
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
PA-1010 POWER AMP/POWER SUPPLY.
REMOVAL OF PA-1010 POWER AMP/POWER SUPPLY. (Refer to Figure 23-12.)
1. HF OFF, Radio Master Switch OFF. - x%

3. Open baggage compartment door and locate the PA-1010 Power Amplifier/Power Supply unit
mounted on the baggage compartment forward bulkhead above floor.
4. Disconnect the two coaxial cables going to the receiver/exciter unit
5. Disconnect plug at front of unit. •
6. Release wing nut lock and remove unit.
INSTALLATION OF PA-1010 POWER AMP/POWER SUPPLY.

3. Locate placement of PA-1010 Power Amplifier/Power Supply unit mounted on the baggage com-
partment forward bulkhead above floor.
4. Place unit in mounting tray, tighten wing nut lock.
5. Connect coaxial cables (two) from the receiver/exciter unit.
6. Connect coaxial cable from the antenna coupler.
7. Install plug at front of unit.
CU-110 ANTENNA COUPLER.
REMOVAL OF CU-110 ANTENNA COUPLER. (Refer to Figure 23-12.)
1. HF OFF, Radio Master Switch OFF. /

2. Battery Master OFF/APU disconnected.; .
3. Open baggage compartment door and locate the CU-110 antenna coupler unit mounted on the
baggage compartment forward bulkhead above floor.
4. Disconnect antenna lead-in wire from antenna jack.
5. Disconnect coaxial cable at J 302. . .
6. Disconnect plug at J 301.
7. Release thumb-screw lock and remove uniL
INSTALLATION OF CU-110 ANTENNA COUPLER.

3. Locate placement of CU-110 antenna coupler mounted on the baggage compartment fonward
bulkhead above floor
4. Place unit in mounting tray and tighten thumb screw lock.
5. Connect antenna lead-in wire to antenna jack.
6. Connect coaxial cable to J 302. j
7. Install plug at J 301.
23-13-15
Page 23-35
2J*|Q Issued: J u n e l , 1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B409
PIO
•TO FIXED
17p.O-
J 3 0 1 , P301 -9- P4 ' J 4
CU-110
A.vrrnwi^ on I
COUPLER
O 6 I
oio|
016.
O 8 I
014|
I =
± h 0 7 I PA-IOIOA
012' PA/PS
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A O
•OA I
B O
O 3 I
I C O
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E O
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CONTROL
UNIT oc
J o!
o n
n Oi
O E
m O
O M
H
O V
O J
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ao O a
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RE-1000
I J O Cd
RECEUXR
fo O f EXCITIR
O g
K O
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O T I
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O k I
24 ow
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3S0-H 20-04 12
-i 13 o z
PlOl ' JlOl
Figure 23-11. ASB-100A, HF Interconnecting Diagram

23-13-15
Page 23-36
Issued: June 1,1995
2J20
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B410
1. SCU-10 CONTROL UNIT

2. RE-IOOO RECEIVER/EXCITER
3. PA-1010 POWER AMP/POWER SUPPLY
4. CU-llO ANTENNA COUPLER
5. ANTENNA LEAD-IN
6. ANTENNA
7. TENSION UNIT .
8. FEED THRU INSULATOR
Figure 23-12. ASB-100A, HF System Locator

23-13-15
Page 23-37

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
ANTENNA. [
REMOVAL OF ANTENNA. (Refer to Figure 23-13.)
1. Open baggage compartment and locate antenna lead-in wire at tfie antenna coupler mounted on
baggage compartment fonward bulkfiead.
2. At tfie feed-ttiru insulator, slide tfie rubber nipple fonward on tfie lead-in wire to reveal the termi-
nal nut.
3. Remove nut, disconnect lead-in to antenna coupler.
4. Unwind the bare end of the antenna wire from around the terminal stud to release antenna from
feed thnj insulator.
5. At outer section of insulator on fuselage upper surface, pull wire out of feed-thru insulator.
6. At vertical stabilizer, remove bolt securing antenna wire tenninal and tension unit to mounting
bracket.
7. Remove antenna.
INSTALLATION O F ANTENNA. (Refer to Figure 23-13.)
1. At vertical stabilizer, install tension unit and antenna terminal lug to mounting bracket.
2. Extend antenna wire to the feed-thru insulator mounted on fuselage above baggage compart-
ment area.
3. With slack out of antenna at the insulator, allow about three inches additional length for passage
through insulator. Cut wire four inches beyond this point and strip back the polyethylene shield to
expose approximately four inches of bare wire.
4. Thread wire into feed-thru insulator so bare end extends through the slotted connector stud.
5. Extract bare end from slot in stud (Figure 23-13, Detail A) and wrap tightly around stud 3 1/2 to
four turns below washer.
6. " Install lead-in wire terminal lug and secure with lock nut.
7. At vertical stabilizer, adjust slack loop as required to remove any extra slack out of wire. Tension
antenna to 20 ±1 pounds.
OPERATIONAL TEST.
1. Battery Master ON.

2. Radio Master Switch ON, HF ON.
3.. Select HF at audio switching panel; select headphones or speaker.
4. Tum equipment on at SCU-10 control unit. Select SSB or AM mode.
5. Set channel selector to desired channel and allow 10-20 minute warm-up.
6. Contact station and obtain signal check.
7. Observe relative power meter while speaking. Note that pointer fluctuates on voice peaks, indi-
cating normal modulation. Side tone should be audible. Optimize audio by means of clarifier con-
trol.
8. Contact several other stations on different channels if possible.
9. Terminate Com check and turn equipment O F F .
23-13-19
Page 23-38
Issued: June 1,1995
2J22
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B411
1. RF FEED THRU INSULATOR

2. INSULATED ANTENNA WIRE
o
3. ANTENNA LEAD-IN
4. BARE END OF ANTENNA WIRE
5. SLOTTED CONNECTING STUD
6. WASHER
7. 3 1/2-4 TURNS OF BARE WIRE
8. LOCKING NUT
9. LEAD-IN TERMINAL LUG
10. TENSION UNIT
11. MOUNTING BRACKET
12. TERMINAL LOCKING NOT,
BOLT AND WASHER
13. LUG
Figure 23-13. Fixed Antenna Installation

23-13-19
Page 23-39
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
EMERGENCY LOCATOR TRANSMITTER (ELT) .
The ELT-10 is an automatically activated emergency locator transmitter. The transmitter may be manual-
ly activated by means of the unit's ON-OFF-ARM switch. When activated, the ELT will radiate an omnidirectional
RF signal on the international distress frequencies. The radiated signal is modulated with a distinctive audio
swept tone.
The electrical power for the ELT transmitter is totally supplied by its own self-contained all<aline battery.
For portable use, the ELT can be easily removed from its mounting in the airplane. To comply with FAA regula-
tions, the battery must.be replaced no later than the replacement date marked on the transmitter label. The bat-
tery must also be replaced if the transmitter has been used in an emergency situation or if accumulated test time
exceeds one hour.
REMOVAL OF ELT. (Refer to Figure 23-14.)
1. Open baggage compartment door and locate the ELT mounted in the upper aft area of compart-
ment.
2. Set the ON-OFF-ARM switch to OFF.
3. Disconnect the antenna cable at front of unit
4. Holding the ELT with one hand, release latch on mounting strap and slide unit out of mounting.
INSPECTION OF ELT.
— NOTE —
Every three months or after 100 hours of flight time, whichever comes first,
the battery pack should be removed and inspected.
1. After removal of ELT, extend the portable antenna by pulling the antenna tab out.
2. Remove the screws that secure the control head to the battery casing.
3. Slide the control head out of the battery.case. The battery connection leads are approximately
three inches in length.
4. Disconnect the battery by releasing the snap-off battery terminals from the transmitter printed cir-
cuit board.
5. Check battery pack for leakage.
— NOTE —
Leakage will show up as a white residue which normally occurs first
around the battery leads.
6. Check for corrosion at battery terminals, PC board and components.

7. Check for security of battery leads.
23-14-02
Page 23-40
Issued: June 1,1995
2J24
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B412
Figure 23-14. ELT Instailation

23-14-02
Page 23-41
Issued: J u n e l , 1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
BATTERY PACK REPLACEMENT.
In accordance with FAR 92.207(c), batteries must be replaced when the transmitter has been in use for
more than one cumulative hour or when 50% of their usefullife has expired. - -
1. Remove and discard old battery pack.
— WARNING —
Do not discard battery paclt in fire, as an explosion may result and toxic
fumes wiiriie produced.
2. Apply a bead of sealant (supplied with each new battery pack) around joint of control head with a
small stiff brush or stick.
3. Connect the new battery pack terminals to the snap-on terminals on the transmitter printed circuit
board.
4. Reinsert the control head section into the battery pack, being careful not to pinch the wires.
— NOTE —
The control head can only fit one way. If the screw holes do not line up,
rotate the battery pack one-half turn and reinsert.
5. Replace screws securing control head.

6. Stow the portable antenna by pushing antenna back and into its channel until pin stop is
reached.
7. Record the expiration date of the new battery on the outside of the transmitter Make entry in log
book as to expiration date of new battery.
INSTALLATION O F ELT.
1. Slide unit into mounting bracket, ensuring that the arrowed label side is showing.
— NOTE —
' The mounting bracket and the ELT case are tapered, thus the unit can fit
the bracket only one way. Both bracket arrow and unit arrow should point
forward.
2. Secure the mounting strap.

3. Connect antenna cable to unit. Ensure the antenna contact separator is in place.
4. Position the ELT switch to ARM. Unit is now ready for activation by either the impact switch or
the ON position.
23-14-04
Page 23-42
Issued: June 1,1995 2 K2
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
TESTING EMERGENCY LOCATOR TRANSMITTER. ' "
The transmitter operates on the emergency frequencies of 121.5 and 243 IVIHz; both of these frequencies
are monitored by the various FAA installations. Before performing any operational test of the ELT, ttie following
precautions should be observed:
— CAUTION —
Testing of an ELT should be conducted in a screen room or metal enclo-
sure to ensure that electromagnetic energy is not radiated during testing. If
a shielded enclosure is not available, testing may be performed in accor-
dance with the following procedures:
A. Test should be no longer than three audio sweeps.

B. If the antenna is removed, a dummy load should be substituted during the test.
C. Test should be conducted only within the time period made up of the first five minutes
after any hour.
D. If the operational tests must be made at a time not included within the first five minutes
after the hour, the test should be coordinated with the closest FAA tower or flight service
station.
Consult FAA advisory circular AC20-81 for detailed information concerning above caution.
1. Tune the airplane's communications receiver to 121.5 f^Hz and switch the receiver ON; deacti-
vate the squelch, and turn the receiver volume up until a slight background noise is heard.
— WARNING —
Whenever the unit is checked by moving the transmitter ON/OFF/ARM
switch from the arm to the ON position, it must then be moved to the OFF
position before reverting to the ARM position again.
— CAUTION —
Under normal conditions, the transmitter switch must be set to ARM.
2. On the transmitter, set the ON/OFF/ARM switch to the ON position. Keep the switch in this posi-
tion for only a few seconds; then set to the OFF position. Return to the ARM position.
— NOTE —
The test transmission should have been picked up by the airplane commu-
nications receiver. During cold weather, there may lye a slight delay before
transmission occurs.
3. A transmitter which is functioning property should emit a characteristic downward swept tone.
4. When the test is completed, move the transmitter ON/OFF/ARM switch to the OFF position then
to the ARM position.
23-14-05
Page 23-43
Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
INADVERTENT ACTIVATION.
Stopping inadvertent activation at ttie transmitter is accomplished in the following manner.

1. . Improper switch selection is corrected by rotating the switch to the OFF position and then to the
ARIVI position.
2. If the transmitter is inadvertently activated through impact, deactivate by pushing in on the
Orsl/OFF/ARM switch.
— NOTE —
As a routine precaution, it is recommended that the ELT battery be
replaced at the earliest opportunity after inadvertent activation and a func-
tional test be made in accordance with Testing Emergency Locator
Transmitter. Note, however, that the problem may not be in the transmitter.
Check the following:
A. Proper spacing of antennas so as to minimize antenna conducted RF. '

B. Rigidity of the transmitter installation.
ELT FIXED ANTENNA.
REMOVAL OF E L T FIXED ANTENNA. (Refer to Figure 23-14.)
1; Open baggage compartment door and locate ELT mounted in upper aft area of compartment.
2. Disconnect antenna assembly at front of ELT unit.
3. Remove antenna cable from mn along stringer.
4. Locate bracket where antenna emerges through fuselage into dorsal fin.
5. Cut ty-rap securing cable, break seal at hole in fuselage and pull antenna out of dorsal fin and
bracket.
INSPECTION O F E L T ANTENNA.
Inspect antenna for any damage.
— NOTE —
Avoid tfending antenna. Any sharply bent or kinked antenna should be
replaced. Antenna damage may cause operational failure of unit.
23-14-09
Page 23-44
Issued: June 1,1995
2K4
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
INSTALLATION OF ELT FIXED ANTENNA.
1. Connectantenna to ELT at front of unit. '

2. Run antenna along upper surface of ELT mounting bracket and along stringer to point of exit
under dorsal fin. Secure witfi ty-rap as shown.
3. . Push end of antenna through grommet in bracket and through hole in fuselage into dorsal fin.
4. Seal hole in fuselage with RTV-102 sealant.
MICROPHONE SWITCH.
The microphone switch which activates the headset microphone is located on the control wheel, on the
forward side of the left grip.
TROUBLESHOOTING.
Troubles peculiar to the microphone system are listed in Chart 2304 along with their probable causes and
suggested remedies.
CHART 2304. TROUBLESHOOTING (MICROPHONE SYSTEM)
fîcrophone inoperative Open circuit in microphone Locate open circuit and repair or
switch and/or wiring replace switch and/or wiring as
necessary
Microphone is hot - always on Microphone switch shorted. Replace switch.
REMOVAL OF MICROPHONE SWITCH. (Figure 23-15.)
— WARNING —
Ensure all switches and equipment are turned off and all autopilot
circuit breakers are pulled. The Master Battery and alternator
switches must be left in the OFF position to prevent injury to
personnel and/or damage to equipment.
1. Remove two screws from cover on top left grip of control wheel.
2. Remove two screws from autopilot trim switch.
3. Remove hexagon nut from switch on left grip, forward side of control wheel.
23-15-02
Page 23-45
2 Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
Figure 23-15. Removal of IMicrophone Switch
4. Lift microphone switch from control wheel, label and identify wires prior to disconnect. Allow suffi-
cient wire length to perform splice connection for new switch installation.
INSTALLATION OF MICROPHONE SWITCH. (Refer to Figure 23-15.)
— WARNING —
Ensure all switches and equipment are turned OFF and all autopilot circuit
breakers are pulled. The Master Battery and alternator switches must be
left in the OFF position to prevent injury to personnel and/or damage to
equipment.
1. Twist connect corresponding wires in control wheel to existing wires on microphone switch, sol-
der connection, and apply sufficient heat shrink insulation as required.
2. Insert/stow wires into hole on left grip fonward side of control wheel and place microphone switch
in respective position per illustration.
3. Install hexagon nut to base of microphone switch.
4. Install two screws to secure autopilot trim switch.
5. Install two screws to secure cover.
23-15-03
Page 23-46
Issued: June 1,1995
2K6
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
AUDIO INTEGRATINa SYSTEM. . . . .
The audio integrating system provides a means for centralized control of all receiver audio outputs, both
communications and navigational, for distribution to headphones or cabin speaker. Provision is also made at the
panel for selection of microphone input to either Com-1 or Com-2 transceiver.
DESCRIPTION.
The AMR-350 audio/marker panel provides all of the necessary functions for integrated audio control. It is
composed of two sections, an audio switching section and an integral beacon marker receiver. See Figure 23-14
for detailed appearance and location of controls and indicators.
The audio section of the unit provides switching for seven inputs; two VHF navigational receivers, one
ADF, one DME, and one marker beacon input. Operation of panel toggle switches selects any of these inputs for
speaker or headphone audio monitoring purposes. A three-position rotary switch selects Com-1 or Com-2 trans-
ceiver mike input, with the last position being used for a ramp hailer speaker, if so equipped. The "Auto" position
insures audio follows the selected Com system.
In airplanes having an HF communications system in addition to the above, an extra HF panel position is
required. The AMR-350H audio/marker panel is designed for the extra HF input, and is provided in airplanes so
equipped. Some airplanes having an HF installation were equipped with a KMA-20-04 audio panel, being func-
tionally similar to the AMR-350H.
Both pilot and co-pilot positions are furnished with a mike and headphone jack. These are located on the
lower right and left instrument panels. The microphone must be matched to the transceiver input requiring a stan-
dard 100 ohm impedance microphone (Shure 488-T or equivalent). The headphones are standard 500 ohm
impedance units.
Operator selects Com-1 or Com-2 and speaker or headphone audio as desired. After energizing the
selected transceiver and readying the system for operation, depressing the push-to-talk switch and speaking in
mike results in voice transmission to the selected station. Received information is routed through the audio panel
to speaker or headphones. When operator desires to monitor any of the panel inputs, operation of the proper tog-
gle switch provides the selected audio.
TROUBLESHOOTING.
Refer to Chart 2305 for Audio/Marker Panel troubleshooting procedures.
23-52-00
Page 23-47
2K7 Issued: June 1,1995

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B413
CONTROL CONTROL CONTROL CONTROL-
Figure 23-16. AiVIR 350 Audio/IUIarl(er Panei, Controis and Indicators
23-52-00
Page 23-48
Issued: June 1,1995
2K8
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
-CHART 2305. TROUBLESHOOTING (AUDIO/MARKER PANEL)
No audio at headphones. Check wiring from affected Repair de'fective wire(s).

phone jack to pin 15, plug
P-2 at audio panel. Check
system ground at pin 1 to
mounting tray.
If wiring OK, defective Replace audio panel.

audio panel.
Headphone audio OK, no Check wiring from affected Repair defective wire(s).
speaker audio. speaker to pin 4, plug P-2
check ground at pin 1.
Wiring OK. Reverse speaker Replace defective speaker.

connections temporarily to
isolate defective speaker
(prior to A/F 0456). -
Neither speaker operating Defective isolation amp- Replace audio panel.

