Enviro 21-00-09rev13

12037 N.
Highway 99
Seminole, OK 74868
Phone (405) 382-0731
http://www.enviro-ok.com
OPERATING, SERVICING, AND COMPONENT
MAINTENANCE MANUAL
WITH ILLUSTRATED PARTS LIST
CESSNA 510
R-134a AIR CONDITIONING SYSTEM COMPONENTS:
1) COMPRESSOR DRIVE MODULE ASSEMBLY, PART # 1133610-4

CESSNA PART # 9912660-14
2) CONDENSER BLOWER ASSEMBLY, PART # 1134620-5

3) EVAPORATOR MODULE ASSEMBLY, PART # 1133300-1

4) RECEIVER DRYER ASSEMBLY, PART # 1134275-1

5) CHECK VALVE PART # 1310150-2
ATA SPECIFICATION 21-00-09
Enviro Systems Original Release July 18, 2007

Copyright © 2019 21-00-09
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May 2, 2019
12037 N. Highway 99
Seminole, OK 74868
Phone (405) 382-0731
RECORD OF REVISIONS
REV DESCRIPTION OF CHANGE DATE APPROVAL

ORIGINAL ISSUE 07/18/07 BH
1 Added into IPL attaching hardware for several components 08/24/07 BH
2 Added in procedures on removing and installing Power Relay 10/25/07 BH
and inserted new IPL calling out Power Relay.
3 Figure 1….Changed to reflect correct measurement 01/16/08 BH
Was…new length .875 in, min length .440 in
Is…….new length .895 in, min length .395
4 Title Page… 01/28/08 BH
Was…Cessna Part # 9912660-1
Is…….Cessna Part # 9912660-14
5 Added references to “thread sealant primer Loctite 7471” 03/12/08 BH
throughout the manual.
6 Updated Storage, Section 14. Updated information 05/5/08 BH
concerning cold weather operations under General and
System Off Season/On Aircraft Functional Testing.
7 Change to IPL Figure 10003 Assembly Details 05/6/09 BH
Item 110 was AN960-8 is NAS1149FN832P
ENGR DCN 24708
8 Change to IPL Figure 10001 Assembly Details 02/16/10 BH
Item 31 was AN960-10 is NAS1149F0363P
ENGR DCN 25816.

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May 2, 2019
12037 N. Highway 99
Seminole, OK 74868
Phone (405) 382-0731
RECORD OF REVISIONS - Continued

9 IPL Fig 10001 item-80-Motor Brush Shunt was p/n 1251171-6 08/01/11 BH
is 1251171-1 quantity was 4 is 1. IPL Change all AN960
washers to NAS equivalent. Table 2 add RL100E as
alternative Sec. 7.1 add Warning, Label Table 3.5 &3.6
Change Column Titles Type Inspection and Replacement
Service hours to Unit Operating Hours. Add Figure 3.3, 3.4,
3.5. Sec 3.4 deleted remaining brush length calculation
example and Figure 1, renumber subsequent figures. .
Section 8.2.1.2: change verbiages to reflect replacement of
brushes and add CAUTION referring to commutator wear
condition examples. from Sections 2 thru 10 Remove IPL
item numbers from instructions. Section 12.2.1 was Motor
bearing will be inspected every 500-1000 operational hours. Is
Motor bearing will be inspected according to Section 7
Inspection Schedule Table 3.5
10 Table 3.5 change column heading from Service Hours to Unit 01/17/12 BH
Operating Hours IPL Fig 10001 item-80-Motor Brush Shunt
was p/n 1251171-1 is 1251171-6
11 Added Section 12.4 / Modified Sections 5.3.9.6 and 9.3.1.4 to 11/5/13 BS

improve and more clearly describe correct Brush Shunt wire
routing procedures
12 Table 3.5: Changed Drive Motor Brush mandatory 5/4/16 BS
replacement from 500 hours to 800 hours per Cessna request.
Table 3.6: Removed Statement – “Blower Motor must be removed
and replaced between 4900-5100 hours in service” This is an on-
condition replacement item
12.5.2: Changed new compressor oil level – Was: 3 oz. Is: 7
oz.
13.4: Removed reference to General Motors service bulletin
83-12-21 as service bulletin is no longer available.

Copyright © 2019 21-00-09
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12037 N. Highway 99
Seminole, OK 74868
Phone (405) 382-0731
13 Page 4 – added note that “Manuals must be obtained through 5/2/19 BS

Textron Aviation Technical Publications Department”
Removed “List of Effective Pages” page
Updated format of footer throughout the document
Post page 17, all page numbers were corrected to be
sequential and same format from beginning to end
9.3.2 added note for K1134608-3 to replace 1134608-1 fan
blade
9.3.2.1 Labeled Obsolete
Added section 9.3.2.2. 1134608-3 installation procedures
Page 61 added K1134608-3 illustration
Page 62 added obsolete vs. replacement fan blade
comparison
Figure 10001 added items 74, 75, & 76
Figure 10001 labeled items 70 & 73 obsolete and non-
procurable
Manuals must be obtained through Textron Aviation Technical

Publications Department

Copyright © 2019 21-00-09
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May 2, 2019
12037 N. Highway 99
Seminole, OK 74868
Phone (405) 382-0731
RECORD OF TEMPORARY REVISIONS

Copyright © 2019 21-00-09
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May 2, 2019
12037 N. Highway 99
Seminole, OK 74868
Phone (405) 382-0731
LIST OF SERVICE BULLETINS
SERVICE DESCRIPTION DATE

BULLETIN # RELEASED

Copyright © 2019 21-00-09
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May 2, 2019
12037 N. Highway 99
Seminole, OK 74868
Phone (405) 382-0731
TABLE OF CONTENTS
RECORD OF REVISIONS ................................................................................................................................... 2

RECORD OF TEMPORARY REVISIONS ........................................................................................................... 5
LIST OF SERVICE BULLETINS ......................................................................................................................... 6
LIST OF EFFECTIVE PAGES ............................................................................................................................. 6
TABLE OF CONTENTS ...................................................................................................................................... 7
LIST OF ILLUSTRATIONS ................................................................................................................................. 9
LIST OF TABLES ................................................................................................................................................ 9
INTRODUCTION................................................................................................................................................ 10
1.0 MANUAL INTRODUCTION .................................................................................................................. 10
1.1 General introduction (How to Use): .................................................................................................. 10
1.2 Acronyms, Abbreviations, and Symbols:......................................................................................... 10
1.3 Standard Torque Values: ................................................................................................................... 12
1.4 Documents required: .......................................................................................................................... 12
1.5 Consumable Products:....................................................................................................................... 12
DESCRIPTION AND OPERATION ................................................................................................................... 13
2.0 R-134a AIR CONDITIONING SYSTEM DESCRIPTION AND OPERATION ...................................... 13
2.1 General:................................................................................................................................................ 13
2.2 System Description and Operation: .................................................................................................. 14
2.3 System Component Description and Operation:............................................................................. 15
TESTING AND FAULT ISOLATION ................................................................................................................. 18
3.0 R-134a AIR CONDITIONING SYSTEM COMPONENT – TESTING AND FAULT ISOLATION ......... 18
3.1 General:................................................................................................................................................ 18
3.2 Compressor Drive Module Assembly / Condenser Blower Assembly testing
procedures: ......................................................................................................................................... 18
3.3 Evaporator Module Assembly Testing Procedures ........................................................................ 19
3.4 System Leak Check Testing Procedure: .......................................................................................... 19
3.5 Fault Isolation (Trouble Shooting): ................................................................................................... 21
SCHEMATIC AND WIRING DIAGRAMS .......................................................................................................... 24
4.0 R-134a AIR CONDITIONING SYSTEM SCHEMATIC AND WIRING DIAGRAMS ............................. 24
4.1 R-134a Refrigerant Flow Schematic: ................................................................................................ 24
4.2 R-134a System Electrical Schematic: ............................................................................................... 25
DISASSEMBLY ................................................................................................................................................. 26
5.0 R-134a AIR CONDITIONING SYSTEM COMPONENT - DISASSEMBLY.......................................... 26
5.1 General:................................................................................................................................................ 26
5.2 Receiver Dryer Disassembly Procedures: ....................................................................................... 27
5.3 Compressor Drive Module Disassembly Procedures ..................................................................... 27
5.4 Evaporator Module Disassembly Procedures ................................................................................. 30
5.5 Condenser Blower Disassembly Procedures .................................................................................. 31
CLEANING ........................................................................................................................................................ 32
6.0 R-134a AIR CONDITIONING SYSTEM COMPONENT – CLEANING PROCEDURES ..................... 32
6.1 General:................................................................................................................................................ 32
6.2 Compressor Drive Module Cleaning Procedures: ........................................................................... 33
6.3 Condenser Blower Assembly Cleaning Procedures: ...................................................................... 33
6.4 Evaporator Module Cleaning Procedures: ....................................................................................... 34
CHECK (INSPECTION SCHEDULE) ................................................................................................................ 36
7.0 R-134a AIR CONDITIOING SYSTEM COMPONENT – INSPECTION SCHEDULE .......................... 36
7.1 Compressor Drive Module and Condenser Blower Inspection Schedule: ................................... 36
7.2 Evaporator Module inspection schedule: ........................................................................................ 40
REPAIR.............................................................................................................................................................. 41

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12037 N. Highway 99
Seminole, OK 74868
Phone (405) 382-0731
8.0 R-134a AIR CONDITIONING SYSTEM COMPONENT – REPAIR PROCEDURES........................... 41

8.1 General:................................................................................................................................................ 41
8.2 Compressor Drive Module Repair Procedures: ............................................................................... 41
8.3 Receiver Dryer Assembly Repair Procedures: ................................................................................ 42
8.4 Condenser Blower Assembly Repair Procedures ........................................................................... 43
8.5 Evaporator Module Repair Procedures: ........................................................................................... 44
ASSEMBLY ....................................................................................................................................................... 46
9.0 R-134a AIR CONDITIONING SYSTEM COMPONENT - ASSEMBLY................................................ 46
9.1 General:................................................................................................................................................ 46
9.2 Receiver Dryer Assembly Procedures: ............................................................................................ 47
9.3 Compressor Drive Module Assembly Procedures .......................................................................... 47
9.4 Evaporator Module assembly procedures ....................................................................................... 55
9.5 Condenser Blower Assembly Procedures ....................................................................................... 56
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT .......................................................................................... 56
10.0 SPECIAL TOOLS/EQUIPMENT........................................................................................................... 57
10.1 General:................................................................................................................................................ 57
ILLUSTRATED PARTS LIST ............................................................................................................................ 59
11.0 R-134a AIR CONDITIONING SYSTEM COMPONENT ILLUSTRATED PARTS LISTING ................ 59
11.1 Introduction: ........................................................................................................................................ 59
SPECIAL PROCEDURES ................................................................................................................................. 68
12.0 SPECIAL PRODECURES .................................................................................................................... 68
12.1 Motor Insulation Resistance Check: ................................................................................................. 68
12.2 Motor Bearing Inspection: ................................................................................................................. 68
12.3 Motor Brush Seating Procedure: ...................................................................................................... 69
12.4 Compressor Oil Level Check: ............................................................................................................ 69
SERVICING ....................................................................................................................................................... 71
13.0 R-134a AIR CONDITIONING SYSTEM SERVICING PROCEDURES ................................................ 71
13.1 General:................................................................................................................................................ 71
13.2 Evacuating The System (R-134a): ..................................................................................................... 71
13.3 Charging The System (R-134a): ........................................................................................................ 72
13.4 Flushing The System (R-134a): ......................................................................................................... 73
STORAGE ......................................................................................................................................................... 72
14.0 COMPRESSOR DRIVE MODULE ASSEMBLY STORAGE PROCEDURES ..................................... 72
14.1 General:................................................................................................................................................ 72
14.2 System Long Term Shelf Storage: .................................................................................................... 72
14.3 System Off Season Functional Tests: .............................................................................................. 73

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12037 N. Highway 99
Seminole, OK 74868
Phone (405) 382-0731
LIST OF ILLUSTRATIONS
Figure 1 R-134a Refrigerant Flow Schematic................................................................................................ 24

Figure 2 Electrical Schematic ......................................................................................................................... 25
Figure 3 Brush Removal Details ..................................................................................................................... 30
Figure 3.3: Commutator Excellent Condition Example ............................................................................... 37
Figure 3.4: Commutator Serviceable Condition Example .......................................................................... 38
Figure 3.5: Commutator Unserviceable Condition Example ...................................................................... 39
Figure 5 Belt Tensioning Reference............................................................................................................... 54
Figure 10001 Compressor Drive Module Assembly 1133610-4................................................................... 60
Figure 10001 Compressor Drive Module Assembly Details ........................................................................ 63
Figure 10002 Condenser Blower Assembly 1134620-5 ................................................................................ 64
Figure 10002 Condenser Blower Assembly Details ..................................................................................... 65
Figure 10003 Evaporator Module Assembly 1133300-1 ............................................................................... 66
Figure 10003 Evaporator Module Assembly Details .................................................................................... 67
LIST OF TABLES
Table 1 Standard Torque Values .................................................................................................................... 12

Table 2 Consumable Products ....................................................................................................................... 12
Table 3 Trouble Shooting List ........................................................................................................................ 21
Table 3.5 Compressor Condenser Inspection and Replacement ............................................................... 36
Table 3.6 Evaporator Inspections................................................................................................................... 40
Table 4 Gates Sonic Tension Meter Data ...................................................................................................... 54
Table 5 Blower Motor Electrical Connections............................................................................................... 55
Table 6 Refrigerant Charge ............................................................................................................................. 72
Table 7 Typical Operating Values................................................................................................................... 73