(prior to A/F 0456). lifier.
No nriike output. Check wiring from affected Repair defective wire(s).

mike jack to pins 7 & 8,
plug P-2. Check system
ground at pin 1.
If wiring OK, defective Replace audio panel.

rotary switch in panel.
No mike excitation voltage, Check 28 volts input at pin 10,

plug P-1.
If voltage input OK, Replace audio panel.

defective component in
audio panel.
23-52-00
Page 23-49
.2K9 Issued: June 1,1995

r
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHART 2305. TROUBLESHOOTING (AUDIO/MARKER PANEL) (cont)
Only one mike works in Defective PTT switch on Repair/replace.

both jack positions. non-operable mike.
Check for worn, frayed or Repair/replace.

damaged mike cord.
Defective mike. Replace mike.
Only one set of phones Worn, frayed or damaged Repair/replace.

work in both jack posi- phone cord.
tions.
Defective headphones. Repair/replace.
No speaker or phone No voltage to panel. Check wire from pin 10,

output. plug P-1 to radio panel
circuit breaker. Repair
or replace.
Checkpowerground, pin 11,

P-1. Repair or replace.
Replace circuit breaker.
23-52-00
Page 23-50
Issued: June 1,1995 2 K1 0

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
AMR-350 AUDIO/MARKER PANEL.
REMOVAL O F AMR-350 AUDIO/MARKER PANEL.
1. Radio Panel C/B OFF, Radio Master Switcti O F F .

3. Twist turnIocl< on front of panel to unlocked position.
4. Witlidraw unit from mounting tray and remove.
INSTALLATION OF AMR-350 AUDIO/MARKER PANEL.
1. Radio Panel C/B OFF, Radio Master Switcti O F F .

3. Insert unit in mounting tray and twist turnlock to locked position.
OPERATIONAL TEST O F AMR-350 AUDIO/MARKER PANEL.
1. Battery Master ON/Auxiliary Power Unit ON.

2. Radio Master Switcti ON. Com-1, Com-2 ON.
3. Select Com-1 at audio panel.
4. Select headpfiones or speaker at audio panel.
5. Nav-1, Nav-2 Receivers ON.
6. Select operating frequency of known station in vicinity.
7. Contact station and obtain Com cfieck, Com-1 and Com-2.
8. Verify Com-1 and Com-2 can be selected at audio panel.
9. Select "Auto". Audio sfiould follow Com system in use.
10. Verify Com-1 and Com-2 speaker/phone toggle switcties are functional.
11. Terminate Com cfieck; Com-1 and Com-2 O F F .
12. Listen for Nav-1, Nav-2 audio output. Verify Nav-1 and Nav-2 toggle switcfies are functional.
13. Repeat Step 12 for remaining tfiree toggle switcfies. It may not be possible to receive any actual
audio on tfiese last tfiree positions. However, sufficient background noise sfiould be audible to
ascertain toggle switcfies are functional.
14. Set marker HI/LO/TEST switcfi to test. All tfiree marker ligfits sfiould illuminate.
15. Turn O F F all equipment.
AUDIO SWITCHING PANEL.
REMOVAL OF KMA-20/AMR-350 H AUDIO SWITCHING PANEL. (Refer to Figure 23-10, Detail A.)
1. HF OFF, Radio Master Switcfi OFF.

3. Remove front panel turnlock.
4. Witfidraw unit from panel.
5. Disconnect plug at rear of unit (KMA-20).
6. Remove unit.
23-54-01
Page23-51
Issued: June 1,1995
2K11
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B414
AMR-350/AMR-35OM
AUDIO/MARKER PANEL
M<t-350/S51 Jl
REMOTE MARKER
NOT USED.
LICKTS
NO CONNECTION
(OPTIONAL)
AMBER LAMP
BLUE LAMP
WHITE LAM?
MARKER ANT MARKER ANTENNA
o
ANTENNA SHIELD
• 1 3 . 7 5 V DIMMER
• 2 7 . 5 V DIMMER
2A
TO RADIO PANEL C.B. INPUT POWER •13.75 V
X MOUNTING TRAY
POWER CNO
NOT USED
CNO LUG
J2
NOT USED
AUDIO CNO
NO CONNECTION
CABIN SPKR 3 . 2 OHMS
EXT SPKR 8 OHMS
NO CONNECTION
AIRCRAFT n V——O- AIRCRAFT MICROPHONE
VHF-J51 MICROPHONE
AIRCRAH KEYLINE
COMMUNICATIONS P/0
PI HF MICROPHONE
TRANSCEIVER
HF K E Y L I N E .
MIC INPUT 5 COM I MICROPHONE m V H F I M I C )
KEYLINE 9 COM 1 KEYLINE ( K V H F I KEYLINE)
• 1
A F CNO e COM 2 MICROPHONE (KVHF 2 MIC)
AUDIO 500n 13 COM 2 K E Y L I N E (K V H F 2 K E Y L I N E )
SPEAKER 1 2 HEADPHONE C U T
HF AUDIO
COM I AUDIO ( » V H F 1 A U D I O )
COM 2 AUDIO { » V H F 2 A U D I O )
NAV 1 AUDIO
VHF-251
NAV 2 AUDIO
COMMUNICATIONS P/0
PI A D F AUDIO ( » A O F 1 A U D I O )
TRANSCEIVER
DME AUDIO ( » A D F 2 A U D I O )
MIC INPUT 5 M A R K E R AUDIO
KEYLINE 9 HOT USED
A F CNO 6
AUDIO soon 13
SPEAKER 12
« INDICATES DESIGNATIONS FOR
VIR-351
(5^ AMR-350H.
NAVIGATION RECEIVER P/0

PI
NAV AUDIO
AUD C N O
VlR-351
NAVIGATION RECEIVER PA)
PI
NAV AUDIO
AUD CNO
Figure 23-17. Audio/Marker Panel Interconnecting Diagram

23-54-01
Page 23-52
Issued: June 1,1995
2K12
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
INSTALLATION OF KMA-20/AMR-350 H AUDIO SWITCHING PANEL. (Refer to Figure 23-10, Detail A.)
1. HF OFF, Radio Master Switch O F F .

3. Place in approximate position at instrument panel.
4. Connect plug at rear, (KMA-20), insert unit in mounting tray. Insure connector properly mated
(AMR-350). - -
5. Install unit and tighten screws or turnlock as applicable.
KMA-20 AND AMR-350 H OPERATIONAL CHECK (HF).
1. Perform operational test per the sections titled SB-10 Transceiver Operational Check (Fixed
Antenna) or Operational Test (Fixed Antenna) as applicable.
2. Verify HF can be' selected at audio panel.
3. Verify auto feature is operational when switching from HF to any other Com system. Audio
should switch to Com system in use.
4. Verify HF audio panel switch is functional in all three positions; off (center), headphones or
speaker.
— NOTE —
The remaining switches select VHF Com-1 and Com-2 and other functions
not applicable to HF.
5. Turn equipment OFF.
REMOVAL OF HEADPHONES AND MICROPHONES.
Both headphones and microphones are jack-connected to the system when in use. Unplugging from the
phone or mike jack is the only requirement for removal.
CABIN LOUDSPEAKER.
REMOVAL OF CABIN LOUDSPEAKER.
1. Remove screws securing speaker grill cover.

2. "Spring" headliner free in speaker area to clear speaker removal.
3. Remove speaker.
INSTALLATION OF CABIN LOUDSPEAKER.
1. "Spring" headliner in speaker area to allow speaker placement.

2. Install speaker.
3. Replace speaker grill cover. .. .
23-56-02
Page 23-53
2 3 Issued: June t, 1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
^ MAINTENANCE MANUAL
STATIC DISCHARGING.
A total of 16 ESD-3 discfiarge wicks are installed on tfie airplane; tfiree on eacfi wing, tfiree on eacfi fiori-
zontal stabilizer, tfiree on tfie vertical stabilizer and one on the tail cone.
DESCRIPTION.
As an airplane passes through freezing rain, dust, sand and snow, contact is made with particles, which
after impact, leave a positive or negative charge on the airplane. As the charge builds up, a potential is reached
at which time the accumulated charge begins to leak off the airplane and antennas, thus generating a broadband
radio frequency noise. This noise is received on ADF and HF, as well as on VHF receivers. Noise of this type can
cause navigational errors in flight as well as excessive receiver noise, resulting in unreliable communications. To
minimize these effects, the static discharger wicks bleed off the static charge quietly and effectively.
STATIC WICKS.
REMOVAL OF ESD-3 STATIC DISCHARGE WICKS. (Refer to Figure 23-18.)
1. Remove mounting base/doubler from control surface. Leave static wick in place on the base.
Remove Cherry rivets per Chapter 20.
INSTALLATION OF ESD-3 STATIC DISCHARGE WICKS. (Refer to Figure 23-18.)
1. Attach static discharger to mounting plate at designated locations with two rivets.
2. Attach wick base/doubler to control surface. Ensure a good electrical bond by thoroughly clean-
ing surfaces which will come in contact.
23-62-02
Page 23-54
Issued: June 1,1995
2K14
A E R O S T A R AIRGRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
VERT. STAB., TYP.
TAIL, TYP. BOTTOM SIDE, L § R

DETAILO
o o 12 (OR 20 ON LATER A / C )
AWG WIRE
INST. DETAIL, TYP.
EXISTING GROUND STUD
Figure 23-18. Static Discharge Installation (Typ)

23-62-02
Page 23-55
2K15 Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
GRIDS 2K16 THRU 2L24

INTENTIONALLY LEFT BLANK
2K16
AEROSTAR
A I R C R A F T C O R P O R A T I O N
AEROSTAR
MAINTENANCE
MANUAL
CARD 3 OF 7
AEROSTAR 600
AEROSTAR 601
AEROSTAR 601P
AEROSTAR 602P
AEROSTAR 700P
AEROSTAR AIRCRAFT CORPORATION
(PART NUMBER 761 732)

3A1
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
Page 3A2 Through 3B3

Have Been Intentionally Excluded
Please Refer To Pages 1A2 Through 183
3B4
ELECTRICAL POWER
3B5
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHAPTER 24 - ELECTRICAL POWER
T A B L E OF CONTENTS/ EFFECTIVITY
CHAPTER
SECTION GRID
24-00-00 GENERAL 3B8

24-03-00 Precautions 3B14
24-04-00 System Test 3B14
24-10-00 ALTERNATOR DRIVE 3B14
24-13-00 Alternator Belt Service 3B15
24-20-00 AC GENERATION 3B17
24-23-00 Precautions 3B17
24-24-00 Inverters 3B17
24-30-00 DC GENERATION 3B18
24-32-00 , Precautions 3820
24-33-00 Prestolite Alternator 3B21
24-34-00 Volt/Ammeter 3B22
24-35-00 Voltage Regulator 3B24
24-36-00 Over-Voltage Relay- 3C4
24-37-00 Isolation Diode 3C4
24-38-00 Power Circuit Breakers 3C5
24-39-00 Batteries 3C7
24-40-00 EXTERNAL POWER 3C13
24-41 -00 Description 3C13
24-42-00 Troubleshooting 3C13
24-43-00 Precautions 3C13
24-44-00 Battery/APU Relay 3C14
24-45-00 Auxiliary PoweTSbcket 3C15
24 - ContyEffec.
Page -1
Issued: June 1,1995
3B6
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHAPTER 24 - ELECTRICAL POWER (cont.)
CHAPTER
SECTION GRID
24-50-00 ELECTRICAL LOAD DISTRIBUTION 3C15

24-51-00 Description 3C15
24-52-00 Troubleshooting 3C15
24-53-00 Equipment Circuit Breakers 3C16
24-54-00 Avionics Bus Relay 3C17
24-55-00 Electrical Circuits 3C19
24-55-01 Description 3C19
—NOTE—
Refer to Cfiapter 91 for all wiring diagrams (Schematic).
24 - ContVEffec.
Page - 2
Issued: June 1,1995 3 57
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
GENERAL.
The Aerostar is equipped with a 28 volt negative ground electrical system composed of two 12 volt batteries,
two DC alternators, and protective devices such as regulators, over-voltage relays, isolation diodes and circuit
breakers. Provision is made for the connection of external power through a standard three prong receptacle.
Aerostar 700P's and some 600, 601, 601P, and 602P's have one 24 volt battery.
DESCRIPTION.
The>two 12 volt batteries, connected in series, are used to crank the engines and carry the starting load until
the alternators come on the line at 2000 rpm maximum.,The output of the alternators is impressed across the
main power bus. Each alternator is capable of carrying the entire normal electrical load by itself. Once the
alternators come up to speed, charging of the batteries will occur through normal regulator action. A panel
mounted combination volt/ammeter monitors the system voltage and current. Electrical circuits are fed from the
main power bus through circuit breakers while the radio and similar equipment is fed from the avionics bus.
TROUBLESHOOTING.
Refer to Troubleshooting Charts 2401, 2402 and 2403.
THIS SPACE INTENTIONALLY LEFT BLANK
24-02-00
Page 24-01
Issued: June 1,1995
3DO
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHART 2401. TROUBLESHOOTING (BATTERY)
No power available when Battery circuit breal<er Reset circuit breaker.

master battery switch tripped.
turned on.
Defective master battery Replace switch.
Defective APU relay. Replace relay.
Discharged batteries. Recharge or replace.
Short or open in battery Inspect and ringout circuit.

circuit. Repair as required.
Insufficient power to Batteries low. Recharge batteries or start

start engines. engines with APU.
Loose or poor connection Inspect and ringout circuit.

in battery or starting
circuit.
Dead (discharged) End of useful life. Replace battery.

battery.
\
Low charging rate. Check voltage regulator.
Raise charging rate.
Battery standing too Recharge battery if left un-

long. used three weeks or more.
Equipment left on Recharge battery.

accidentally.
Short circuit (ground) Inspect and ringout wiring

in wiring, (battery circuit).
Excessive corrosion in Spillage of electrolyte Use care in adding water.

battery compartment. from over-filling.
Vent lines leaking or Repair or clean lines.

clogged.
Charging rate too high. Check voltage regulator.
Battery consumes Charging rate too high. Check voltage regulator.

excessive water.
Cracked case, one or more Replace battery.
cells.
24-02-00
Page 24-02
Issued: June 1,1995
3B9
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHART 2402, TROUBLESHOOTING (ALTERNATOR)
, Trouble Cause Remedy
Zero output bn volt/ Altemator circuit Reset circuit breaker.

ammeter regardless of breaker tripped.
engine RPM (alternator^
fails to conhe on tfie
line.) ~
Alternator drive belt Re-tension drive belt or
broken, loose or replace.
glazed.
Open output circuit. Ctieck 80-amp fuse at fuse

filter unit mounted on
engine. If OK: Cfieck entire
field circuit to isolate the
faulty component.
Defective alternator. Check alternator for out-

put. Repair or replace.
Open field circuit. Check 10 A fuse at F.S. 176.88

panel.
Output indicated on volt- Voltage regulator out of Re-adjust voltage regulator.