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May 2, 2019
12037 N. Highway 99
Seminole, OK 74868
Phone (405) 382-0731
INTRODUCTION
TASK 21-00-09-99F-801
1.0 MANUAL INTRODUCTION
SUBTASK 21-00-09-99F-001
1.1 General introduction (How to Use):
1.1.1 This operating, servicing and component maintenance manual (CMM) covers the
requirements for field servicing the R-134a air conditioning system for the Cessna 510
aircraft. This document includes component descriptions, servicing, maintenance,
inspection requirements and an illustrated parts list.
1.1.2 This component maintenance manual has been prepared with guidance from the Air
Transport Association of America (ATA) Specification 2200. The user must not change the
repair methods in this manual without authorization from the aviation authorities and the
manufacturer.
1.1.3 This manual gives the procedures to perform the servicing and maintenance of the
component in a workshop environment as well as on the aircraft. Only approved personnel
with the necessary skills shall perform the maintenance procedures in this manual.
Although Enviro Systems tries to cover all conceivable issues that may arise, there may be
issues that are not covered in this manual. In these cases, please call Enviro Systems
customer service.
1.1.4 This manual uses the Maintenance Task Oriented Support System (MTOSS) to organize
the maintenance information. It is divided into maintenance tasks and subtasks, graphics
and tables. Each task consists of one or more subtasks. Each subtask contains procedural
steps and can contain one or more graphics or tables. The maintenance tasks and other
data have special MTOSS numbers that are used for Electronic Data Processing (EDP).
1.1.5 You must use the instructions in this manual to do all the maintenance procedures related to
the component. Read all the related warnings, cautions and notes before you begin work
on the components. Warnings, cautions and notes shown in this manual provide the
following information:
1.1.5.1 WARNING: Discloses vital information in order to prevent injury or death while
performing the maintenance procedure.
1.1.5.2 CAUTION: Discloses vital information in order to prevent damage to the

equipment during the maintenance procedure.
1.1.5.3 NOTE: Discloses more information that will help perform a step of the procedure
or refers to a different procedure.
1.1.6 A complete Illustrated Parts Listing (IPL) is supplied as additional documentation (Section
11) to provide service technicians access to exploded views and a parts list while
performing maintenance, testing, disassembly and assembly procedures. Refer to the IPL
for all figure and item numbers.
SUBTASK 21-00-09-99F-002
1.2 Acronyms, Abbreviations, and Symbols:
Copyright © 2019 21-00-09
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May 2, 2019
12037 N. Highway 99
Seminole, OK 74868
Phone (405) 382-0731
 CMM Component Maintenance Manual

 ATA Air Transport Association
 MTOSS Maintenance Task Oriented Support System
 EDP Electronic Data Processing
 IPL Illustrated Parts Listing
 BTUH British Thermal Unit per Hour (standard in U.S. heating and air-conditioning)
 Db Dry Bulb
 RH Relative Humidity
 CFM Cubic Feet per Minute
 In.w.g Inch of Water Gage
 VCS Vapor Cycle System
 MSDS Material Safety Data Sheet
 PSIG Pressure Per Square Inch, Gage
 SAE Society of Automotive Engineers
 CCW Counter Clockwise
 CW Clockwise
 FOD Foreign Object Damage
 OAT Outside Air Temperature

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Seminole, OK 74868
Phone (405) 382-0731
SUBTASK 21-00-09-99F-003
1.3 Standard Torque Values:
TYPE FASTENER DESCRIPTION/LOCATION TORQUE

.25-28 SET SCREW ALL LOCATIONS 40-50 IN-LBS
6-32 SCREW ALL LOCATIONS 8-10 IN-LBS
¼-28-UNF ALL LOCATIONS 50-70 IN-LBS
5/16-24UNF ALL LOCATIONS 100-140 IN-LBS
3/8-24UNF ALL LOCATIONS 160-190 IN-LBS
3/8 PLUMBING CONNECTIONS RECEIVER DRYER INLET PORT 130-160 IN-LBS
½ PLUMBING CONNECTIONS COMPRESSOR DISCHARGE PORT 300-400 IN-LBS
½ PLUMBING CONNECTIONS COIL HEADERS 250-325 IN LBS
Table 1 Standard Torque Values
SUBTASK 21-00-09-99F-004
1.4 Documents required:
 Illustrated Parts Listings (IPL) (included with this manual)
SUBTASK 21-00-09-99F-005
1.5 Consumable Products:
PART NUMBER DESCRIPTION REMARKS

11602 SEALANT RTV BLACK
7471 THREAD SEALANT PRIMER LOCTITE
569 THREAD SEALANT LOCTITE
RL100H or RL100E EMKARATE ESTER REFRIGERANT OIL
Table 2 Consumable Products

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May 2, 2019
12037 N. Highway 99
Seminole, OK 74868
Phone (405) 382-0731
DESCRIPTION AND OPERATION
TASK 21-00-09-99F-802
2.0 R-134a AIR CONDITIONING SYSTEM DESCRIPTION AND OPERATION
SUBTASK 21-00-09-99F-006
2.1 General:
2.1.1 Air conditioning systems installed on aircraft are not considered a primary flight system.
However, an air conditioning system does perform the important function of providing
passenger and flight crew comfort during aircraft movement on the ground and while in
flight. Aircraft air conditioning systems not only provide effective passenger cooling, but
must also maintain a high level of reliability to minimize aircraft downtime due to
unscheduled repairs.
2.1.2 In order to ensure component reliability and achieve a long service life for which the system
is designed, periodic inspection and preventive maintenance must be performed. Failure to
complete periodic inspections, service, or maintenance schedules may reduce product life
and potentially void manufacturer’s warranty.
2.1.3 Inspections, servicing, and/or maintenance schedules are presented in the following
sections. This will ensure component and/or system reliability and performance are
maintained when performed at the specified intervals.
WARNING: SERVICE TECHNICIANS ARE ADVISED TO OBSERVE STANDARD SAFETY
PRECAUTIONS, SUCH AS WEARING PERSONAL SAFETY GEAR, TO PREVENT INJURY WHILE
PERFORMING SERVICE TO THE UNIT. LIQUID REFRIGERANT CAN CAUSE FROSTBITE AND/OR
BLINDNESS.
WARNING: PROPER VENTILATION IS REQUIRED. KEEP REFRIGERANTS AND OILS AWAY FROM
OPEN FLAMES. REFRIGERANTS CAN PRODUCE POISONOUS GASSES IN THE PRESENCE OF A
FLAME. WORK IN A WELL VENTILATED AREA AND AVOID BREATHING REFRIGERANT /LUBRICANT
VAPOR MIST IF ACCIDENTAL DISCHARGE OCCURS.
WARNING: AVOID USE OF COMPRESSED AIR. DO NOT INTRODUCE COMPRESSED AIR OR
OXYGEN INTO AN AIR CONDITIONING SYSTEM OR REFRIGERANT CONTAINER. R-134a IN THE
PRESENCE OF AIR OR OXYGEN ABOVE ATMOSPHERIC PRESSURE MAY FORM A COMBUSTIBLE
MIXTURE.
2.1.4 Do not discharge R-134a refrigerant into the atmosphere. Although its ozone depletion
potential is zero, it can have an effect on global warming. In the United States recovery and
recycling are mandated by the Clean Air Act.
2.1.5 Refrigerant recovery/recycling service equipment must be approved for use with R-134a
refrigerant. Recycling machines must be approved by Underwriters Laboratories (UL) and
meet SAE standard J2210 and SAE standard J2099 for refrigerant purity.