meter does not meet mini- normal operating range. (Refer to section tiitled
mum value specified in Prestolite Alternator.)
system test.
Defective voltage regul- Replace.
ator.
Higfi resistance connec- Inspect circuit for loose or

tions in field or output corroded connections.
circuit. Repair as required.
Open or sfiorted rectifier Check alternator for

diode in alternator defective rectifier, replace.
output winding
(stator).
24-02-00
Page 24-03
issued: June 1,1995
3B10
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHART 2402. TROUBLESHOOTING (ALTERNATOR) (cont) ;
80-amp fuse in alternator Isolation diode grounded. Check insulated spacers at

output blows. May also diode heat sink. Check
trip circuit breaker. diode internal resistance.
Replace as required
Alternator circuit Short in wiring between Inspect and ringout circuit.

breaker trips. circuit breaker and main Repair as required.
bus.
Excessive ammeter fluctu- Excessive resistance in Check all connections in

ation. - fieldîrcuit. field circuit. Repair as re-
quired.
Defective over-voltage Check over-voltage relay.

relay. Replace as required.
Defective voltage regulator Replace voltage regulator.
24-02-00
Page 24-04
Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHART 2403. TROUBLESHOOTING (MISCELLANEOUS)
Alternator light on " Bulb burned out. Replace bulb.

annunciator panel fails
to light.- •
Defective voltage sensor. Repair or replace sensor.
Alternator light on Defective voltage sensor. Repair or replace sensor.

annunciator panel remains
lit with alternator show-
ing normal output.
Shorted transistor jn the Replace transistor on early
signal conditioner (if model annunciator panels
equipped with signal Replace signal conditioner
conditioner). otherwise.
Volt/ammeter will not Defective "push to read Replace switch.

read voltage. voltage" switch.
Volt/ammeter will not Defective circuit Replace switch.

read current (amps). selector switch.
•
Wire broken on back of Repair wiring.
switch.
Volt/ammeter will not Blown voltmeter fuse(s). Replace fuse(s).

read all selected
positions
Defective circuit selector Replace switch.
switch.
Wire broken on back of Repair wiring. '

switch.
Blown fuse(s). Replace fuse(s).
24-02-00
Page 24-05
Iss ued:, J une 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHART 2403. TROUBLESHOOTING (MISCELLANEOUS) (cont)
Trouble Cause^ Remedy
Volt/ammeter will not Meter movement coil open. Replace meter.

read eitiier volts or
amps.
No voltage at avionics Blown 30-amp avionics bus Replace fuse.

bus with radio master fuse.
switch on.
Artificial horizon and Defective A G inverter. Replace inverter.

directional gyro inoper-
ative (A/F 0002-0005
only).
Engines will not crank even Loose or broken connections - Repair wiring.
with full Battery or APU on back of magneto
power. switches.
24-02-00
Page 24-06
Issued: June 1,1995 3B13
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
^ MAINTENANCE M A I ^ A L
PRECAUTIONS.
The fbllowihg precautions should be observed when installing, testing or servicing the electrical system:
1. Disconnect the battery before connecting or disconnecting test instruments (except voltmeter) or
' before removing or replacing any unit or wiring.
2. The Auxiliary Power Unit must be turned "ON" and the voltage allowed to stabilize at 24 to 28 volts
before installing the external power plug in the tail receptacle. Since power will be automatically
supplied to the bus,.the more delicate electrical components will be protected from external power
- supply voltage spikes by ensuring that the Radio Master Switch is, OFF and the autopilot circuit
breakers are pulled. The battery and alternator switches must be turned " O F F as long as external
power is connected.
SYSTEM TEST.
1. Test.
A. Perform the following system test:
(1) Start engines. (Refer to Flight Manual for starting procedures.) After engines
warm up, set to 1500 rpm.
(2) Set left and right Alternator Switches to OFF.
(3) Establish system load of 25-30 amps approximately.
(4) Turn Battery Switch " O F P and right Alternator Switch "ON".
(5) Ensure right alternator comes on line and check system voltage (27 ± 1 V
approximate).
(6) Turn right Alternator OFF. Turn left Alternator ON and check that it comes on
line. Check system voltage. (27 ± 1 V approximate.)
(7) If both alternators check OK, turn Battery Switch "ON" and both (right and
left) Alternators "ON".
(8) increase system load to 40 amps and check output of both alternators.
(9) If difference in alternator output is greater than 4 amps, perform the following
step. If difference is 4 amps or less, system is normal arid no further
adjusment is required.
(10) Adjust regulators per section titled Voltage Regulator.
ALTERNATOR DRIVE.
The Alternator Drive operates from the starting ring gear which is fitted with a V groove to
accommodate the alternator drive belt. Located at the forward end of the engine, the drive belt runs
over an adjustable idler pulley to complete the loop to the alternator
24-10-00
Page 24-07
Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
DESCRIPTION.
The 600, 601, 601P, 602P and 700P are fitted with belt driven alternators, one for each engine. The drive
belts are of the V-type, adjustable for proper tension. There is no provision for remote indication of belt function,
other than normal alternator action. Since the drive is fixed, alternator speed is directly proportional to engine
rpm. An alternator warning light will illuminate (A/F 0256 and up) when its respective altemator fails for various
reasons. One of these causes of failure could be a brol<en or slipping drive belt. >tonitoring the altemator output
with the voltammeter will readily determine if an alternator has failed.
TROUBLESHOOTING.
Refer to Troubleshooting Charts 2402 and 2403.
ALTERNATOR BELT SERVICE.
1. Removal/Installation.
A. Removal.
(1) Remove engine cowling.
(2) Remove propeller assembly per Chapter 61.
(3) Remove alternator drive belt.
B. Installation.
(1) Install alternator drive belt. (Refer to AdjustmenfTest.)
(2) Install propeller assembly per Chapter 61
(3) Replace engine cowling.
2. Adjustment/Test.
A. Tension Adjustment.
(1) Loosen idler pulley lock nut (cowling removed).
(2) Rotate idler pulley on its cam mounting to swing down against drive belt.
(3) Using the torque method of checking belt tension, adjust pulley for a belt tension
of 13-15 ft. lbs. for a new belt or 9-11 ft. lbs. for a used belt, (700P, 80 ± 5 lbs
static).
(4) Run engine for 15 minutes at 1200 rpm. Shut down engine and recheck belt tension.
(5) Retention belt as required and tighten pulley lock nut.
(6) Replace cowling.
B. Checking Belt Tension. There are three satisfactory methods of checking altemator belt
tension; however, the first method described will be found more preferable because it is
technically simple and requires little time to accomplish:
(1) Torque fêthod.

(a) Apply a torque indicating wrench to the alternator pulley nut.
(b) Turn nut in a clockwise director) and obsen/e the torque shown on the
wrench the instant the pulley'slips.
24-13-00
Page 24-08
Issued: June 1,1995
3B15
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
(c) Check the torque against the following specification:
CHART 2404. ALTERNATOR BELT TENSION
Torque indicated at
Width of Belt Condition Alternator Pulley
3/8 inch New 11 to 13ft.-lbs.

3/8 inch Used 7 to 9 ft. lbs.
1/2 inch New 13to 15ft.-lbs.
(700P, 80 ± 5 lbs. static)
1/2 inch Used 9 to 11 ft.-lbs.
—NOTE—
The higher tension specified for a new belt is to compensate for the initial
stretch that takes place as soon as it is operated. These higher tension values
should not be applied to belts which previously have been used.
(2) Deflection fêthod.

(a) Attach the hook of a small spring scale to the belt at the approximate
midpoint between the ring gear support and the generator.
(b) Pull on the scale until a reading of 14 pounds (for a new belt) or 10
pounds (for a used belt) is achieved.
(c) Measure the distance the belt has moved with the 10 or 14 pound force
applied. The distance should be 5/16"; if the distance is less than 5/16",
the belt is too tight.
(3) Belt Tension Gauge.
(a) Use a belt tension gauge such as the Burroughs "Deluxe" Model (or
equivalent).
(b) Attach the gauge over the belt per the manufacturer's instnjctions.
(c) Quickly release the handle and reset the tension.
(d) Repeat Steps (b) and (c) several times to eliminate the possibility of an
inaccurate reading.
—NOTE—
Slight variations in readings taken at different locations on the belt are normal.
(e) If a new belt is installed, set the tension about 25% above operating
range to allow for stretch that will occur as soon as the belt has been in
operation.
24-13-00
Page 24-09
3B16
. Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
A C GENERATION. ~ ,
A/F 0002-0005 are equipped with A C powered flight instruments: Artificial Horizon and the Directional
Gyro. From A/F 0006 and up, these instruments were changed to DC or pneumatic power.
DESCRIPTION.
In the AC system, power is supplied by two solid-state P10A Inverters. Input power supplied is converted
to 110 V A C . There are no adjustments.
TROUBLESHOOTING.
Refer to Troubleshooting Chart 2403.
PRECAUTIONS.
The following precautions should be observed before performing any maintenance on the A C system
1. Disconnect the battery ground cable before removing or replacing any unit, or wiring in the
inverter circuit. Accidental grounding or shorting of the battery circuits will cause severe damage
to the units or wiring.
INVERTERS.
The two inverters are located on the aft side of fuselage station 54.25 bulkhead on upper right side. They
can be reached from copilot's station under instnjment panel, forward.
A. Removal (See Figure 24-1).

(1) Master Battery OFF/Auxiliary Power Unit disconnected.
(2) Inverters Switch OFF.
(3) Disconnect electrical leads from inverter. Tag leads for identification
(4) Remove Inverter.
B. Installation.
(1) Identify electrical leads and connect to inverter.
(2) Install inverter
2. Adjustment/Test.
A. Output voltage test.
(1) Master Battery ON.
(2) Inverters Switch ON.
(3) Using voltmeter, check for 100 V AC between terminals E and A of inverter
number 1.
(4) Repeat Step (3) for inverter number 2.
(5) Remove voltmeter and tum off equipment.
24-24-00
Page 24-10
Issued: June 1,1995 3 B17

AER0S1AR>AIRCRAFT
600/601/601P/662P/700P
MAINTENANCE MANUAL
B416
ARTIEICiAL HORIZON F.S. 54.25
DIRECTIONAL GYRO
INVERTERS
SWITCH
AC: INVERTERS
Figure 24-1. A C System
DC GENERATION.
Tlie electrical power is generated by two self-excited Prestolite alternators,-belt driven by eacfi engine.
Eacfi altemator is capable of providing tfie normal power requirement of tfie airplane ensuring sufficient backup in
tfie event tfiat one alternator fails. Voltage regulation is achieved by the use of regulators arid over voltage relays.
The entire system is protected by fuses and circuit breakers. Two 12-volt batteries connected in series provide
starting power and a reserve in case of total alternator failure. Model 700P's and sdnia-600, 601. 601P, and
602P's, use one 24 volt battery. ',•>' ; •
DESCRIPTION. (See Figure 24-2 for Component Location.)
The 70-amp alternators ~(50-amp on earlier models) are provided with individual switches located on the
instrument panel as a means of checking alternator circuit operaticln, and to permit disconnecting either or both
alternators from the main power bus. Should an alternator faiY, or an engine not be running, the respective
alternator switch should be fumed off. Since the alternators arej self-exciting, turning the adjacent Master Battery
switch "OFF" will not affect alterpator operation. The Prestcjiite alternator, due to its design, has self-limiting
current characteristics and needs rio current limiting unit in ttie regulator. Under nomial operation the system load
is balanced between the two alternators. However, eacfi one.is capable of carrying the entire normal load by
itself. Each alternator is protected by a 70-amp circul?i:'breal(er rnou^ on the equipment circuit breaker panel,
and in addition, an 80-amp fuse located near the Estimator affords additional protection for the output (positive)
side of the altemator. i''
Page 24-11
3B1 8 Issued^June 1,1995

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
The Volt/Ammeter reads the current flow of the entire system. Pushing a button on the left side of the
volt/ammeter enables the meter to read the system voltage. A three-position selector switch selects the circuit to
be read on the meter. Total system current flow or individual alternator current flow can be selected.
—NOTE-
TO read individual alternators, it is necessary that the left alternator switch
be OFF to check the right alternator and conversely the right alternator
switch be OFF to read the left alternator. Tliis is because both alternators
feed a common bus.
Voltage regulation is accomplished by use of solid-state vpltage regulators. These regulators, one for
each alternator, have no moving parts and are adjustable for alternator output. A balanced load between the two
alternatprS'is thus possible.
the alternator system is protected from excessive voltage output by incorporating over-voltage relays.
These relays sense an over-voltage condition, interrupting their respective altemator field when the oven/oltage
condition occurs. To put the alternator back on the line, the relay must be reset manually by setting the alternator
switch to " O F F then to "ON".
Each 70-amp alternator output line is protected by an isolation diode mounted on a finned heat sink.
These diodes provide the following functions:
1. Prevent a fault in the altemator or ailtemator power cable from affecting the remaining power
sources.
2. Allow each voltage regulator to sense individual alternator output for correct regulation.
Figure 24-2. Eiectricai System Locator
•^4-31-00
Page 24-12
IssuediJdnel, 1995
3B19
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
3. To allow each over-voltage relay to sense individual altemator output, thus avoiding dual altemator
disengagement in the event of a single alternator over-voltage condition.
—NOTE—
A transient over-voltage condition of sufficient magnitude may penetrate
tfie isolation diode to trip both over-voltage relays. In this case the faulty
alternator must be identified by trial and error and turned off.
Power circuit breakers are provided for alternator protection against excessive current demand as
follows: on airplanes fitted with 50-amp alternators (unless retro-fitted per SB600-24), individual 50-amp remote
circuit breaker (re-set by a 5-amp panel mounted circuit breaker) protects each alternator, and a 73-amp remote
circuit breaker (re-set by a 5-amp panel mounted circuit breaker) protects the entire electrical system. On
airplanes modified per SB600-24, the three remote circuit breaker relays and the three 5-amp panel mounted
circuit breakers are replaced by three 70-amp panel mounted circuit breakers which protect the individual
alternator and battery power cables. On airplanes equipped with 70-amp alternators there will be either a
separate 73-amp remote circuit breaker (re-set by a 5-amp panel mounted circuit breaker) protecting each
alternator and the battery power input cable, or three 70-amp panel mounted circuit breakers which protect the
individual alternator and battery power input cables. All airplanes from A/F 0190 and subsequent employ the
latter method.
Vent lines are provided in order to exhaust battery fumes and fluid from the battery compartment, located
just forward of the tail cone or just aft of the baggage compartment.
The alternator annuciator lights give an indication when one or both alternators fail. When the Master
Battery switch is on and the engines are not running, both the left and right alternator lights will illuminate to show
the indicating system is functional. After engine start-up and the alternators come on the line, a voltage sensor
activates to extinguish the lights. In the event of alternator failure, lack of voltage output would cause the sensor
to turn on the affected indicator light. The Altemator Waming lights are located on the upper left copilot's panel or
annunciator panel (if installed). The Push-to-Test switch on the annunciator panel illuminates all of the lamps at
once, but does not test the alternator indicating system.
PRECAUTIONS.
Precautions to be observed when installing, testing or servicing the alternator system:
1 Disconnect the battery before connecting or disconnecting test instruments (except voltmeter)
and before removing or replacing any unit or wiring. Accidental grounding or shorting at the
regulator, alternator, ammeter or accessories will cause severe damage to the units and/or
wiring.
.0 To avoid damage to the transistorized regulators, do not at any time connect battery directly to
the regulator or alternator field terminal (except as specified in the alternator flash starting
procedure, Adjustment/Test).
The field circuit must never be grounded on this system at the alternator or regulator Grounding
of the field terminal at either the alternator or regulator will damage the regulator.
24-32-00
Page 24-13