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12037 N. Highway 99
Seminole, OK 74868
Phone (405) 382-0731
SUBTASK 21-00-09-99F-007
2.2 System Description and Operation:
2.2.1 The cabin cooling system installed in the Cessna Model 510 aircraft operates using a closed
vapor cycle concept using refrigerant R-134a as the heat absorption media. The R-134a air
conditioning system cools the aircraft in a similar manner as systems found in an
automobile or home. However, aircraft air conditioning systems contain components which
are designed to be light weight, compact, provide high performance, and provide the ability
to operate at extreme altitudes and ambient temperatures.
2.2.2 The concept of air conditioning a room, cabin or cockpit is straight forward. Examples of a
system are shown in Figures 2 and 3 (refer to Schematic and Wiring Diagrams, Section 4).
Refrigerant is the media which absorbs and rejects the room or cabin heat. By continuous
recirculation of the warm cabin air, heat is absorbed in the evaporator module(s) and is
rejected to the outside through the system condenser. When the system is turned on, the
electric motor drives the R-134a compressor at a constant speed and capacity which
compresses the R-134a refrigerant gas to a high pressure. The hot, high pressure gas then
passes through the condenser coil where it is cooled and condensed into a warm liquid at
constant pressure. The warm liquid is then routed into a receiver-dryer container where the
liquid and any remaining gas are separated and any moisture is absorbed. The warm, dry
liquid is then directed to the evaporator module expansion valve where the high pressure
liquid is expanded to a low pressure. The expansion process creates a super cool gas
which passes through the evaporator coil and absorbs heat from the warm cabin air passing
over the coils. The warm low pressure refrigerant then enters the R-134a compressor
where the process starts all over again. In addition to cooling the cabin air, a refrigerant
type system also removes a large percentage of the moisture in the air as well as removing
dust and pollen particles in the air. Thus, the system conditions the air as well as cooling it.
As a safety feature, the unit is also equipped with a binary pressure switch. This switch
prevents the unit from operating if the discharge pressure becomes excessively high. The
switch also prevents the unit from operating if the internal pressure is very low due to
leakage or low ambient temperatures.

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Seminole, OK 74868
Phone (405) 382-0731
SUBTASK 21-00-09-99F-008
2.3 System Component Description and Operation:
2.3.1 The R-134a air conditioning system on the Cessna Model 510 uses the Compressor Drive
Module Assembly (PN 1133610-4), the Condenser Blower Assembly (PN 1134620-5),
Evaporator Module Assemblies (PN 1133300-1), the Receiver Dryer (PN 1134275-1), and
the Check Valve (PN 1310150-2).
2.3.2 The COMPRESSOR DRIVE MODULE ASSEMBLY (PN 1133610-3) has a rated capacity of
13,000 BTUH when operating with the other components in the Cessna Model 510 aircraft
at an ambient temperature of 105°F OAT and with a cabin temperature of 80°F dry bulb and
67°F wet bulb. Under this condition the nominal current consumption is 82 AMPS at 28
VDC.
2.3.3 The Compressor Drive Module Assembly is packaged to meet the aircraft installation
requirements and contains the following major components (refer to Figure 10001):
 Compressor / Fan Drive Motor
 Compressor Assembly
2.3.3.1 COMPRESSOR DRIVE MOTOR: The compressor drive motor has a double-
ended shaft and operates on 28 VDC power with a current draw of 77 AMPS
nominal. One output shaft drives the R134a compressor and the other end drives
the cooling fan. The motor design power is 2.33 HP at 5920 RPM. The motor is
specially designed to provide a high starting torque to overcome the compressor
startup requirements. The motor is a brush commutated, permanent magnet
design and was selected for its efficiency, excellent controllability, long life, and
low vibration. The motor shaft is supported on high speed ball bearings for
reliability and friction reduction.
2.3.3.2 COMPRESSOR ASSEMBLY: The compressor assembly contains an R134a

compressor and 5.01 inch pitch diameter pulley assembly. The compressor
incorporates a six-piston wobble plate, variable displacement design. The
compressor also features anti-slugging features that eliminate the need for a
suction trap/accumulator. The compressor displacement is 6-125 cc/rev. and has
light-weight aluminum housing. The pulley assembly is designed for a positive grip
.375 pitch timing belt and contains a radial bearing to assure no side loads are
transmitted into the compressor input shaft. The assembly is designed for an
operating speed of 1000-3000 RPM and has a maximum speed of 8000 RPM.

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Seminole, OK 74868
Phone (405) 382-0731
2.3.4 The CONDENSER BLOWER ASSEMBLY (PN 1134620-5) is designed to provide up to

18,000 (BTUH) of heat rejection capacity with an ambient air inlet condition of 105° F (db)
and 50% RH (relative humidity). The condenser blower airflow is 600 CFM (cubic feet per
minute) with a static pressure of 2.0 in.w.g. Voltage is 28 VDC and current is 20 AMPS
(max).
2.3.5 The Condenser Blower Assembly is packaged to meet the aircraft installation requirements
and contains the following major components (refer to Figure 10002):
 Vane Axial Blower
 Shroud Assembly
 Condenser Coil Assembly
2.3.5.1 VANE AXIAL BLOWER: A brushless D.C. three blade, 7.0 inch diameter fan,
supplies the condenser cooling air. The fan blade is constructed of A356
aluminum alloy, weighs 1 lb., and has a speed rating up to 9500 RPM. The fan
motor is a 28 VDC brushless design, built to increase reliability over the brush
motor design.
2.3.5.2 SHROUD ASSEMBLY: The shroud assembly is constructed of .093, a high

impact, fire retardant, self-extinguishing, corrosion resistant, lightweight
polycarbonate material. The shroud assembly also includes a support bracket that
is constructed of 6061-T6 aluminum.
2.3.5.3 CONDENSER COIL ASSEMBLY: The condenser coil assembly is a copper tube
and aluminum fin configuration with 6061-T6 aluminum support brackets. The
required coil heat rejection is 18,000 BTUH based on a 105°F ambient day.
Condenser cooling airflow and coil sizes are based on the design cooling capacity
and compressor input horsepower. The coil working pressure is up to 530 PSIG.
2.3.6 The EVAPORATOR MODULE ASSEMBLIES (PN 1133300-1) are designed to provide
7,000 (BTUH) of cooling capacity each, with an ambient air inlet condition of 80° F (db) and
50% RH (relative humidity). The evaporator module provides an air flow of 200 CFM (cubic
feet per minute). The blower is designed to be used in both the air conditioning mode and
as a recirculation mode during aircraft heating. The blower contains three speeds (high,
mid, and low) with mid speed 50% of high speed and low speed 25 % of high speed. The
assembly operates on 28 VDC, 10 Amps max, and has a power usage of 280 Watts max.
2.3.7 The Evaporator Module Assembly is packaged to meet the aircraft installation requirements
and contains the following major components (refer to Figure 10003):
 Coil Assembly
 Blower Motor
 Blower Wheel
 Expansion Valve
 Evaporator Housing