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
4. Do not ground the adjusting tool to the regulator base when adjusting the voltage regulator, or
the regulator will be damaged. The adjusting tool should be non-conducting or insulated with a
plastic sleeve to avoid grounding.
5. The alternator must not be operated on open circuit with the rotor winding energized.
6. Do no attempt to polarize the alternator; it is not required. Any attempt to do so may result in
damage to the alternator, regulator or circuits. (Refer to Alternator Flash Starting Procedures,
Adjustment/Test.)
7. Reversed battery connections may damage the diodes, airplane wiring or other components of
the alternator system. Observe battery polarity for a negative ground.
8. Accidental interchange of regulator leads will damage regulator.
PRESTOLITE ALTERNATOR.
The Prestolite alternator is located on the lower left forward end of the engine, accessible by removing
the lower engine cowling.
1 - Removal/Installation
A. Removal.
(1) Master Battery switch OFF/Auxiliary Power Unit disconnected.
(2) Alternator switches OFF.
(3) Remove upper and lower engine cowling and left half of nose cowl.
(4) Loosen tension idler pulley to loosen alternator drive belt.
(5) Disconnect alternator output plug and remove alternator.
B. Installation.
(1) Install alternator and reconnect alternator output plug.
(2) Install alternator drive belt on alternator pulley.
(3) Adjust idler pulley on its eccentric to provide proper belt tension. (Refer to
Generator/Alternator Drive, section titled Alternator Belt Service for belt installa-
tion.)
(4) Replace engine cowling.
2. Adjustment/Test.
A. Perform System Test per section titled System Test.
—NOTE—
An alternator which is new or has not been used recently will lack the
residual magnetism in the rotor which is essential to self-excite the alterna-
tor. Under these circumstances, the following procedure must be perfor-
med to bring the alternator on line.
24-33-00
Page 24-14
Issued: June 1,1995
3B21
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B. Alternator Flash Start Procedure.
1 . (1) Attach one end of an 18-gauge clip-lead to a battery power cable break-out on
the electrical systems panel, (main remote circuit breaker or any ammeter shunt
on 50-amp systems, starter motor cable stud or starter relay stud on 70-amp
systems). Avoid touching airplane ground with clip-lead.
(2) With appropriate engine running at 1500 rpm, and a load of less than 10 amps
on line, turn "ON" appropriate alternator switch.
(3) Momentarily touch the I terminal of the voltage regulator (either terminal of the
overvoltage relay will also work) with the free end of the clip-lead. The altemator
should immediately come on line and stay on after momentary contact is made.
- (4) Allow alternator to remain on line charging for at least five minutes to allow rotor
to magnetize.
_^ (5) Turn alternator Master switch OFF then ON again to verify that alternator will
self-excite and stay on line.
VOLT/AMMETER.
The combination Volt/Ammeter is located immediately beneath the control column in the lower left
copilot's panel.
A. Removal.
(2) Remove screws securing meter to instrument panel and bring meter out of panel.
(3) Disconnect wires from meter.
(4) Tag and tape wires individually pending reinstallation.
(5) Remove meter.
B. Installation.
(1) Untape electrical leads and identify each.
(2) Connect leads to meter ensuring correct placement.
(3) Install meter.
2. Adjustment/Test.
A. Voltage test
(1) Master Battery ON, alternators OFF.
(2) Push button on lower left meter case to read system voltage. Note reading.
(3) Using a multimeter take voltage reading at any convenient location on the cath-
ode side of the isolation diodes, a battery cable break-out at master electrical
panel or at the battery in the battery compartment. Note reading.
(4) The readings in Steps (2) and (3) should agree within 1/2 volt
(5) Turn Master Battery OFF.
24-34-00
Page 24-15
3 B22 Issued: June 1,1995

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B. Current test.
(1) Master Battery ON alternators OFF

(2) Turn on sufficient electrical equipment to establisfi a 10 amp load. Note wfiat
electrical equipment is ON. Note ammeter reading
(3) Turn O F F electrical equipment from Step (2). Set Master Battery switcfi OFF.
(4) Open battery compartment.
(5) Disconnect ground cable from battery (negative terminal).
(6) Set multimeter for current reading on 12 amp scale. Connect negative lead
(blacl<) to negative post of battery and positive lead (red) to ground cable.
(7) Set Master Battery switch ON. Turn on same electrical equipment as noted in
Step (2). Note reading on multimeter.
(8) Readings in Step (2) and Step (7) should agree within 1/2 amp.
(9) Turn off all equipment. Turn Master Battery OFF. Disconnect multimeter and
reconnect battery ground cable.
(10) Close battery compartment cover.
EXISTING ALTERNATOR
ISOLATION DIODES AT F. S. 176. 88
120A6S
TEMPORARY 8 GAUGE
JUMPER STRAP
119A6S
Figure 24-3. Jumper Strap Installation
24-34-00
Page 24-16
Issued: June 1,1995
3B23
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL ;
VOLTAGEREGULATOR.
The voltage regulators, one for each alternator, are mounted on the master electrical panel located at
fuselage station 176.88 bulkhead at the aft end of the passenger cabin. Remove "Royalite" panel for access.
A. Removal. (See Figure 24-4.)
(1) Master Battery Switch OFF/Auxiliary Power Unit disconnected.
(2) Open battery compartment cover and disconnect ground side of battery (negative
terminal).
(3) Disconnect electrical leads from voltage regulator. Tag each lead for identification.
(4) Remove regulator
B. Installation.
(1) Install regulator
(2) Identify tagged leads and connect to voltage regulator. Ensure correct connec-
tions are made to regulator terminals.
(3) Connect battery ground cable (negative terminal).
(4) Close battery compartment cover
2. Adjustment/Test.
—NOTE—
The following procedure should be followed whenever a new alternator or
voltage regulator is installed, or it is found that bus voltage is low or alter-
nator is out of balance.
A. Adjust Regulator.
(1) Initial set-up procedure.
(a) Prior to starting the adjustments, add a temporary jumper strap (anode
to anode) between altemator output diodes (Figure 24-3).
(b) Lift the wire from the "PAR" terminal of either regulator and temporarily
secure the free end so it will not touch ground during the adjustment.
(2) Adjustment procedure.
—CAUTION—
During all tests and adjustments on these regulators make certain that the
"field" circuits including any meter or test leads connected to these circuits
are always protected from accidental contact with ground or other circuits.
Even a momentary ground contact for an instant may permanently damage
the regulator.
24-35-00
Page 24-17
3g24 Issued: June 1,1995

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
(a) Tum "OFF" the left altemator field switches.
(b) Turn "ON" the right alternator field switches.
(c) Start the right engine and idle for a period of 5 -10 minutes with an electrical load
, of 15-30 amps (by activating normal airplane loads and monitoring volt/am-
meter for total current) and an engine rpm of 1200.
(d) As required, carefully adjust the right regulator for 28.5 volts DC, using a
voltmeter (of at least 20 K ohm/volt sensitivity) connected to the regulator bus
terminal (at an rpm of 1200). A digital electronic voltmeter is recommended.
-NOTE-
Several operations of connecting and disconnecting the PAR circuit are
required by the following steps. (For convenience a temporary switch may
be installed to accomplish this requirement)
(e) Shut down the right engine and connect the voltmeter between the field termi-
nals of the left and right voltage regulators in addition to the system wires
already connected to these terminals. The positive (red) lead of the test meter
shall be connected to the right engine voltage regulator (Use a 30 or 50 V meter
scale initially).
(f) Again, start the right engine and alternator system as in Step (c). (Do not
operate left engine at this time.)
(g) Turn "ON" the left engine alternator switch and slowly rotate the left regulator
voltage adjustment while observing the voltmeter between the field tenninals.
-NOTE-
tfa reverse (down scale) reading is obtained, turning the adjustment coun-
terclockwise will bring the meter upscale.
(h) Slowly set the left regulator adjustment to a point where the voltmeter reads a
low (minimum) value. Any reading from 0 to 8 volts is acceptable. A stable read-
ing should not be expected. A low meter range such as the 10V scale may be
used for this adjustment.
(i) Reconnect the wire to join the "PAR" terminals of the two regulators and verify
that the meter drops to a very low value (0.2 to 0.5 volts) and is stable. Continue
operation in this manner for 5 -10 minutes.
(t) Make final touch-up of adjustment of the balance by briefly opening the "PAR"
circuit between the right and left regulators and tweaking the left regulator adjust-
ment for a minimum reading of the meter between the regulator field temriinals.
Again, any reading from 0 to 8 volts is acceptable with the "PAR" lead discon-
nected.
(k) Restore all wiring to normal, replace "Royalite" panel. Adjustment is complete.
(I) As a final check, with both engines operating, verify that the right and left alterna-
tors are sharing the electrical load by obsen/ing left and right altemator output
on the volt/ammeter. There should be no more than 4 - 5 amps difference (maxi-
mum allowable), although a difference of 2 amps or less can be expected.
(m) Shut down engines. Turn fvlaster Battery, and Altemator switches OFF.
24-35-00
Page 24-18
Issued: June 1,1995
3C1
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
8419
^ ISOLATION DIODE INSTALLATION
Figure 24-4. Master Electrical Panel
24-35-00
Page 24-19
Qfô Issued: June i ; 1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B420
Figure 24-4. iViaster Eiectricai Panel (cont.)
24-35-00
Page 24-20
Issued: June 1,1995
3C3
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
>. 3 Inspection/Check. - • ., . -
A. Perform system test per section titled System Test.
-NOTE-
If system voltage is out of tolerance (27.75 ± 1 volt) or alternator output is
out of balance by more than 4 amps, regulators must be adjusted per
adjustment procedure in section titled Voltage Regulator.
OVER-VOLTAGE RELAY.
I-
Ttie over voltage relays, one for eacfi alternator, are mounted on ttie master electrical panel located at
fuselage station 176.8 (at ttie aft end of thie cabin on the right side). Remove "Royalite" panel for access.
A. Removal, see Figure 24-4.
(1) ' • Master Battery Switch OFF/Auxiliary Power Unit disconnected.
(2) Open battery compartment cover and disconnect ground side of battery (nega-
tive terminal).
(3) Disconnect electrical leads from relay. Tag leads for identification.
(4) Remove relay.
B. Installation.
(1) Install relay.
(2) Identify tagged leads and connect to relay, insuring correct connections are
made to relay terminals.
(3) Connect battery ground cable (negative terminal).
(4) Close battery compartment cover
ISOLATION DIODE.
The isolation-diodes, one for each alternator, are mounted on a finned heat sink on the master
electrical panel located at fuselage station 176.88 bulkhead at the aft end of the cabin, right side. Remove
"Royalite" panel for access. For /VP 0001-0190 the heat sink is frame-mounted on the right side and forward of
the copilot's station.
A. Removal, see Figure 24-4. _
(2) Open battery compartment cover and disconnect ground side of battery (negative
terminal).
(3) Locate diode/heat sink assembly on lower left side of eiectricai panel.
(4) Remove screws securing diode/heat sink assembly to panel.
(5) Disconnect electrical leads (3) from diode. Tag leads for identification.
-NOTE-
Removal of diode mounting nut disconnects one of three electrical leads
and releases diode from heat sink.
(6) Remove diode and heat sink.
24-37-00
Page 24-21
Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B. Installation.
(1) Assemble diode to tieat sink ensuring ttiat insulating spacers are properly
- installed. (Refer to Figure 24-4).
(2) Identify tagged leads and connect to diode. Tigtiten diode terminal nuts carefully
to avoid damage to diode.
—CAUTION-
DO not exceed 30 Inch/pounds torque on diode mounting nut, or damage to
diode will result.
(3) Install diode/heat sink assembly on electrical panel.

(4) Reconnect battery ground cable (negative terminal).
(5) Close battery compartment cover.
2. Inspection/Check
A. Remove diode from heat sink. (Refer to Removal/Installation.)
B. Inspect the insulating spacers for deterioration of the Themialloy insulating material.
Replace as required.
C. Take ohmmeter reading of diode internal resistance. It should be 500 ohms in one
polarity. Reading should be 10 megaohms or more for other polarity. A lower resistance
ratio indicates a faulty unit which should be replaced.
D. Replace diode assembly. When assembling diode to heat sink, ensure insulating rings
are centered in mounting holes. (Refer to Figure 24-4, Detail A.)
POWER CIRCUIT BREAKERS.
The three 70-amp power circuit breakers are located above the equipment circuit breakers on the lower
right copilot's panel.
A Removal, refer to Figure 24-5.
(2) Remove battery compartment access cover, and disconnect battery ground
cable (negative terminal).
(3) Remove "Royalite" panel from circuit breakers section per Chapter 39.
(4) At circuit breaker panel (copilot's station) remove screws securing each comer of
lower section of panel, allowing panel to move inward.
(5) Remove bus bars from affected circuit breaker.
(6) Remove electrical leads and tag each for identification.
(7) Remove threaded ring nut from front of circuit breakers.
(8) Remove circuit breaker.
24-38-00
Page 24-22
Issued: June 1,1995
3C5
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
. B.' Installation. . -
(1) Install circuit breal<er in panel, tighten ring nut to secure.
;(2) .•- Identify and connect electrical leads to circuit breaker.
(3) install bus bars on circuit breaker.
(4) Place lower section of panel in position and secure with the four corner screws.
(5) Install "Royalite" panel per Chapter 39.
(7) Close battery compartment access cover.
24r38-00
Page 24-23
3C6 Issued:June 1,1995

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
BATTERIES.
The standard battery installation (except for the 700P) is two 12 volt batteries connected in series in the
battery compartment located just forward of the tail cone.
A single 24 volt battery installed in the previously mentioned compartment is available as an option on
later 602P's.
The 700P has a single 24 volt battery located at F.S. 275.00. This installation is also available as a
retrofit kit for 600, 601, 601P and 602P's. Refer to Figure 24-6.
-WARNING-
Remove watches, rings and other jewelry before reaching into battery
compartment to avoid accidental arcing and possible severe personal injury.
(1 ) Master Battery OFF/Auxiliary Power Unit disconnected.
^ (2) Verify all equipment switches are OFF, Radio Master Switch O F F and all autopi-
lot circuit breakers are pulled.
(3) Remove battery compartment access cover.
(4) Disconnect negative cable(s). Tag cable(s) for identification.
(5) Disconnect positive cable(s). Tag cable(s) for identification.
(6) Remove all vent lines.
(7) Remove battery hold-down frame.
(8) Remove battery(ies).
B. Installation.
-CAUTION-
Ensure batteries are installed with correct polarity, or severe electrical
damage may result to electrical system.
(1) Place battery(ies) in compartment, ensure placement allows correct polarity to

cables
(2) Install battery hold down frame. Safety the hold-down wing nuts (24 volt single
battery).
(3) Connect positive cable.
(4) Connect vent exhaust lines.
(5) Verify polarity is correct and connect negative cable.
(6) Close battery compartment access cover.
2. Adjustment/Test.
A. Test.
(1) With new batteries, or when reinstalling batteries, read the electrolyte specific
gravity with a hydrometer A reading of 1.265 - 1.275 (1.285 minimum for 24 volt
single battery) for all cells represents a completely charged battery. A reading of
1.150 indicates a completely discharged condition. A difference of .050 between
cells indicates the battery is approaching the end of its useful life.
-NOTE-
When charging batteries, both should tie charged to the same level rather
than only one. When replacing batteries, both should be replaced as a pair.
24-39-00
Page 24-24
Issued: June 1,1995
3C7
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B653
1. AUXILIARY POWER UNIT RELAY

2. A.P.U. SOCKET
3. REBAT BATTERY INSTALLATION
24-39-00
Page 24:25

AEROSTAR AIRCRAFT
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MAINTENANCE MANUAL
Figure 24-6. Battery Instailation (cont)
24-39-00
Page 24-26
Issued: June 1,1995
3C9
AEROSTAR AIRCRAFT
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MAINTENANCE MANUAL
24-39-00
Page 24-27
3C10 Issued: June1,1995

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
O TINSTALLATION
E L E D Y N E BATTERY
(F.S. 275.00) TOOR ALSO AVAILABLE AS A RETROFTr KIT FOR 600,601,601R AND 602P'S
Figure 24-6. Battery Installation (cont)
24-39-00
Page 24-28
Issued: June 1,1995
3C11
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
D141
•T E L E D Y N E B A T T E R Y I N S T A L L A T I O N
(SINGLE 24 V O L T BATTERY) (OPTIONAL O N LATER 602P'S)
1. AUXILIARY POWER UNIT RELAY