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Seminole, OK 74868
Phone (405) 382-0731
2.3.7.1 COIL ASSEMBLY: The evaporator coil assembly contains the evaporator coil,
mounting hardware, rubber grommets and female flared fittings. The coil is
constructed of copper tube and aluminum fins with aluminum support brackets.
2.3.7.2 BLOWER MOTOR: The evaporator blower motor operates on 28 VDC with a
current draw of 10 amps and has a design RPM of 5250-6250. The blower motor
is a brushless design with an integrated controller. It was selected for its
efficiency, excellent controllability, long life and low vibration at high speeds. The
motor has three speeds, low speed designed for the heating recirculation
requirement and mid and high speed designed for maximum system cooling. The
motor shaft is supported on high-speed ball bearings for reliability and friction
reduction.
2.3.7.3 BLOWER WHEEL: The blower wheel is the component that is used in concert
with the blower motor and provides for the movement of air.
2.3.7.4 EXPANSION VALVE: The expansion valve is a thermostatic type. The valve
provides the proper refrigerant flow while maintaining constant return gas
superheat at all evaporator heat load conditions. Controlling the evaporator
refrigerant flow based on cooling demand prevents coil freeze up. This allows the
system cooling capacity to best meet transient aircraft heat load demands.
2.3.7.5 EVAPORATOR HOUSING: The evaporator housing and blower scroll are
constructed of high impact, fire retardant, self-extinguishing, and corrosion
resistant, lightweight polycarbonate material. The blower scroll has successfully
passed blower wheel containment testing.
2.3.8 The RECEIVER DRYER ASSEMBLY (PN 1134275-1) consists of a refrigerant container,
Schrader valve, high pressure charging port and a binary pressure switch. The receiver-
dryer is constructed of steel and contains a standpipe, wire filter, desiccant and a sight glass
for observing refrigerant charge. The receiver dryer assembly is provided with a corrosion
resistant baked enamel finish. The receiver volume is approximately 40 cubic inches and
can store up to 1.8 pounds of refrigerant at 240 PSIG. The Schrader valve located in the
container inlet port allows for the binary pressure switch to be removed without venting the
system refrigerant charge.
2.3.9 The CHECK VALVE (PN 1310150-2) is a component used in the bleed air system and is
not directly related to the air conditioning system. The only maintenance actions for this
component are removal and replacement. For removal and replacement of the check valve,
refer to the aircraft maintenance manual.

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TESTING AND FAULT ISOLATION
TASK 21-00-09-70-801
3.0 R-134a AIR CONDITIONING SYSTEM COMPONENT – TESTING AND FAULT ISOLATION
SUBTASK 21-00-09-99F-009
3.1 General:
3.1.1 Testing and Fault Isolation of the R-134a Air Conditioning System may be necessary if the
system does not operate and/or perform in accordance with information contained herein.
Therefore it is necessary for the service personnel to diagnose the discrepancy by
troubleshooting the system and its components. To assist in this diagnoses, refer to table 3
(Trouble Shooting List)
SUBTASK 21-00-09-70-001
3.2 Compressor Drive Module Assembly / Condenser Blower Assembly testing procedures:
3.2.1 Ensure that power is applied to the aircraft and that the air conditioning system is switched
on using the cockpit mounted selector switch. Gain access to the Compressor Drive
Module and Condenser Blower Assembly (refer to the aircraft maintenance manual for
removal of access panels and other hardware that might need to be removed). Verify that
these components are operating and perform the following:
 Verify that system is running smoothly and that there is no excessive noise and/or vibration
coming from the assembly.
 Verify that the system is cooling properly.
3.2.2 If there is excessive noise and/or vibration coming from the compressor drive module and/or
the condenser blower assembly or the system is not cooling, refer to the Disassembly
procedures in section 5 and Check (inspection) procedures in section 7. This will help in
identifying whether one or more components are dirty or damaged and are in need of repair
or replacement.

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SUBTASK 21-00-09-70-002
3.3 Evaporator Module Assembly Testing Procedures
(refer to Figure 10003):
3.3.1 Verify blower motor operation in all three speed positions using cockpit mounted selector
switch.
3.3.2 While blower motor is operating in all positions, listen carefully for the following:
 Verify that there is a distinct and noticeable change in sound of blower motor when changing
from low, mid, and high speed positions. This indicates that the cockpit selector switch is
functioning properly and that the blower motor is responding accordingly.
 Verify that there is a smooth transition when changing from low, mid, and high speed
positions, and that there is no excessive noise or vibration coming from the blower motor
during the change. Excessive noise could indicate that the blower wheel is rubbing against
the blower scroll.
3.3.3 If there is excessive noise and/or vibration coming from blower motor/wheel assembly
during this test, please refer to the disassembly procedures in section 5 and inspection
procedures in section 7. This will help in identifying whether the blower motor wheel is dirty
or damaged and is need of repair or replacement, the blower scroll is dirty or damaged and
is need of repair or replacement, or the blower motor itself is in need of replacement.
3.3.4 Verify that the system is cooling properly.
SUBTASK 21-00-09-70-003
3.4 System Leak Check Testing Procedure:
3.4.1 A leak check of the refrigerant plumbing system is important to ensure the system maintains
its charge to provide the designed performance and reduce damage to system components.
A periodic check of the system charge is required to determine if any loss of refrigerant has
occurred.
3.4.2 A system leak check is required any time one or more of the following conditions occur:
 New system plumbing installation
 Component replacement in the plumbing system
 Line or hose rupture
3.4.2.1 Remove, if required, all panels, doors, shrouds, etc, to gain access to
system/component being leak checked (refer to aircraft maintenance manual).
3.4.2.2 Remove, if required, any enclosures or access doors to expose all tubing, hoses,
fittings, etc. to the system components.
3.4.2.3 Verify all plumbing connections are tight.
3.4.2.4 Verify that power is removed from aircraft. If it is not practical to remove aircraft
power, technician must pull and collar applicable circuit breakers.

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CAUTION: HIGH PRESSURE HOSE (RED) IS CONNECTED TO PORT MARKED “D” AND THE LOW
PRESSURE HOSE (BLUE) IS CONNECTED TO THE SERVICE PORT MARKED “S”. INCORRECT
CONNECTION COULD RESULT IN MANIFOLD DAMAGE AND/OR INCORRECT PRESSURE READINGS.
3.4.2.5 Remove service port caps from the A/C system. The high pressure service port is
located on the receiver-dryer and low pressure service port is located on the
compressor suction header.
3.4.2.6 Close all manifold gauge valves and verify hose connections are tight.
3.4.2.7 Connect R-134a refrigerant charging manifold. R-134a service gauges contain
quick-connect fittings to minimize refrigerant loss. To install quick-connect, push
on firmly until locked (a "clicking" sound is heard). Hold the grip ring and pull to
remove quick-connect fittings.
3.4.2.8 Connect yellow charging hose to a regulated dry nitrogen source

NOTE: An adapter is required to connect yellow charging hose to the nitrogen source.
CAUTION: DO NOT EXCEED 200 PSIG NITROGEN PRESSURE DURING PROCEDURE OR DAMAGE TO
EXPANSION VALVE WILL RESULT.
3.4.2.9 Regulate nitrogen source to a pressure of 200 PSIG maximum.
3.4.2.10 Slowly open high pressure (red) manifold valve and allow system pressure to
increase gradually until a pressure of 200 psig is achieved. Allow time for system
pressure to equalize across expansion valve and note final system pressure.
CAUTION: DO NOT USE ANY LEAK DYE IN R-134a SYSTEM OR DAMAGE TO SYSTEM MAY RESULT.
CAUTION: DO NOT OVER TIGHTEN PLUMBING CONNECTIONS. STRIPPED THREADS OR CRACKED
FLARES MAY RESULT.
3.4.2.11 Apply soapy leak check fluid to each fitting connection. If leaks are detected,
attempt to tighten fitting without over tightening. If leak cannot be corrected with
tightening, system must be evacuated (refer to Servicing, Section 13) and then
fitting must be disconnected and new thread sealant and loctite primer applied.
3.4.2.12 Using a wire brush and cleaning solvent, completely remove old thread sealant.
Apply a thin layer of thread sealant primer to fitting threads.
CAUTION: WHEN APPLYING THREAD SEALANT, TAKE EXTREME CARE TO KEEP SEALANT OFF
FIRST 2 OR 3 THREADS.
3.4.2.13 Apply thread sealant on all male fitting threads sparingly.