2. APU SOCKET
3 . TELEDYNE BATTERY INSTALLATION
Figure 24-6. Battery Installation (cont)
24-39-00
Page 24-29
1
AEROSTAR AIRCRAFT
;600/601/601 P/6b2P/700P
MAINTENANCE MANUAL
3. Cleaning/Painting.
A. Cleaning.
(1) The
T battery and compartment can be cleaned by using a solijtibn of baking soda
and water mixed at 1 lb. per gallon.
-CAUTION-
Baking soda and water will neutralize the electrolyte if allowed to enter the
battery, causing a discharged condition. This would require replacing the
electrolyte and recharging the battery.
(2) After cleaning with baking soda and water, thoroughly rinse with clear water.
(3) Apply a light coat of petroleum jelly (or equivalent) to battery temninals and cable
connections to retard corrosion.
(4) IEnsure battery hold-down frame is tight and secure.
B. Painting.
(1) EBattery compartment can be protected with a coat of battery compartment paint
as required. (Zinc chromate primer MIL-P-8585 and #20-131, Black, Acid
resistant spray, T E M P C O PRODUCTS, CLEVELAND, OHIO).
EXTERNAL POWER.
External Auxiliary Power can be connected to the airplane's electrical system by means of a tail-mounted
power socket and the Battery/APU relay.
DESCRIPTION.
The airplane is equipped with a polarized power receptacle for connection of auxiliary power located in
the lower aft end of the fuselage at fuselage station 370.00. A relay operated by the Master Battery switch selects
airplane battery or the externally connected auxiliary unit. Setting the Master Battery switch to ON operates the
Bat/APU relay to connect the batteries to the electrical system. When the Master Battery switch is in the O F F
position, the relay will de-energize and connect the APU socket terminals to the electrical system.
TROUBLESHOOTING.
Refer to Troubleshooting Chart 2401.
PRECAUTIONS.
The Auxiliary Power Unit must be switched ON and the voltage allowed to stabilize at 24 - 28 volts before
installing the external power plug in the tail receptacle. Since power will be automatically supplied to the bus, the
more delicate electrical components will be protected from external power supply voltage spikes by ensuring the
Master Radio switch is OFF and the auto pilot circuit breakers are pulled. The battery and altemator switches
must be oft as long as external power is connected.
24-43-00
Page 24-30
Issued: June 1,1995
3C13
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
BATTERY/APU RELAY.
The Battery/APU relay is located on the aft side of the battery compartment barrier inside the tail cone.
1. ' Removal/Installation.
A. Removal, see'Figure24:^6.
(1) f^/laster BatteryÔFF/Auxiliary Power Unit disconnected.
(2) Disconnect battery ground cable (negative terminal).
(3) Remove tail cone.
(4) Remove relay cover.
(5) Remove all electrical leads from relay terminals. Tag each lead for identification.
(6) Remove relay.
B. . Installation.
(1) Install relay. Identify tagged leads and connect to relay terminals.
(2) Replace relay cover. Reconnect battery ground cable.
(3) Replace tail cone.
(4) Replace battery compartment cover.
2. Adjustment/Test.
A. • Battery/APU functional test.
(1) l\/laster Battery OFF/Alternator switches OFF.
(2) Master Radio switch OFF.
(3) Pull auto pilot circuit breakers (OFF).
(4) Auxiliary Power Unit ON. Allow voltage to stabilize at 24 - 28 V.
-CAUTION-
Ensure all switches and equipment are turned off and all auto pilot circuit
breakers are pulled prior to connecting an external power unit. The master
batt. and alternator switches must be left in the off position until the external
power unit is disconnected to protect the voltage regulators and system electrical
equipment from voltage transients and possible damage.
(5) Install external power plug to airplane tail receptacle (APU socket).
(6) Read system voltage at volt/ammeter on instrument panel. Should be 24
28 volts in accordance with APU voltage in Step (4).
(7) Unplug external power. Turn OFF Auxiliary Power Unit.

(8) Set Master Battery switch to ON and read system voltage. Meter reading of volt-
age indicates Bat/APU relay is functional. Turn Master Battery OFF.
24-44-00
Page 24:31
3C14
Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
AUXILIARY POWER SOCKET.
The Auxiliary Power Socket is located at the aft end of the fuselage just fonward of the tail cone, lower
side.
(2) Disconnect battery ground cable (negative terminal).
(3) Remove tail cone.
(4) Remove electrical leads from APU socket. Tag leads for identification.
(5) Remove power socket.
B. Installation.
(1) Locate power socket placement and install socket.
(2) Identify tagged leads and connect to power socket.
(4) Replace tail cone and battery compartment cover.
2. Adjustment/Test.
A. Refer to Battery/APU Functional Test in section titled Battery/APU Relay.
ELECTRICAL LOAD DISTRIBUTION.
The airplane's electrical load distribution is affected by applying the battery or alternator power to a main
bus from which all of the electrical systems are fed through appropriate circuit breakers. A secondary bus
connected to the main bus by a relay or an auxiliary switch feeds all of the avionics equipment, also through
individual circuit breakers.
DESCRIPTION.
The circuit breaker panel, located in the lower right side of the instrument panel, contains all of the circuit
breakers for the airplane's electrical systems. Each of the push-to-reset type circuit breakers will "pop-out" when
excessive current flows through its circuit. After allowing 1 - 3 minutes for cooling, may be reset by pushing it in
until it clicks. Should a breaker pop out a second time, it should be left out until the cause has been corrected as
a malfunction is indicated. Effective with A/F 0190 and subsequent, the circuit breakers are not only push-to-reset
but are also of the pull-to-disable type, except for the altemator and battery breakers.
The Avionics bus is fed from the main bus by means of the Avionics bus relay which is energized to the
closed position by setting the Radio Master switch to ON. This relay is located under, and forward of the copilot's
panel. A 30-amp fuse located on the relay assembly is provided as protection for the Avionics bus. Since this fuse
is inaccessible in flight. Avionics power can be regained by closing the Auxiliary Radio switch, providing the
normal amount of power to the Avionics bus as an emergency measure, not to exceed 25 amps.
TROUBLESHOOTING.
Refer to Troubleshooting Charts 2401 and 2402.
24-52-00
Page 24-32
Issued: June 1,1995
3C15
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
EQUIPMENT CIRCUIT B R E A K E R S . (For Power Circuit Breal<ers, refer to section titled Power Circuit Breal<ers.)
The equipment circuit breakers are located on the lower right copilot's panel.
1. Removal/lnstallalion.
(2) Disconnect ground side of battery (negative terminal).
(3) Remove "Royalite" panel from circuit breakers section per Chapter 39.
(4) Locate affected circuit breaker on circuit breaker panel.
(5) ' Disconnect leads from lower terminal of circuit breaker, tag for identification
(6) Remove upper screw securing bus bar to circuit breaker. Depending on circuit
breaker location, entire bus bar may have to be removed to allow removal of cir-
cuit breaker.
(7) Remove ring nut and washer from panel side of circuit breaker (front).
(8) Remove circuit breaker.
B424
It »i » J 1 M*
# # #
to >o
00 00 000 00 00
1 ^ ^ ® 6) © ) © © © © © © © 0
'XAV (>•'•I • • ii..* i>t ' I I '«•««! t r i l l ' I f '
• iO-O (o— 1; -•<.« T ^jj, Ml tP*,<M
O 0 0 0 0 0 0 0 0
oooooo
— % II* »•'• H « i 'wii
Ift*- I K W r t M l <10-
o REAR VIEW
BUS BAR
a
11 11
EQUIPMENT IS3
CIRCUIT BREAKERS-
2,5,10 a 15 AMP
Figure 24-7. Equipment Circuit Breakers
24-53-00
Page 24-33

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B. Installation. ; •
(1) Prepare circuit breaker for mounting by removing top terminal screw (as viewed
from rear) and ring mounting nut and washer.
(2) Insert circuit breaker into its mounting hole in panel and secure with ring nut and
washer.
(3) Secure circuit breaker to bus bar with screw removed in Step (1).
(4) Identify tagged leads and connect to lower circuit breaker terminal.
(5) Install "Royalite" panel per Chapter 39.
(6) At battery compartment, connect ground cable to battery (negative terminal).
Close battery compartment access cover.
2. Adjustment/Test.
A. Test.
(1) N/laster Battery ON.
(2) Check circuit breaker operation by pulling out to disable and reset by pushing in
until breaker clicks.
(3) Operate equipment protected by circuit breaker to ensure normal function. Break
circuit by pulling out to disable. Reset circuit breaker. Equipment OFF-ON
ensures normal circuit breaker action.
-NOTE-
The circuit breal<er is factory set to breal( at current value indicated on
breaker and is not adjustable in the field.
AVIONICS BUS RELAY.
The Avionics Bus Relay is located on the right side fonward of the copilot's panel.
(2) Disconnect ground side of battery (negative terminal).
(3) Disconnect electrical leads from relay including jumper to fuse holder. Tag leads
for identification.
(4) Remove relay.
B. Installation.
(1) Identify tagged leads and connect to relay. Connect jumper from fuse holder to
relay.
(2) Install relay.
(3) At battery compartment connect ground cable to battery (negative terminal).
Close battery compartment access cover.
24-54-00
Page 24-34
Issued: June 1,1995
3C17
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
C517
• 1. 3 0 A M P F U S E
:,' 2 . S P I K E ARRESTOR
3. A V I O N I C S B U S R E L A Y
4. G R O U N D I N G STUD
5. A V I O N I C S R E L A Y SHELF
6. F.S. 68.00
7 F.S. 65.00
8. A P P R O X . 2 "
9. A P P R O X . 5 " F R O M E N D O F S H E L F
A / F NO.0365 THRU 0714
VIEW A - A
A / F NO. 0715 AND UP

A / F NO.0365 A N D U P
6
u 9-
Tp AVIONICS
BUS
TO MASTER
RADIO S W .
TO M A I N B U S
VIEW B-B VIEW A - A
Figure 24-8. Avionics Relay
24-54-00
Page 24-35

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
2. Adjustment/Test.
A. Test.
(1) Master Battery switch ON.
(2) Set Master Radio switch to ON, Auxiliary Avionics bus switch OFF.
(3) Tum ON any avionics equipment (example: Com 1 Transceiver).
(4) Turn Master Radio switch O F F . The equipment turned on inStep (3) should go
off. Set Master Radio switch ON. Equipment in Step (3) should go on.
(5) Equipment OFF-ON in Step (4) ensures Avionics bus relay is operating normally.
(6) Verify operation of Auxiliary Radio Master switch by lifting guard and turning
switch ON. Equipment should follow OFF-ON of Steps (2) through (5).
ELECTRICAL CIRCUITS.
The following electrical circuits are grouped functionally. For detailed schematic diagrams refer to
Chapter 91.
DESCRIPTION.
1. Power Plant Circuits.

A. The following functions are electronically monitored by gauges on the instrument panel
which are connected to sensors or transmitting elements within the engine.
(1) Cylinder Head Temperature.
(2) Oil Temperature.
(3) Exhaust Gas Temperature.
(4) Tachometer.
B. Starting System.
(1) Circuits that connect the starting motors to the main electrical power through
starting solenoids, initiated by the ignition switch.
C. Magnetos.
(1) Circuits that enable ignition switch selection of magnetos either-right, left or both
for each engine.
D. Battery System.
(1) Provides 24 volt battery power for engine cranking.
(2) Carries the initial starting load.
(3) Reserve power in case of alternator failure.
E. Altemator System.
(1) Provides the control and regulation of alternator power which energizes all of the
airplane's electrical systems.
(2) Battery charging after engine start.
24-55-01
Page 24-36
issued: June 1,1995
3C19
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
F. Volt/Ammeter.
(1) Monitors the system voltage and load current, either the total alternator output or
individually.
(2) Indicates battery voltage and load when.alternators are off.
2. Auxiliary-Power.
A. Provides for the connection of external power through a relay for the operation of
'the electrical system.
' B. • Engine cranking if batteries are discharged.
3. Fuel System Circuits.
, A. . Fuel Boost Pump; provides fuel pressure for starting and upon demand.
B. Fuel Selector: operates valves to select different fuel sources.
C. Fuel Quantity: accurately monitors the remaining fuel supply.
D. Fuel Flow.
4. • Flight Instruments Circuits.
A. Artificial Horizon.
B. Directional Gyro.
C. Turn and Bank Indicator.
D. Trim.
(1) Elevator trim
(2) - Rudder trim.
E. Trim Indicators.
(1) Elevator trim indication.
(2) Rudder trim indication.
(3) Wing Flap position.
5. Gear Position Warning.

6. Nose Gear Steering and Shimmy Damp Solenoid.
7. Heat.
A. Cabin heating and ventilating.
• B. Defroster.
C. Pilot Heater.
D. Oxygen Regulator Heater (A/F 0001-0130).
8. Turbo Waste Gate Actuators.
A. Circuits used in the operation and control of the turbo charging system which provides
sea-level manifold pressure to approximately 22,000 feet altitude.
-END-
24-55-01
Page 24-37
3Q2Q Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
3C21
CHAPTER
EQUIPMENT/FURNISHINGS
( 1!
3C22
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHAPTER 25 - EQUIPMENT/FURNISHINGS
CHAPTER
SECTION GRID
25-00-00 GENERAL 3D3

25-02-00 Troubleshooting 3D6
25-10-00 FLIGHT/PASSENGER COMPARTMENT 3D7
25-11-00 Standard Interior 3D7
25-11-01 Seats 3D7
25-11-02 Operation of Seats 307
25-11-03 Removal of Seats 3D7
25-11-04 Installation of Seats 3D7
25-11-05 Adjustment 3D7
25-11-06 Covers 3D8
25-11-07 Removal of Seat Royalite Covers 3D8
25-11-08 Installation of Seat Royalite Covers 3D8
25-11 -09 Track Plunger 3D8
25-11-10 Removal of Seat Track Plunger 3D8
25-11-11 Installation of Seat Track Plunger 3D11
25-11-12 Recline Mechanisms 3D11
25-11-13 Removal of Recline Mechanism (Left Center and
Left Rear Seats) 3D11
25-11-14 Installation of Recline Mechanism (Left Center
and Left Rear Seats) 3D11
25-11-15 Adjustment of Recline Mechanism (Left Center
and Left Rear Seats) 3D 14
25-11-16 Removal of Recline Mechanism (Right Side Seats) 3D14
25-11-17 Installation of Recline Mechanism (Right Side Seats) 3D14
25-11-18 Seat Back (Pilot Seat) 3D14
25-11-19 Removal of Seat Back (Pilot Seat) 3D14
25-11 -20 Installation of Seat Back (Pilot Seat) 3D14
25-11-21 Armrest 3D16
25-11 -22 Removal of Armrest 3D16
25-11-23 Installation of Armrest 3D16
25-12-00 Executive Interior 3D16
25-12-01 Seats 3D16
25-12-02 Seat Back (Swivel Seat) 3D16
25-12-03 Removal of Seat Back (Swivel Seat) 3D16
25-12-04 Installation of Seat Back (Swivel Seat) 3D16
25-12-05 Break-Over Bracket (Swivel Seat) 3D16
25-12-06 Removal of Break-Over Bracket (Swivel Seat) 3D16
25-12-07 Installation of Break-Over Bracket (Swivel Seat) 3D18
25 - ContyEffec.
Page -1

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
CHAPTER 25 - EQUIPMENT/FURNISHINGS (cont)
T A B L E O F CONTENTS/EFFECTIVITY
CHAPTER
SECTION GRID
25-10-00 FLIGHT/PASSENGER COMPARTMENT (cont)

25-12-00 Executive Interior (cont)
25-12-01 Seats (cont)
25-12-08 Locl<ing Pin and Bracket (Swivel Seat) 3D18
25-12-09 Removal of Locking Pin and Bracket 3D18
25-12-10 Installation of Locking Pin and Bracket 3D18
25-12-11 Hydrolok Recline Mecfianism (Swivel Seat) 3D18
25-12-12 Removal of Hydrolok Recline Mecfianism 3D18
25-12-13 Installation of Hydrolok Recline Mecfianism 3D18
25-12-14 Table 3D22
25-12-15 Removal of Table Assembly 3D22
25-12-16 Installation of Table Assembly 3D22
25-13-00 Sfioulder Hamess Inertia Reel 3D22
25-13-01 Removal of Sfioulder Harness Inertia Reel 3D22
25-13-02 Installation of Sfioulder Harness Ine'rtia Reel 3D22
25-14-00 Fumisfiings 3D22
25-14-01 Sun Visors 3D22
25-14-02 Glaresfiield 3D22
25-14-03 Removal of Glare sfiield ' 3D22
25-14-04 Installation of Glare shield ' 3E2
25-15-00 Covers and Panels 3E2
25-15-01 Cabin Aft Bulkhead Cover 3E2
25-15-02 Removal of Cabin Aft Bulkhead Cover Assembly 3E2
25-15-03 Installation of Cabin Aft Bulkhead Cover Assembly 3E2
25-15-04 F.S. 176.88 Bulkhead Cover Panel 3E2
25-15-05 Removal of F.S. 176.88 Bulkhead Cover Panel 3E2
25-15-06 Installation of F.S.I 76.88 Bulkhead Cover Panel 3E2
25-15-07 Armrest Panels 3E4
25-15-08 Removal of Left Armrest Panel 3E4
25-15-09 Installation of Left Armrest Panel 3E4
25-15-10 Removal of Right Armrest Panel 3E4
25-15-11 Installation of Right Armrest Panel 3E4
25-15-12 Head Liner Panels/Overhead Duct 3E5
25-15-13 Removal of Headliner Panels and Overhead Duct 3E5
25-15-14 Installation of Headliner Panel and Overhead Duct 3E5
25-15-15 Accent Panels 3E7
25-15-16 Removal of Accent Panels (Right and Left) 3E7
25-15-17 Installation of Accent Panels (Right and Left) 3E7
25-15-18 Oxygen Regulator Accent Panel 3E7
25-15-19 Removal of Oxygen Regulator Accent Panel 3E7
25-15-20 Installation of Oxygen Regulator Accent Panel 3E7
25 - ContTEffec.
Page - 2
Issued: June 1,1995
3C24
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
.CHAPTER 25 - EQUIPMENT/FURNISHINGS (cont)
CHAPTER
SECTION GRID
25-10-00 FLIGHT/PASSENGER COMPARTMENT (cont) —

25-15-00 Covers and Panels (cont)
25-15-15 Accent Panels (cont)
25-15-21 Left Accent Light Panel 3E7
25-15-22 Removal of Left Accent Light Panel 3E7
25-15-23 Installation of Left Accent Light Panel 3E8
25-15-24 Cabin Light Accent Panels 3E8
25-15-25 Removal of Cabin Light Accent Panels 3E8
25-15-26 Installation of Cabin Light Accent Panels 3E8
25-16-00 Moldings 3E8
25-16-01 Windshield Moldings 3E8
25-16-02 Removal of Windshield Moldings 3E8
25-16-03 Installation of Windshield Moldings 3E9
25-16-04 Overhead Window Moldings .3E9
25-16-05 Removal of Overhead Window Moldings 3E9
25-16-06 Installation of Overhead Window Moldings 3E9
25-16-07 Removal of Window Moldings 3E10
25-16-08 Copilot's Window Molding 3E10
25-16-09 Removal of Copilot's Window Molding 3E10
25-16-10 Installation of Copilot's Window Molding 3E10
25-16-11 Right and Left Fonward, and Left Center
Passenger Window Moldings 3E10
25-16-12 Removal of Right and Left Fonward, and
Left Center Passenger Window Moldings 3E10
25-16-13 Installation of Right and Left Forward, and
Left Center Passenger Window Moldings 3E11
25-16-14 Emergency Exit Window Molding 3E11
25-16-15 , Removal of Emergency Exit Window Moldings 3E11
25-16-16 . Installation of Emergency Exit Window Moldings 3E11
25-16-17 Aft Passenger Window Molding 3E11
25-16-18 Removal of Aft Passenger Window Molding 3E11
25-16-19 Installation of Aft Passenger Window molding 3E13
25-16-20 Cabin Door Window Molding 3E13
25-16-21 Removal of Cabin Door Window Molding 3E13
25-16-22 Installation of Cabin Door Window Molding 3E13
25-17-00 Window Shade (700P) 3E13 .
25-17-01 Removal of Window Shade 3E13
25-17-02 . Installation of Window Shade 3E14
25-50-00 BAGGAGE COMPARTMENT 3E14
25 - Cont/Effec.
Page - 3

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
3D2
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
GENERAL.
The equipment and furnishings covered in this chapter consist of the seats and seat hardware, table,
glare shield, shoulder harness inertia reels, carpeting, super soundproofing, interior trim panels, and sun visors in
the flight/passenger compartment; and the carpeting, trim panels and overhead light in the baggage
compartment. The accessory compartment in the nose section requires no maintenance other than that
necessary to maintain the water tight integrity of the door. Refer to Chapter 52 for door maintenance.
The equipment and furnishings in all 600, 601, 601P, 602P and 700P's are designed for ease of
maintenance, and conform to standard aircraft practice. Changes of minor mechanical significance have been
made at year/model changes, and trim material and design will vary with year of manufacture and customer
preference
DESCRIPTION.
The standard interior seat configuration for the 600, 601, 601P, 602P and 700P is shown in Figure 25-1.
Two seats have forward folding baclts; the pilot seat, to allow for ease of entry by copilot and passengers, and the
right side center seat, to allow access to the emergency exit. All seats can be moved forward and aft and all seats
except the pilot seat are equipped with a three position recline mechanism. The positioning and recline levers are
installed on the aisle side of the seats, as is the buckle portion of the seat belt. The seat positioning handle for the
pilot and copilot seats (A/F 0861 and up) is located under the forward edge of the seat. Only the left center and
left rear seats are interchangeable. Although any seat assembly will fit into any Aerostar airplane, several
mechanical changes have been incorporated in the seats making it imperative that the airplane serial number,
seat manufacturer, and assembly number from the data tag on the seat frame be included when ordering
replacement parts.
The executive interior is shown in Figure 25-2. The pilot and copilot seats are identical to those in the
standard interior. The right center seat has a forward folding back, as in the standard interior, and also swivels.
The swivel mechanism is a separiate unit that bolts into the seat frame. In place of the standard three position
recline mechanism, the swivel seat has a Hydrolok mechanism which allows infinite stop positions. The Hydrolok
mechanism is not serviceable in the field and must be returned to the manufacturer for repairs.
Removal/Installation of the swivel seat is the same as for a standard seat.
In the executive interior, the left center seat is replaced with a table which folds away when not in use. A
bracket in each corner of the table assembly is attached to the fuselage structure by means of a screw and
nutplate in the upper fonward bracket, and screws and rivets in the remaining brackets. Refer to Figure 25-10.
The bench seat assembly consists of a standard right center seat and a left rear seat connected together
with appropriate hardware to provide a foldable center armrest. The right side seat back reclines and also folds
forward. Seat back recline levers are located on the outboard sides of the seat. The forward and aft positioning
mechanisms of the two seats are "ganged" together with a single control lever in the center, beneath the seat.
Removal/Installation of the bench seat is basically the same as for a standard seat, the only difference being that
two seats are being removed or installed simultaneously.
The glare shield above the instrument panel is fitted under the defroster diffuser and attached with angle
brackets in the aft comers. The instrument panel trim is held in place with double sided tape.
The carpeting on the cabin floor is held in place by being tucked under the seat tracks. Carpeting on the
heater ducts and other vertical surfaces is attached with 1357 Scotch Grip contact cement.
The Super Soundproofing material is installed under and held in place by the interior trim panels. The
trim above the armrest panels, around the windows, and overhead is held in place by aluminum extrusion
channels riveted to the airframe. Four of these extaision channels also serve as guides for the curtains. Window
moldings on the cabin door and emergency exit are attached with contact cement and double sided tape.
Optional sliding window shades are available on the 700P. These shades are installed on the five
passenger windows and the emergency exit window.
25-01-00
Page 25-01
Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B426
STANDARD INTERIOR
EMERGENCY
EXIT
THESE TWO SEATS ARE

THE ONLY ONES THAT
ARE INTERCHANGEABLE
WITH EACH OTHER
STANDARD ARRANGEMENT
1. PILOT-
2. COPILOT (RECLINING)
3. PASSENGER (RECLINING)
Figure 25-1. Seat Arrangement-Standard Interior
25-01-00
Page 25-02
issued: June 1,1995
3D4
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B427
EXECUTIVE INTERIOR
OPTIONAL ARRANGBCNTS ,
A. PILOT
B. COPILOT (RECLINING)
C. IVRITING TABLE • CSTOl\fED)
D. SVnVEL SEAT (RECLINING)
E.l • BENQ-l SEAT (RECLINING)
F.
Figure 25-2. Seat Arrangement-Executive Interior
25-01-00
Page 25-03
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
TROUBLESHOOTING.
Within the area of equipment and furnishings, the only units which require troubleshooting are the seats
and baggage compartment light. Troubles peculiar to the seats are listed in Chart 2501 along with their probable
causes and suggested remedy, refer to Chapter 33 for lighting troubles.
CHART 2501. TROUBLESHOOTING (SEATS)
Seats will not Seat track plunger not Shorten plunger retracting
slide in tracks. retracting fully. link by bending.
Guide lugs out of ' Adjust guide lugs to same

adjustment level.
Dirt in seat tracks. Clean and wax seat tracks

DO NOT LUBRICATE.
Loose seat rollers. Adjust or replace rollers

as necessary.
Bent seat frame. Adjust seat legs to 11

inches center to center.
Seat tracks loose Adjust seat tracks to 11

or misaligned. inches center to center.
Headrest will not adjust. Dirt in headrest tubes. Clean and lubricate headrest
tubes.
Headrest rods bent. Repair or replace as necessary.
Seat back sticking in Recline mechanism binding. Adjust recline mechanism.

one position.
25-02-00
Page 25-04
Issued: June 1,1995
3D6
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
FLIGHT/PASSENGER COMPARTMENT.
STANDARD INTERIOR.
SEATS.
OPERATION OF SEATS.
Seat Guide Lugs (refer to Figure 25-3) at eacfi comer of seat frame are adjusted to retain lower end of
lug midway between upper and lower inside surface of track slot. (Refer to Figure 25-3.) Whien adjusted properly,
tfie lug will not be riding on eittier tfie upper or lower surface during seat position movement. Tfie roller-spacer
(refer to Figure 25-3) that is located at upper part of lug contacts the side surfaces of track slot to provide lateral
stability to seat. All movement of seat should be on rollers, which contact top surface of track. Thus, the roller
spacer retains the seat in the proper position laterally along the track, and the lower lug portion will retain the seat
vertically by contacting the upper slot surface when accelerated in that plane. Adjustment of the lugs is normally
done at the factory before seat installation.
The only other adjustment required for proper seat operation is the position of the seat-stops, or plunger
(refer to Figure 25-3). These consist of a cylindrical projection riding above each track during seat position
adjustment. The plungers should be free to fall into the stop-hole when the spring loaded retracting handle is
released. If one or the other plunger is riding on an edge of the track and is not centered, it will not be able to fall
freely into the top hole, allowing seat to slide past desired position.
The track slots should be clean and free of dirt and debris that might interfere with the proper operation of
the guide lugs and plungers. Waxing the track will also insure smooth, easy movement of seats.
REMOVAL OF SEATS. (Refer to Figure 25-3.)
1. Loosen top nuts on retaining lugs.

2. Align aft guide lugs with holes in seat tracks and lift rear of seat clear of tracks.
. 3. . Align retaining lugs with holes in seat tracks and lift rear of seat until retaining lugs clear seat
tracks.
4. Align rear guide lugs with holes in seat tracks and lift seat from tracks.
INSTALLATION OF SEATS.
1. Lower forward guide lugs into holes in seat tracks.

2. Slide seat forward and lower retaining lugs into holes in seat tracks.
3. Slide seat forward and lower rear guide lugs into seat tracks.
4. Tighten top nuts on retaining lugs.
ADJUSTMENT.
1. Guide lugs. (Refer to Figure 25-3.)

A. Assemble guide lug to seat frame, leaving nuts (4) loose.
B. Set lug (2) approximately in center space of track by estimating vertical distance that lug
penetrates into track. Position of lug is controlled by adjusting nuts (4) as required.
C. When lug position is correct, secure by tightening top locking nut.
25-11-05
Page 25-05
2Qy Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
2. Plungers. (Refer to Figure 25-3.) . . .
A. With seat installed per Chapter 25, lift retracting handle to release seat, and move seat to
full fonward position.
B. Release handle, push seat aft. Plungers should fall freely into first stop hole.
C. If seat skips over stop and continues moving aft, lateral adjustment of seat frame is
required.
D. Moving seat along track, view position of plungers with respect to stop hole. One or both
may be slightly off-center.
- E. When it is, determined which direction the seat frame(s) must be moved to recenter the
plunger(s), strike the frame at plunger location with a hammer to bend frame a slight
amount in required direction. One blow of hammer is usually sufficient, but more may be
necessary.
F. If trouble is still encountered after performing Step E, it may be necessary to ream stop
hole slightly for plunger to fall freely.
G. • Insure plungers fall freely into each stop position, or repeat steps E and F until proper
operation of plungers is obtained.
—NOTE—
Usually, correcting plunger position at one stop will bring plunger into
alignment with track enabling proper operation at all stop positions.
COVERS.
REMOVAL O F SEAT "ROYALITE" COVERS.
1. Remove seat.
2. Remove roll pins from seat positioning and recline levers and remove levers. Refer
to Figure 25-3.
3. Remove screws securing "Royalite" covers to seat frame and remove covers.
INSTALLATION OF SEAT "ROYALITE" COVERS.
1. Position "Royalite" covers onto seat frame and install attaching screws.
2. Install seat positioning and recline levers and secure with roll pins.
TRACK PLUNGER.
REMOVAL
1. OF SEAT
RemoveTRACK
seat. PLUNGER. (Refer to Figure 25-3 )
2. Remove "Royalite" covers.
3. Remove roll pin securing plunger retracting link to plunger.
4. Drop spring and plunger out through bottom of seat frame.
25-11-10
Page 25-06
Issued: June 1,1995 3D8

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
C145 . . .
1. S E A T T R A C K
2. G U I D E L U G
3. R O L L E R S P A C E R
4. NUT
5. R O L L E R .
6. BOLT
7. N U T
8. FLOOR
9. A N C H O R , S C R E W . W A S H E R , N U T
TRACK DETAIL E N D V I E W
1. F O R W A R D G U I D E L U G
2. S P A C E R
3 NUT
4. RETAINING L U G
5. P L U N G E R R E T R A C T I N G LINK
6. PLUNGER
7. R E A R G U I D E L U G
8 ROLLER
9. R O L L P I N
10. F L A T H E A T P I N . W A S H E R . C O T T E R P I N
Figure 25-3. Seat Hardware
25-11-10
Page 25-07
3D9
issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
Figure 25-3. Seat Hardware (cont)
25-11-10
Page 25-08
Issued: June 1,1995
3D10
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
INSTALLATION OF SEAT TRACK PLUNGER.
1. Install spring and plunger into bottom of seat frame.

2. Install retracting link into plunger and install roll pin.
3. Install "Royalite" covers.
RECLINE MECHANISMS.
Due to differences between left and rigfit side seat frame designs, two. types of recline mecfianisms are
used in the seats. The left center and left rear seats have the type shown in Figure 25-4. This type has an arm
extending from the recline mechanism toward the center of the seat. The seat back return spring connects
between this arm and the seat positioning lever rod. Spring tension on the arm ip some cases, causes the'reclirie
mechanism to tilt outward at the lower edge resulting in binding. Adjustment of the recline mechanism in the left
center and left rear seats is included in this chapter.
The right side seats have the recline mechanism shown in Figure 25-5. This type mechanism has no
spring arm. The seat back return spring connects directly to the recline mechanism, pulling straight downward,
alleviating binding.
REMOVAL OF RECLINE MECHANISM (Left Center and Left Rear Seats). (Refer to Figure 25-4.)
1. Remove seat.
3. Disconnect recline mechanism clevis from seat back frame.
4. Disconnect seat back return spring from spring arm.
5. Remove bolt and bushing attaching recline mechanism to seat frame, and remove recline mech-
anism.
INSTALLATION OF RECLINE MECHANISM (Left Center and Left Rear Seats).
1. . Connect seat back return spring to spring arm.

2. Install recline mechanism, bolt and bushing onto seat frame.
3. . Connect recline mechanism clevis to seat back frame.
4. . Install "Royalite" covers.
25-11-14
Page 25-09
Issued:June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B425
1. RECLINE MECHANISM 7. JAM NUT

2. BUSHING 8. CLEVIS
3. WASHER 9. CLEVIS PIN
4. BOLT 10. SEAT BACK FRAME
5. NUT 11. SEAT BOITCM FRAME
6. SEAT BACK RETURN SPRING 12. MOUNTING BRACKET
Figure 25-4. Reciine lUlechanism (Left Center and Left Rear Seats)
25-11-14
Page 25-10
Issued: June 1,1995
3D12
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B430
1. RECLINE MECHANISM 7. J A M NUT

2. BUSHING 8. CLEVIS
3. WASHER 9. CLEVIS PIN
4. BOLT 10. S E A T BACK FRAME
5. NUT 11. S E A T BOTTOM FRAME
6. SEAT BACK RETURN SPRING 12. MOUNTING BRACKET
Figure 25-5. Recline Mechanism (Riglit Side Seats)
-. 25-11-14
Page 25-11
2Q-|2 . Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
ADJUSTMENT OF RECLINE MECHANISM (Left Center and Left Rear Seats). (Refer to Figure 25-4.)
1. Remove seat.
2. Place seat upside-down on work bencfi.
3 Loosen jam nut on recline mechanism rod.
4 Press down on spring arm to force recline mechanism away from seat frame, tight against bolt
head washer.
5. Tighten jam nut.
6. Release spring arm. Recline mechanism should be centered between mounting bracket and bolt
head washer. Recline mechanism should operate freely with no binding.
REMOVAL OF RECLINE MECHANISM (Right Side Seats). (Refer to Figure 25-5.)
1. Remove seat.
2. Place seat back in fully reclined position.
4. Disconnect recline mechanism clevis from seat back, and place recline mechanism in upright
position to relieve spring tension.
5 Disconnect seat back return spring.
6 Remove bolt and bushing attaching recline mechanism to seat frame and remove recline mecha-
nism.
INSTALLATION OF RECLINE MECHANISM (Right Side Seats).
1. Connect seat back return spring to recline mechanism

2. Install recline mechanism, bolt and bushing onto seat frame.
3. Connect recline mechanism clevis to seat back.
4. Install "Royalite" covers.
SEAT BACK (Pilot Seat).
REMOVAL OF SEAT BACK (Pilot Seat). (Refer to Figure 25-6.)
1 Open "Velcro" fastener at base of seat back.