CAUTION: WHEN APPLYING R-134a OIL TO FLARE AND O-RING, TAKE EXTREME CARE TO KEEP OIL
AWAY FROM FITTING THREADS
3.4.2.14 Apply a light coating of R-134a refrigerant oil to flare and/or O-ring to prevent
metal galling or O-ring damage.
3.4.2.15 Tighten joints as required to stop leaks (refer to Table 1, Section 1.3 for torque
values).

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CAUTION: VENT SYSTEM PRESSURE VERY SLOWLY TO ASSURE COMPRESSOR OIL IS NOT
VENTED WITH THE NITROGEN. DO NOT LET AIR ENTER THE SYSTEM.
3.4.2.16 After leak check is finished and system integrity is sound, turn off nitrogen source,
disconnect yellow charging hose from nitrogen source and slowly release nitrogen
pressure to zero.
3.4.2.17 Close manifold valve.
3.4.2.18 System is now ready for charging (refer to Servicing, Section 13).
SUBTASK 21-00-09-81-001
3.5 Fault Isolation (Trouble Shooting):
3.5.1 The following list of system/component failures and/or abnormal operation and possible
solutions is only a partial listing of what may occur. The more informed service personnel
are in the operation of the system and its various components, the less time will be required
to diagnose failures. Use this trouble shooting list as well as all information contained in this
manual, to aid in diagnosing system faults. Contact Enviro Systems customer service for
any items not listed in this trouble shooting list.
NOTE: Refer to Refrigerant Flow (Figure 1) and Electrical Schematic (Figure 2), Section 4.
INDICATION PROBABLE CAUSE POSSIBLE SOLUTION
A. No System Power 1. Ground power not connected 1. Plug in ground power cart
2. Aircraft power switch off 2. Energize power switch
B. Power On But System Will 1. Air conditioner breaker off 1. Turn on

Not Operate
2. Air conditioner breaker failed 2. Replace
3. Air conditioner mode switch failed 3. Replace
4. Relay(s) failed 4. Replace
5. Failed pressure switch 5. Replace
6. Failed drive motor 6. Replace
7. Vented system 7. Pressure check, evacuate and
charge
8. Low ambient temperature 8. Normal cut out function
9. Drive motor fuse blown 9. Replace
10. Contactor control line fuse blown 10. Replace
Table 3 Trouble Shooting List

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C. System Operates But Does 1. Low refrigerant charge 1.Charge as required
Not Cool
2. Overcharged system cutout 2. Reclaim refrigerant as required
3. Failed Compressor 3. Replace
4. Failed Drive Motor 4. Replace
5. Broken Belt 5. Replace
6. Failed expansion valve(s) 6. Replace
7. Evaporator blower switch failed 7. Replace
8. Evaporator blower motor failed 8. Replace
9. evaporator blower failed 9. Replace
10. evaporator blowers circuit 10. Energize or Replace
breaker
11. Relays failed 11. Replace
12. Evaporator module air inlet 12. Remove Debris
clogged
13. Expansion valve inlet clogged 13. Remove Debris
14. Excessive moisture in system 14. Replace receiver dryer
15. Excessive oil in system 15. Drain excessive oil
D. Evaporator Noisy 1. Blower wheel out of round 1. Replace

2. Blower wheel hitting scroll 2. Align
3. Defective blower motor bearing 3. Replace motor
4. Loose mounting bracket 4. Tighten hardware
5. Air inlet clogged 5. Remove debris
E. Compressor Noisy 1. Loose drive belt 1. Tension belt

2. Drive belt hitting cover 2. Align belt & adjust bracket
3. Motor fan hitting shroud 3. Adjust as required
4. Defective compressor 4. Replace
5. Defective drive pulley 5. Replace
6. Loose pulley 6. Tighten or replace
7. Loose mounting hardware 7. Tighten as required
8. Loose hose assembly 8. Secure as required
9. Loose fan blade 9. Tighten or replace

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F. Compressor Assembly Will 1. Circuit Breaker failed or off 1. Energize or replace

Not Operate
2. Relay failed 2. Replace
3. Pressure switch failed 3. Replace
4. Drive motor failed 5. Replace
5. Drive motor fuse blown 6. Replace
6. Ground power cart not plugged 7. Connect as required
in
7. Low ambient temperature 8. Normal cutout
8. Low refrigerant charge 9. Charge system
9. Motor temperature switch failed 10. Replace switch
G. No Evaporator Module Air 1. Circuit breaker off 1. Energize or replace

Flow
2. Mode switch failed 2. Replace
3. Fan speed switch failed 3. Replace
4. Seized motor 4. Replace
5. Blower wheel failed 5. Replace
6. Blocked air ducts 6. Remove debris
7. Aircraft power not on 7. Energize
8. Ground power not on 8. Energize
H. Evaporator Module Coil 1. No air flow 1. Turn fan on

Freezing
2. Expansion valve failed or 2. Remove debris or replace
clogged
I Pressure Switch Cycles (High 1. System over charged 1. Reclaim refrigerant as required
Pressure Cutout)
2. Condenser coil inlet air 2. Normal condition
extremely hot
3. Condenser inlet clogged 3. Remove debris
4. Discharge line clogged or 4. Replace or straighten line
kinked
5. Excessively high ambient 5. Normal Condition
temperature

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SCHEMATIC AND WIRING DIAGRAMS
21-00-09-99-801
4.0 R-134a AIR CONDITIONING SYSTEM SCHEMATIC AND WIRING DIAGRAMS
SUBTASK 21-00-09-99-001
4.1 R-134a Refrigerant Flow Schematic:
4.1.1 The following schematic shows the system components and the flow of the R-134a
refrigerant.
Figure 1 R-134a Refrigerant Flow Schematic

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SUBTASK 21-00-09-99-002
4.2 R-134a System Electrical Schematic:
4.2.1 The following electrical schematic shows a general representation of system components
and how they interrelate to each other. For detailed system schematics refer to the Cessna
Maintenance Manual and Wire Diagram Manual.
Figure 2 Electrical Schematic

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DISASSEMBLY
TASK 21-00-09-00-801
5.0 R-134a AIR CONDITIONING SYSTEM COMPONENT - DISASSEMBLY
SUBTASK 21-00-09-99F-010
5.1 General:
PERFORMING SERVICE TO THE UNIT.
CAUTION: SERVICE TECHNICIANS MUST PREVENT CONTAMINATION OF INTERNAL SYSTEM
PLUMBING DURING ANY SERVICING AND/OR MAINTENANCE OPERATION. THIS INCLUDES NOT
ALLOWING THE RECEIVER DRYER TO BE EXPOSED TO ATMOSPHERIC CONDITIONS FOR ANY
LENGTH OF TIME. ALL PLUMBING LINES SHOULD REMAIN CAPPED WHENEVER POSSIBLE DURING
THE SERVICING OF THE SYSTEM.
CAUTION: RECEIVER DRYER MUST BE REPLACED ANY TIME THE VCS PLUMBING IS OPENED FOR
MAINTENANCE. REFER TO DISASSEMBLY (SECTION 5) AND ASSEMBLY (SECTION 9).
NOTE: Refer to Testing and Fault Isolation (Section 3) for establishing the condition of the component or
most probable cause of detected malfunction(s) to determine extent of disassembly required. Disassembly
should only be performed to the extent necessary to access any faulty subassembly.
5.1.1 Gain access to the Compressor Drive Module, Condenser Blower Assembly, Evaporator
Module, or Receiver Dryer (refer to the aircraft maintenance manual for removal of access
panels and other hardware that might need to be removed)
5.1.2 Verify that power is removed from aircraft. If it is not practical to remove aircraft power,
technician must pull and collar applicable circuit breakers.
5.1.3 Partial disassembly of system components and other subcomponents is required in order to
facilitate the required inspections in accordance with the inspection schedule (Section 7).
Disassemble the components just enough to perform the required inspection.
5.1.4 If replacement of any component is required, further disassembly may be required. If
component requires complete disassembly, keep all parts of each subassembly in a
separate and clean tray.
5.1.5 In the event that a component requires disassembly and the removal of refrigerant plumbing
lines or hoses, ensure that the system refrigerant charge has been recovered prior to
starting maintenance (refer to Servicing, Section 13).
NOTE: Do not disassemble the parts unnecessarily

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5.1.6 Refer to Illustrated Parts Listing (IPL) for figure/item numbers (Section 11).
5.1.7 Tools, fixtures, equipment, or consumable items required:
 Small hand tools and socket set
 Straight edge
 Measuring device
 Micrometer
 Scribe or wire hook
 Volt or OHM meter (digital)
 Shop air, 40 PSIG max
 Respiration mask
SUBTASK 21-00-09-00-001
5.2 Receiver Dryer Disassembly Procedures:
5.2.1 Removal of Receiver Dryer
5.2.1.1 Verify that system refrigerant charge has been recovered (refer to Servicing,
Section 12)
5.2.1.2 Disconnect electrical wiring to binary pressure switch.
5.2.1.3 Disconnect refrigerant plumbing connection from receiver dryer inlet port.
5.2.1.4 Disconnect discharge refrigerant line from receiver dryer outlet port.
5.2.1.5 Loosen receiver dryer attaching clamps and slide receiver dryer out.
SUBTASK 21-00-09-00-002
5.3 Compressor Drive Module Disassembly Procedures
5.3.1 Removal of Belt Cover
5.3.1.1 Remove belt cover attaching screws.
5.3.1.2 Remove belt cover from assembly.

5.3.2 Removal of Drive Belt and Pulley
CAUTION: DO NOT BEND OR TWIST THE DRIVE BELT EXCESSIVELY DURING REMOVAL OR
DAMAGE MAY RESULT.
5.3.2.1 Remove belt cover per 5.3.1.

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5.3.2.2 Remove turn buckle locking device and loosen motor support bolt as well as turn
buckle bolt attachments.
5.3.2.3 Loosen drive motor pulley set screws.
5.3.2.4 Slide drive pulley and belt from motor shaft, while at the same time sliding the
drive belt off the compressor pulley.
5.3.3 Removal of Compressor Assembly
5.3.3.1 Remove belt cover, drive belt, and drive pulley per 5.3.1 and 5.3.2.
5.3.3.2 Disconnect condenser refrigerant lines from compressor plumbing port and cap off
immediately.
5.3.3.3 Remove compressor mounting bolts and washers.
5.3.3.4 Lift compressor from mounting bracket.

5.3.4 Removal of Drive Motor
5.3.4.1 Remove belt cover, drive pulley, and belt per 5.3.1 and 5.3.2.
5.3.4.2 Remove fan shroud and drive pulley as required.
5.3.4.3 Remove main motor mounting bolt and turn buckle attachment bolt.
5.3.4.4 Remove wire clamp and then remove electrical mounting assembly.
5.3.4.5 Remove positive and negative motor leads from relay terminal and negative
terminal respectively. Remove positive lead from relay by removing supplied
hardware. Remove negative motor lead by removing the bolt from terminal block.
(ie attachment stud)
CAUTION: TAKE EXTREME CARE WHEN REMOVING DRIVE MOTOR FROM ASSEMBLY OR DAMAGE
TO FAN OR FAN SHROUD COULD OCCUR.
5.3.4.6 Carefully pull motor away from motor support bracket, taking care not to damage
fan shroud.
5.3.5 Removal of Fan Shroud
5.3.5.1 Remove motor fan shroud retaining clamp.
5.3.5.2 Carefully remove shroud from motor

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5.3.6 Removal of Fan
5.3.6.1 Remove fan shroud per 5.3.5.
5.3.6.2 Remove motor shaft retaining nut and washer.
5.3.6.3 Remove fan hub set screw.
5.3.6.4 Slide fan assembly and spacer from motor shaft.

5.3.7 Removal of Hour Meter
5.3.7.1 Remove wire clamp (1 screw) and detach electrical assembly (4 screws, 4 nuts on
bottom of unit).
5.3.7.2 Detach hour meter from bracket (2 screws, 2 nuts on backside). Cut wire ties if
necessary to keep terminals attached to back of hour meter.
5.3.7.3 Mark terminal position for proper wire orientation in reassembly.
5.3.7.4 Remove hour meter from assembly.

5.3.8 Removal of Power Relay
5.3.8.1 Disconnect electrical connections and mark polarity.
5.3.8.2 Remove relay mounting hardware and carefully slide relay from assembly.
5.3.9 Removal of Drive Motor Brushes
5.3.9.1 Remove drive motor fan shroud per 5.3.5.
5.3.9.2 Remove brush cover screen, attaching screws, and washers.
5.3.9.3 Remove brush shunt wire attaching screw from brush rack terminal.
CAUTION: DO NOT ALLOW BRUSH SPRING TO SNAP AGAINST BRUSH OR BRUSH DAMAGE MAY
RESLULT.
5.3.9.4 Lift brush spring and slide brush from brush rack.
5.3.9.5 Perform Check (Inspection Schedule), Section 7.
5.3.9.6 Refer to Section 9.3.1.4 for proper installation of brush assembly

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Figure 3 Brush Removal Details
SUBTASK 21-00-09-00-003
5.4 Evaporator Module Disassembly Procedures
5.4.1 Removal of the Evaporator Blower Motor/Wheel
5.4.1.1 Disconnect electrical power from blower motor by removing leads from power
source.
5.4.1.2 Remove blower motor attachment screws and lock washers

CAUTION: USE EXTREME CARE TO PREVENT DAMAGE OR BENDING OF BLOWER MOTOR WHEEL.
5.4.1.3 Carefully remove blower motor/blower wheel assembly from scroll. A putty knife or
similar tool may be required to break the RTV seal around the mounting plate.
Save sealing gasket for reinstallation.
5.4.1.4 Loosen blower wheel set screw on blower motor shaft and remove blower wheel.
5.4.2 Removal of Expansion Valve
CAUTION: SYSTEM MUST BE EVACUATED AND REFRIGERANT RECLAIMED PRIOR TO REMOVING
THE EXPANSION VALVE.
5.4.2.1 Disconnect expansion valve from coil header tube fitting and place protective cap
onto header tube fitting opening.
5.4.2.2 Remove expansion valve bulb from evaporator coil outlet header.