2 Carefully push seat cover material away from break-over bracket, and remove bolts attaching
seat back to break-over bracket
3. Remove pivot bolt from opposite hinge.
4. Pull seat back up and out.
INSTALLATION OF SEAT BACK (Pilot Seat).
1. Position seat back onto break-over bracket and hinge, and install attach bolts.
2. Close "Velcro" fastener at base of seat back.
25-11-20
Page 25-12
Issued: June 1,1995
3D14
600/601/601P/602P/700P
MAINTENANCE MANUAL
B430
• 1. SEAT BACK FRA>E

2. WASHER
5. BREAK-OVER BRACKET
4 . STOP BOLT
5. ATTACH BOLT
6 . SPACER
7. BACK LOCKING CLIP
8. NUT -
9. SEAT BOTTOM FRAME
10. PIVOT BOLT
Figure 25-6. Piiot's Seat Breai<-Over Bracitet
25-11-20
Page 25-13
3D15 issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
ARMREST.
REMOVAL OF ARMREST. (Refer to Figure 25-7.)
1. Remove seat.
2. Open "Velcro" fastener at base of seat bacl<.
3. Reach up inside seat back and locate armrest bar under foam padding.
4. Cut foam to allow access.
5. Carefully separate foam and disconnect spring from armrest bar.
6. Remove roll pin from inboard end of bar and pull bar out.
INSTALLATION O F ARMREST.
1. Install armrest bar into support bracket..

2. Install roll pin into inboard end of armrest bar.
3. Connect spring to armrest bar.
4. Close "Velcro" fastener at base of seat back.
EXECUTIVE INTERIOR.
SEATS
SEAT BACK (Swivel Seat).
REMOVAL O F S E A T B A C K (Swivel Seat).
1. Disconnect "Hydrolok" from break-over bracket. Refer to Figure 25-8.

2. Remove pivot bolts from seat back.
3. Lift seat back up and out. Break-over bracket will come out with seat back.
INSTALLATION O F S E A T BACK (Swivel Seat).
1. Position seat back (with break-over bracket installed) onto seat.

2. Install pivot bolts.
3. Connect "Hydrolok" to bottom of break-over bracket.
BREAK-OVER B R A C K E T (Swivel Seat).
REMOVAL OF BREAK-OVER B R A C K E T (Swivel Seat).
1. Remove seat back.

2. Remove bolt securing break-over bracket to seat back and remove break-over bracket. Refer to
Figure 25-8.
25-12-06
Page 25-14
Issued: June 1,1995
3D16
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
B432
1. ARMREST
2. ARMREST BAR
3. ARMREST SUPPORT BRACKET „
4. SEAT BACK FRAME - "AISLE. SIDE
5. ROLL PIN
6. SPRING
Figure 25-7. Seat Bacic Armrest
25-12-06
Page 25-15
Issued: June 1,1995
3017
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE.MANUAL
INSTALLATION OF BREAK-OVER B R A C K E T (Swivel Seat).
1. Position break-over bracket onto lower left corner of seat back.

2. Install pivot bolt and upper and lower stop bolts. Refer to Figure 25-8.
3. Install seat back.
LOCKING PIN AND B R A C K E T (Swivel Seat).
REMOVAL OF LOCKING PIN AND B R A C K E T (Swivel Seat).
1. Remove recline and swivel mechanism levers, and upper "Royalite" cover.
2. Remove pivot bolt and separate swivel mechanism. Refer to Figure 25-9.
3. Remove pin connecting locking pin to actuating lever.
4. Remove bolts attaching locking pin bracket to upper swivel plate, and remove bracket, locking
pin and spring.
INSTALLATION OF LOCKING PIN AND BRACKET (Swivel Seat).
1. Install roll pin, washer and spring onto locking pin. Refer to Figure 25-9.
2. Install locking pin into bracket, position bracket onto upper swivel plate and install bracket attach
bolts.
3. Connect locking pin to actuating lever.
4. Position upper swivel plate onto lower swivel plate and install pivot bolt.
5. Install upper "Royalite" cover and recline and swivel mechanism levers.
"HYDROLOK" RECLINE MECHANISM (Swivel Seat).
REMOVAL OF HYDROLOK RECLINE MECHANISM (Swivel Seat).
1. Place seat in fully reclined position and lock.

2. Remove recline and swivel mechanism levers, and upper "Royalite" cover.
3. Disconnect "Hydrolok" from break-over bracket on seat back frame. Refer to Figure 25-8.
4. Remove "Hydrolok" actuating lever.
5. Remove nut and spacer from fonward end of "Hydrolok". Slide "Hydrolok" aft and remove.
INSTALLATION OF HYDROLOK RECLINING MECHANISM (Swivel Seat).
1. Lock "Hydrolok" in compressed position.

2. Position "Hydrolok" onto seat frame and install spacer and nut onto fonward end. Refer to Figure
25-8.
3. Connect "Hydrolok" to break-over bracket.
4. Install "Hydrolok" actuating lever.
5. Install upper "Royalite" cover and recline and swivel mechanism levers.
25-12-13
Page 25-16
Issued: June 1,1995 3018

600/601/601P/602P/700P
B433
1. IIYDROLOK MEOIANISM
2. HYDROLOK ACTUATING LEVER
3. ACTUATING <LEVER SET SCREW
4. SPACER
5. RECLINE LEVER
6. SEAT BACK FRAME
7. BREAK-OVER BRACKET
8. PIVOT BOLT
9. STOP BOLT
Figure 25-8. Swivel Seat Break-Over Bracket and "Hydrolok"
25-12-13
Page 25-17

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B434
1. PIVOT BOLT
2. WASHER
3. PIVOT BOLT BUSHING
4. PIVOT BOLT NUT
5. UPPER SWIVEL PLATE
6. LOWER SWIVEL PLATE
7. SPACER
8. SWIVEL LEVER
9. LOCKING PIN ASSEMBLY
10. ROLL PIN
1. ACTUATIMG LEVER
2. PIN
3. LOCKING PIN
4. WASHER
5. COTTER KEY
6. LOCKING PIN BRACKET
7. SPRING
8. WASHER
9. ROLL PIN
10. BRACKET ATTACH BCLT
11. WASHER
12. NUT
13. UPPER SWIVEL PLATE
Figure 25-9. Swivel lUlechanism
25-12-13
Page 25-18
3D20
Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B434
1 1.. TOP ASSEMBLY
Figure 25-10. Tabie Assembiy
25-12-13
Page 25^19

AEROSTAR AIRCRAFT
.600/601/601P/602P/700P
MAINTENANCE MANUAL
TABLE. , , .
REMOVAL OF T A B L E ASSEMBLY. (Refer to Figure 25-10.)
1. Remove annrest and accent panels forward and aft of table assembly.
2. Remove screws attacfiing table mounting bracl<ets to fuselage structure, and remove table
assembly.
INSTALLATION OF T A B L E ASSEMBLY. (Refer to Figure 25-10.)
1. Position table assembly and install attacfi screws into mounting brackets.
2. Install accent and armrest panels fonA/ard and aft of table assembly.
SHOULDER HARNESS INERTIA REEL.
REMOVAL OF SHOULDER HARNESS INERTIA REEL. (Refer to Figure 25-11)
1 Remove inertia reel cover.

2 To gain access to mounting screws, pull shoulder harness out until fully extended.
3. Remove mounting screws, and remove inertia reel.
INSTALLATION OF SHOULDER HARNESS INERTIA REEL.
1. Remove inertia reel cover.

2. Pull shoulder harness out until fully extended.
3. Position inertia reel and install mounting screws.
4. Install inertia reel cover.
FURNISHINGS.
SUN VISORS. (Refer to Figure 25-12.)
The tinted sun visors are attached to the airframe above the windshield with adjustable tension mounting
brackets. Tension is adjusted by tightening or loosening the bracket pivot bolt.
G L A R E SHIELD.
REMOVAL O F G L A R E SHIELD. (Refer to Figure 25-13.)
1. Remove nuts attaching glare shield to angle brackets.

2 Remove annunciator panel trim panel.
3 Pull glare shield aft slightly to clear annunciator panel, then lift up to clear magnetic compass.
4. Pull glare shield aft, from under defroster defuser and remove.
25-14-03
Page 25-20
Issued: June 1,1995
3D22
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B438
Figure 25-11. Inertia Reel (Cover Removed)
25-14-03
Page 25-21
Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B436
Figure 25-12. Sun Visors
24-14-03
Page 25-22
Issued: June 1,1995 3D24

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B437
Figure 25-13. Glareshield Angle Bracket
2^14-03
Page25r23
Issued: June 1,1995
3E1
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
INSTALLATION O F G L A R E SHIELD.
1. Slide forward edge of glare shield under defroster defuser.

2. Lower glare shield over magnetic compass.
3. Slide glare shield forward over annunciator panel.
4. Install annunciator trim panel.
5. Install nut attaching glare shield to angle brackets.
COVERS AND PANELS.
CABIN AFT BULKHEAD COVER.
REMOVAL OF CABIN A F T BULKHEAD COVER ASSEMBLY. (Refer to Figure 25-15.)
1. Remove hat rack carpeting.

2. Remove air duct cover(s).
3. Remove inboard center screws from center panel.
4. Pull cover assembly fonward and out.
INSTALLATION OF CABIN AFT BULKHEAD COVER ASSEMBLY.
1. Position cover assembly onto cabin aft bulkhead.

2. Install attach screws in center panel.
3. Install air duct cover(s).
4. Install hat rack carpeting.
F U S E L A G E STATION 176.88 BULKHEAD COVER PANEL.
REMOVAL OF F U S E L A G E STATION 176.88 BULKHEAD COVER PANEL. (Refer to Figure 25-15.)
1. Remove air duct cover(s).

2. " Remove attach screws from center of cover panel.
3 Pull cover panel up from behind seat tracks.
4 Pull cover panel down to release from under forward edge of hat shelf and remove cover.
INSTALLATION O F F U S E L A G E STATION 176.88 BULKHEAD COVER PANEL.
1. Slide top edge of cover panel up under forward edge of hat shelf.
2. Place bottom edge of cover panel behind aft ends of seat tracks.
3. Install air duct covers.
4. Install cover panel attach screws.
25-15-06
Page 25-24
Issued: June 1,1995
3E2
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B440
Figure 25-14. Armrest Panel Installation
25-15-06
Page 25-25
Issued: June 1,1995
3E3
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
ARMREST PANELS.
REMOVAL OF LEFT ARMREST PANEL. (Refer to Figure 25-15.)
1. Remove screws in fonward edge of armrest panel near aft edge of cabin door.
2. Press upper portion of armrest downward to release from extrusion channel.
3. Lift armrest up and out.
INSTALLATION OF LEFT ARMREST PANEL.
1. Slide clips at bottom edge of armrest panel over upper edge of heater duct Refer to Figure 25-14.
2. Press upper edge of annrest panel downward and insert under extrusion channel.
3. Install screws at fonward edge of armrest panel near aft edge of cabin door.,
REMOVAL OF RIGHT ARMREST PANEL.
—W07E—
The forward edge of the right armrest panei is fitted very tightly near the
instrument panel and cannot be released from the extrusion channel
unless first slid aft.
1. Press upper aft portion of armrest panel downward to release from extnjsion channel.
2. Pull armrest panel aft until forward edge is accessible.
3. Press forward section downward to release from extrusion channel.
4. Lift amnrest panel up and out.
INSTALLATION OF RIGHT ARMREST PANEL.
1. Slide forward clip at bottom edge of armrest panel over upper edge of heater duct, approximately
6 inches aft from instrument panel.
2. Slide panel forward to microphone bracket.
3. Press upper edge of panel above forward clip downward, and insert under extrusion channel.
4. Slide remaining clips over heater duct and slide panel forward to instrument panel.
5. Press remainder of panel upper edge downward and insert into extrusion channel.
25-15-11
Page 25-26
Issued: June 1,1995 3E4
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
HEADLINER PANELS/OVERHEAD DUCT.
REMOVAL OF HEADLINER PANELS AND OVERHEAD DUCT.
1. Remove sun visors. ••• '• -

2. Remove cabin loudspeaker per Chapter 23. ' .
3. Remove moldings from pilot's and copilot's overhead windows. . '
4. Remove overhead light accent panels.
5. Drill out rivets attaching headliner/light panel extrusion channel to airframe.
—CAUTION—,
" The headliner/light panel extrusion channel is boned to the headliner. Do
not try to remove extrusion channel by itself; damage to the headliner will
result.
6. Pull headliner outboard and remove.

7. Remove cabin aft bulkhead cover assembly.
8. Remove screws attaching aft end of overhead duct to blower plenum.
—CAUTION—
The aft end of the overhead duct is bonded to the blower plenum with RTV
silicone rubber adhesive sealant. This seal must be broken, or the overhead
duct may l>e damaged upon removal. - '
9. Break seal between aft end of overhead duct and blower plenum.
10. Drill out rivets attaching overhead duct to airframe.
11. Carefully lower overhead duct until overhead map light wiring is accessible.
12. Disconnect knife splices in map light wiring.
13. Lower and remove overhead duct.
14.
Remove sealant from aft end of overhead duct and blower plenum.
INSTALLATION OF HEADLINER PANELS AND OVERHEAD DUCT:

1. Apply RTV silicone rubber adhesive sealant (or equivalent) to area of blower plenum where
plenum and overhead duct join.
2. Position overhead duct, and install screws attaching duct to blower plenum.
3. Connect map light wiring.
4. Install rivets attaching overhead duct to airframe.
5. Position headliner and install rivets attaching headliner/light panel extrusion channel to airframe.
6. Install overhead light/accent panel.
7. Install cabin aft bulkhead cover assembly.
8. Install pilot's and copilot's overhead window moldings.
9. Install cabin loudspeaker per Chapter 23.
10. Install sun visors.
25-15-14
. Page 25-27
3E5 lssued:.June 1,1995

AEROSTAR AIRGRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
1. EXTRUSION CHANNEL
2. EXTRUSION CHANNEL/CURTAIN GUIDE
' /J 3 ARMREST PANEL
4. ACCENT PANEL
5. WINDOW MOULDING.
6 TRIM PANEL
7. SEAT TRACKS
8. EMERGENCY EXIT HANDLE COVER
9. HEADLINER PANEL
10 BULKHEAD COVER PANEL
FS. 176 88
11. AIR DUCT COVER (600, 601
RIGHT SIDE ONLY. 601 P. 602P
AND 700P BOTH SIDES)
12. CABIN AFT BULKHEAD COVER
ASSEMBLY
13 ACCENT'LIGHT PANEL (OXYGEN
REGULATOR PANEL 601, 601 P. 602P.
AND 700P)
14 OVERHEAD DUCT
15 WINDSHIELD MOULDINGS
1 2
Figure 25-15. Interior Trim
25-15-14
Page 25-28
Issued: June 1,1995 3E6
AEROSTAR AIRCRAFT
600/60.1/601 P/602P/700P
MAINTENANCE MANUAL
ACCENT PÂNELS.
Both the left and right accent panels are divided into two sections. The forward section of the right accent
panel houses the oxygen system gauges and regulator (if installed), and two small lights which aid in illuminating
the instrument panel. The fonward section of the left accent panel, fonward of the cabin door, also houses two
lights.
REMOVAL OF A C C E N T PANELS (Right and Left).
1. Remove armrest.
2. Drill out rivets and remove armrest extrusion channel.
3. Pull accent panel down to release from upper extrusion channel, and remove.
INSTALLATION OF A C C E N T PANELS (Right and Left).
1. Insert upper edge of accent panel under extrusion channel.

2. Position arrnrest extrusion channel onto lower edge of accent panel and attach with pop rivets.
OXYGEN REGULATOR A C C E N T PANEL.
REMOVAL OF OXYGEN REGULATOR ACCENT PANEL.
1. Remove oxygen regulator handle, gauge bezels and lenses, and cover plate per Chapter 35.
2. Press upper edge of accent panel downward to release from extrusion channel.
3. ' Disconnect and tag light wiring, and remove accent panel.
INSTALLATION OF OXYGEN REGULATOR ACCENT PANEL.
1 Connect wiring to lights in accent panel. Refer to Chapter 91.

2. Position accent panel over oxygen regulator and gauges with lower edge in extrusion channel.
3. Press upper edge of panel downward and insert into upper extrusion panel. .
4. Install oxygen regulator cover plate, lenses and bezels, and regulator handle per Chapter 35.
LEFT ACCENT/LIGHT PANEL.
REMOVAL OF LEFT ACCENT/LIGHT PANEL.
1. Move cabin door windlace outward and slide accent panel aft.
2. Disconnect and tag light wiring, and remove accent panel.
25-15-22
Page 25729
. Issued: J u n e l , 1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
INSTALLATION OF LEFT ACCENT LIGHT PANEL.
1. Connect ligtit wiring. Refer to Chapter 91.
2. : Slide panel fonward into extrusion channels from cabin door.
CABIN LIGHT/ACCENT PANELS.
REMOVAL OF CABIN LIGHT/ACCENT PANELS.

1. Remove cabin aft bulkhead cover assembly.
2. Remove inertia reels.
3. Remove trim panels at fonward and aft edges of windows.
4. Remove copilot and right side passenger window moldings.
5. Remove left side passenger window moldings.
6. Drill out rivets attaching upper extrusion channel/curtain guides to airframe, and remove upper
extrusion channel/curtain guides.
7. Carefully lower light panel until light wiring is accessible.
8. Disconnect knife splices in light wiring, and remove panel.
9. Pull bulbs out from back of reflector cups, and retain for installation into replacement panel.
INSTALLATION OF CABIN LIGHT/ACCENT PANELS.
1. Install bulbs into reflector cups.

2. Connect light wiring.
3. Position light panel and upper extrusion channel curtain guide and install rivets attaching extru-
sion channel curtain guide to airframe.
4. Install window moldings.
5. Install trim panels at fonward and aft edges of window moldings.
6. Install inertia reels.
7. Install cabin aft bulkhead assembly.
MOLDINGS.
WINDSHIELD MOLDINGS.
REMOVAL OF WINDSHIELD MOLDINGS.
1. Remove nuts from screws attaching glare shield to angle brackets.

2. Remove annunciator panel trim.
3. Pull glare shield aft, clear of annunciator panel. Lift glare shield up, and rest on top of magnetic
compass.
4. Remove sun visors.
5. Remove screw at top center of windshield moldings.
6. Remove screw in windshield molding near forward end of upper extrusion channel/curtain
guide.
7. Remove glare shield angle brackets.
8. Lift windshield molding out of lower extrusion channel/curtain guide and remove.
25-16-02
Page 25-30
Issued: June 1,1995
3E8
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
INSTALLATION OF WINDSHIELD MOLDINGS.
1. Place bottom edge of windsfiield molding into lower extrusion channel curtain guide.
2. Install screw into molding near fonward end of upper extrusion channel/curtain guide."
3. Install screw at top center of windshield moldings.
5. Install glare shield angle brackets.
6. Reposition glare shield, and install nuts onto screws attaching glare shield to angle brackets.
7. Install annunciator panel trim.
OVERHEAD WINDOW MOLDINGS.
REMOVAL OF OVERHEAD WINDOW MOLDINGS.
1. . ' Remove sun visors.

2. Remove screw at top center of windshield moldings:
3. Remove screws in windshield moldings near forward end of upper extrusion channel/curtain
guide. Pull molding forward out of way.
4. Slide overhead-window molding fon/vard to release front aluminum trim strip between molding
and headliner panel.
5. Pull center of molding forward and aft edges downward and.outward to release from overhead
duct extnjsion channel.
6. Push molding inboard to release from upper extrusion channel/curtain guide; and remove.
INSTALLATION OF OVERHEAD WINDOW MOLDINGS. ^
1. Place outboard edge of overhead window molding into upper extnjsion channel curtain guide.
2. Bow molding downward and insert inboard edge into overhead duct extrusion channel.
3. Install aluminum trim strip onto aft edge of molding, and slide molding aft until flush with head
liner panel. -
4. Install screws in overhead window moldings near forward end of upper extrusion channel/cur-
tain guide.
5. Install screw at top center of windshield molding.
25-16-06
Page 25-31
3E9 issued: June 1,1995

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
REMOVAL OF WINDOW MOLDINGS.
Procedures for removing window moldings vary, depending upon wfiich window the molding is being
removed from, and whether the airplane is equipped with oxygen or not. If the airplane is equipped with oxygen,
the oxygen mask outlets on the trim panels between windows must be removed, per Chapter 35 prior to removing
the trim panel itself. Window moldings on the emergency exit and cabin door are attached with contact cement
and double sided tape.
COPILOT'S WINDOW MOLDING.
REMOVAL OF COPILOT'S WINDOW MOLDING.
1. Remove outside air temperature gauge per Chapter 39.

2. Remove copilot's.inertia reel.
3. Remove trim panel between copilot's window and forward right side passenger window.
4. Remove screw from windshield molding adjacent to upper fonward corner of copilot's window.
5. Remove bottom edge of windshield molding from extnjsion channel;
6. Pull center of molding's vertical sides inward and down to release from upper extrusion channel.
7. Lift window molding out of lower extrusion channel and remove.
INSTALLATION O F COPILOT'S WINDOW MOLDING.
1. Place lower edge of molding into lower extnjsion channel.

2. Bow molding inward and insert upper edge into upper extrusion channel.
3. Position molding and install bottom edge of windshield molding into extrusion channel.
4. Install screw into windshield molding, adjacent to upper forward comer of copilot's window.
5. Install trim panel between copilot's window and fonward right side passenger window.
6. Install copilot's inertia reel.
7. Install outside temperature gauge per Chapter 39.
RIGHT AND LEFT FORWARD, AND LEFT CENTER PASSENGER WINDOW MOLDINGS.
REMOVAL OF RIGHT AND LEFT FORWARD, AND LEFT CENTER PASSENGER WINDOW MOLDINGS.
1. Remove copilot's inertia reel (forward passenger windows only).

2. Remove trim panels at forward and aft edges of window.
3. Pull center of molding's vertical sides inward and down to release from upper extrusion channel.
25-16-12
Page 25-32
issued: June 1,1995 3E10

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
INSTALLATION OF RIGHT AND LEFT FORWARD, AND LEFT CENTER PASSENGER WINDOW MOLDINGS.
1.' Place lower edge of window molding into lower extrusion channel.
2. Bow molding inward and insert upper edge into upper extrusion channel.
3. Position molding and install trim panels at forward and aft edges of window. ;
4. Install copilot's inertia reel (forward passenger windows only).
EMERGENCY EXIT WINDOW MOLDING.
REMOVAL OF EMERGENCY EXIT WINDOW MOLDINGS.
1. Remove emergency exit per Chapter 52.

2. Insert a thin blade between molding and emergency exit frame.
3. Draw blade around entire circumference of molding to separate molding from emergency exit
frame.
4. Remove double-sided tape from emergency exit frame and back of molding.
5. Clean contact cement from emergency exit frame and back of molding with Scotch Grip Solvent
No. 2 (or equivalent).
INSTALLATION OF EMERGENCY EXIT WINDOW MOLDING.
1. Apply 1357 Scotch Grip contact cement (or equivalent) to areas of emergency exit frame and
window frame where frame and molding join. Allow contact cement to dry:until.tacky. '
2. Apply double-sided tape to emergency exit frame per Figure 25-16.
3. - ' ' ' P r e s s window molding onto emergency exit frame and allow 5-10 minutes drying time.
4. Install emergency exit per Chapter 52.
AFT PASSENGER WINDOW MOLDING.
REMOVAL OF A F T PASSENGER WINDOW MOLDINGS.
1. Remove cabin aft bulkhead cover assembly. ^

2. Remove trim panel at forward edge of window.
3. Pull center of molding's forward vertical side inward, down, and forward to release upper edge
from upper extrusion channel.
25-16-18
Page 25-33
Issued: June 1,1995
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
B434
Figure 25-16. Appiication of Double Sided Tape Attaching

Emergency Exit Window lUlolding
25-16-18
Page 25-34
issued: June 1,1995
3E12
AEROSTAR AIRGRAFT
600/601/601 P/602P/r00P
MAINJENANGE MANUAL
INSTALLATION OF AFT PASSENGER WINDOW MOLDINGS. '^T'^-l'^J^^'.r '•': '^K^C
1. Place lower edge of window molding into lower extrusion cfiannel as far fonward as possible.
2. Bow molding inward and insert upper edge of molding into upper extrusion channel.
3. Slide hiolding aft into position and install trim panel at forward edge of window molding.
4. Install cabin aft bulkhead cover assembly.
CABIN DOOR WINDOW MOLDING.
REMOVAL OF CABIN DOOR WINDOW MOLDING.
1. - Remove upper portion of cabin door per Chapter 52.

2. Insert a thin blade between molding and door frame.
3. " Draw blade around entire circumference of molding to separate molding from door frames.
4. Remove double-sided tape from door frame and back of molding.
5. Clean contact cement from door frame and back of molding with Scotch Grip Solvent No. 2 (or
equivalent).
INSTALLATION OF CABIN DOOR WINDOW MOLDING.
1. Apply 1357 Scotch Grip contact cement to areas of door frame and window molding where
frame and molding join. Allow contact cement to dry until tacky.
2. Apply double-sided tape to door frame per figure 25-17.
3. Press window molding onto door frame and allow 5-10 minutes drying time.
4. ' Install upper portion of cabin door per Chapter 52.
WINDOW SHADE (700P).
Window shades are optional on the five passenger windows and the emergency exit door on the 700P.
REMOVAL OF WINDOW SHADE.
1. Push shade all the way up.

2. Remove the molding from around the window per instructions in this chapter.
—NOTE—
When pulling upper side of molding inboard, use care not to allow rolled
up shade assembly to fall out.
~
3. Slide shade out of the top of the shade tracks and remove shade assembly.
25-17-01;
Page 25-35
3E13 , Issued: June 1,1995

AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL
INSTALLATION O F WINDOW SHADE.
—NOTE—
If shade comes unrolled, roll it around an 11/16 inch dowel. Remove dowel
before installing shade.
Shade tracks are glued to window and shade guides are glued to outboard
side of molding with a mixture of ABS plastic shavings or sawdust and
acetone. To a volume of acetone add 20-40% (by weight) of ABS shavings.
Mix until shavings are thoroughly dissolved. Apply cement, pin surfaces
immediately and apply pressure using suitable weights or clamping
devices.
1. Slide shade into the top of the shade tracks.

2. Insure that rolled up portion of shade assennbly is in both guides (at the upper outboard side of
the molding).
3. Reinstall the molding per instructions in this chapter.
4. Check installation by moving shade up and down.
B A G G A G E COMPARTMENT
The furnishings in the baggage compartment consist of trim panels, carpeting and an overhead light.
The aft bulkhead panel is attached with twist-lock fasteners to allow easy access to components located
in the tail section, such as the heater and air conditioner, which require periodic servicing. The remaining trim
panels are attached with Velcro fasteners. Carpeting in the baggage compartment is glued in place.
The baggage compartment light is automatically operated by a pressure switch in the upper right corner
of the door frame. Two styles of light assembly are available: a standard equipment model, shown in Figure 25-
19 which consists of a bulb and reflective backing or a covered model, shown in Figure 25-20. The light cover (if
installed) is removed by pulling downward. Removal and maintenance of either light assembly is obvious upon
inspection.
25-50-00
Page 25-36
Issued: June 1,1995 ^ 4
AEROiSTARÎRCBAFT
605/601/601 P/662P/700Pf
B442
Figure 25-17. Appiication of Double Side Tape Attaching

Cabin Door Window l\/lolding
25-50-00-
Page 25^7
3 El 5 Issued: June 1, .isl95
•V.
AER©STAR AlR€;RAFt
600/601/601 P/6d2PA700P
V h- yp MAINTENANCE MANUAL
..B443
1. FORWARD BULKHEAD TRIM PANEL 5. DOOR TRIM PANEL

2. SIDE WALL TRIM PANEL 6. TUBE COVER
3. RIB COVER 7. CARPETING
4. AFT BULKHEAD TRIM PANEL 8. TWIST-LOCK FASTENER
Figure 25-18. Baggage Compartment Furnishings
25-50-00,
Page 25-38
Issued: June 1,1995
3E16
25-50-00
Page 25-39
3E17 Issued: June1,1'9i95

Figure 25-20. Covered Baggage Compartment Light
25-50-00
Page25-40,- .
issued: June 1, i^95 V3E1 8
AEBOSTAR AIRCRAFT
600/601/601P/60'2P/700'p^
MAiNTENANC;gMANUA|
<5 ,
• -4
lb-
5\
c;
V-'.

Aerostar - Maintenance - Manual - Chapters - 21 To 25

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Aerostar - Maintenance - Manual - Chapters - 21 To 25

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CHAPTER 21 - ENVIRONMENTAL SYSTEMS

21-00-00 GENERAL 2B12

21-20-00 PRESSURIZATION 2C9

21-15-00 PNEUMATIC 2C24

2B5 issued: June 1,1995

CHAPTER 21 - ENVIRONMENTAL SYSTEMS (cont)

21-15-00 PNEUMATIC (cont)

21-17-05 Pneumatic Pressure Gauge 2D2

CHAPTER 21 - ENVIRONMENTAL SYSTEMS (cont)

21-20-00 DISTRIBUTION 2D23

21-30-00 PRESSURIZATION CONTROL 2E10

CHAPTER 21 - ENVIRONMENTAL SYSTEMS (cont)

21-40-00 HEATING 2E22

CHAPTER 21 - ENVIRONMENTAL SYSTEMS (cont)

21-42-00 HEATING (cont.)

CHAPTER 21 - ENVIRONMENTAL SYSTEMS (cont)

CHAPTER 21 - ENVIRONMENTAL SYSTEMS (cont)

21-50-00 COOLING (cont.) —

CHART 2101. TROUBLESHOOTING (PRESSURIZATION)

Trouble Cause Remedy

Cabin fails to pressurize Defective pressure dump Replace switch.

Defective NLG squat switch. Replace switch.

Sticking squat switch actu- Repair/replace pin.

Safety valve solenoid in- Replace solenoid.

Defective dorsal air inlet Replace valve.

Ruptured diaphragm in Repair/replace valve.

Ruptured diaphragm in Repair/replace valve.

Door seals not properly Check pneumatic system

Wiring to safety dump valve Repair/replace wiring.

CHART 2101. TROUBLESHOOTING (PRESSURIZATION) (cont)

Trouble Cause Remedy.

Internal poppet valve in Set controller to 10,000 feet

Adjustable bleed valve Remove obstructions from line.

Failure of internal bellows Set controller to sea level; blow

Insufficient or no bleed Defective left and/or Replace defective switch.

Bleed valve stuck in Verify proper operation per

Bleed valve stuck in Check for obstructions. Replace

Turbocharger problems. Refer to Chapter 81.

CHART 2101. TROUBLESHOOTING (PRESSURIZATION) (cont)

~ Trouble - Cause • Remedy

When throttles are retarded, Defective outflow valve. Replace.

Rapid fluctuation of cabin

c. Diff. press, other than maximum Cabin controller defective. Replace.

Cabin controller poppet valve or Clean poppet valve, replace

d. @ maximum differential pressure. Outflow valve. On new or lowtime airplane

Cabin fails to pressurize on take- "Normal/Dump" switch in Reposition to "Normal" mode.

Wiring to safety dump valve Repair wiring.

CHART 2101. TROUBLESHOOTING (PRESSURIZATION) (cont)

Trouble Cause Remedy

Check valve at base of dorsal fin

Oxygen bottle supply line hitting

Spring on aft side of dump valve Readjust (should be screwed

Broken wire in controller. Replace controller.

Outer select ring on face of Adjust select ring.

Select shaft bent. Replace controller.

Excessive cabin dive on a. New or lowtime aircraft out- a. Replace.

No cabin dive on rotation. "Normal/Dump" switch in Place switch in "Normal" mode.

Safety dump valve not closing Replace squat switch.

CHART 2101. TROUBLESHOOTING (PRESSURIZATION) (cont)

-Trouble Cause Remedy

Cabin goes to maximum Sense line between controller Reconnect line.

CHART 2102. TROUBLESHOOTING (PNEUMATIC SYSTEM) .