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SUBTASK 21-00-09-00-003
5.5 Condenser Blower Disassembly Procedures
5.5.1 Removal of Condenser Blower (vane axial blower)
5.5.1.1 Disconnect power leads to motor.
5.5.1.2 Remove the 6 cap mounting screws that secure the housing of the blower to the
shroud.
NOTE: Note direction of blower airflow before removing the condenser assembly.
CAUTION: TAKE EXTREME CARE NOT TO DAMAGE BLOWER HOUSING OR FAN BLADES WHILE
REMOVING COMPONENT FROM ASSEMBLY.
5.5.1.3 Remove vane axial blower from shroud. A putty knife or similar tool may be
needed to cut RTV between blower and shroud.
5.5.1.4 Lift vane axial blower out of condenser assembly.

5.5.2 Removal of Shroud Assembly
5.5.2.1 Remove condenser blower per 5.5.1.
5.5.2.2 Remove shroud mounting hardware.

CAUTION: TAKE CARE TO PREVENT DAMAGE TO THE SHROUD ASSEMBLY AND COIL WHILE
SEPERATING AND CUTTING RTV.
5.5.2.3 Use a putty knife and cut RTV along shroud and coil mounting surface areas to
free shroud from coil.

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CLEANING
TASK 21-00-09-10-801
6.0 R-134a AIR CONDITIONING SYSTEM COMPONENT – CLEANING PROCEDURES
SUBTASK 21-00-09-99F-011
6.1 General:
6.1.1 This section details the procedures required to perform certain cleaning functions. The
components listed have certain cleaning procedures associated with them, however these
procedures are in no way an all-encompassing list of what may be required. Care should
be taken to follow the listed procedures and to use common sense when using any cleaning
tools or solvents.
PRECAUTIONS, SUCH AS WEARING PERSONAL SAFETY GEAR TO PREVENT INJURY WHILE
WARNING: SERVICE TECHNICIANS ARE ADVISED TO OBSERVE STANDARD SAFETY PRECAUTIONS
SUCH AS WEARING SAFETY GLASSES, GLOVES AND PROTECTIVE CLOTHING WHEN USING
CERTAIN CLEANING SOLVENTS AND/OR CHEMICALS. INGESTION OF CERTAIN SOLVENTS AND/OR
CHEMICALS CAN CAUSE SERIOUS INJURY OR EVEN DEATH. WHENEVER CLEANING PROCEDURES
INVOLVE THE USE OF SOLVENTS AND/OR CHEMICALS, IT IS HIGHLY RECOMMENDED THAT THE
TECHNICIAN REVIEW THE APPLICABLE MSDS (MATERIAL DATA SAFETY SHEET) PRIOR TO
BEGINNING THE PROCEDURE TO FAMILIARIZE THEMSELVES WITH THE HAZARDS ASSOCIATED
WITH THAT SOLVENT AND/OR CHEMICAL, AND APPROPRIATE RESPONSE NEEDED SHOULD
INGESTION OCCUR.
CAUTION: ALWAYS USE PROTECTIVE COVERINGS AND/OR PROTECTIVE CAPS ON OPEN OR
EXPOSED HOLES, PLUMBING, ETC. THIS WILL ENSURE THE COMPONENT STAYS FREE FROM
DIRT, DUST, AND ANY OTHER FOREIGN MATTER.
6.1.2 Gain access to the Compressor Drive Module, Condenser Blower Module, or Evaporator
Module (refer to the aircraft maintenance manual for removal of access panels and other
hardware that might need to be removed)

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SUBTASK 21-00-09-10-001
6.2 Compressor Drive Module Cleaning Procedures:
6.2.1 The following components of the Compressor Drive Module will require periodic cleaning
(refer to the Inspection Schedule in section 7 for time intervals). This is in no way an all-
encompassing list. If at any time during the inspection process a component is found to be
dirty, use a soft cloth to remove all contaminants from external surfaces (refer to Figure
10001).
 Compressor Drive Module Assembly
6.2.1.1 COMPRESSOR DRIVE MODULE ASSEMBLY: Over time, the Compressor Drive
Module assembly will become dirty and require general cleaning. It is essential
that the assembly remain clean to ensure proper operation and optimal
performance. Use soft cloth, a soft utility brush and/or vacuum, or other suitable
cleaning tools, and remove any dirt, dust, or other foreign matter. Prior to the
installation of the brushes, commutator should be cleaned with compressed air
blast to remove any carbon dust or contaminants
SUBTASK 21-00-09-10-002
6.3 Condenser Blower Assembly Cleaning Procedures:
6.3.1 The following components of the Condenser Blower Assembly will require periodic cleaning
(refer to the Inspection Schedule in section 7 for time intervals). This is in no way an all-
encompassing list. If at any time during the inspection process a component is found to be
dirty, use a soft cloth to remove all contaminants from external surfaces (refer to Figure
10002).
 Vane Axial Blower
 Shroud Assembly
CAUTION: USE EXTREME CARE WHEN HANDLING FAN. DO NOT DROP OR APPLY EXCESSIVE
LOADS TO BLADE SURFACES OR FAN IMBALANCE MAY RESLUT.
6.3.1.1 VANE AXIAL BLOWER ASSEMBLY: Over time, the vane axial blower assembly
will become dirty and require general cleaning. It is essential that the assembly
remain clean to ensure proper operation and optimal performance. Gain access
to vane axial blower assembly (refer to the aircraft maintenance manual for
removal of access panels and other hardware that might need to be removed).
Use soft cloth, a soft utility brush and/or vacuum, or other suitable cleaning tools,
and remove any dirt, dust, or other foreign matter.

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Seminole, OK 74868
Phone (405) 382-0731
6.3.1.2 SHROUD ASSEMBLY: Over time, the shroud assembly may show signs of
separating and/or cracking and this can cause the condenser blower assembly to
have less than optimal performance. Gain access to shroud assembly (refer to
the aircraft maintenance manual for removal of access panels and other
hardware that might need to be removed). If there are signs of separation
between the shroud and the condenser assembly, the shroud must be removed
and reinstalled using new RTV (refer to Disassembly, Section 5 and Assembly,
Section 9). Once the shroud is removed, clean the separated areas carefully
with isopropyl alcohol to remove any dirt, dust, and other foreign matter, to
include the old RTV sealant. Refer to Repair (section 8) for resealing
procedures. If there are signs of cracking, the shroud should be removed and
replaced (refer to Disassembly section 5 and Assembly section 9).
CAUTION: USE EXTREME CARE TO PREVENT DAMAGE OR BENDING OF COIL FINS
6.3.1.3 CONDENSER COIL ASSEMBLY: The coil fins will, over time, become clogged
with dirt, dust and other foreign matter. It is essential that the coil fins remain
clear for proper operation of the condenser blower assembly. Gain access to
condenser coil (refer to the aircraft maintenance manual for removal of access
panels and other hardware that might need to be removed). Using a soft utility
brush and/or vacuum, remove any accumulated dirt, dust and other foreign
matter. A small stiff brush such as a tooth brush can be used to break loose any
caked on dirt.
SUBTASK 21-00-09-10-003
6.4 Evaporator Module Cleaning Procedures:
6.4.1 The following components of both the Evaporator Module Assembly will require periodic
cleaning (refer to the Inspection Schedule in section 7 for time intervals) (refer to Figure
10003):
 Evaporator Coil Air Inlet
 Evaporator Housing Assembly
 Blower Assembly
 Condensate Drain (part of Evaporator Housing Assembly)
 Water Deflector
CAUTION: USE EXTREME CARE TO PREVENT DAMAGE OR BENDING OF COIL FINS
6.4.1.1 EVAPORATOR COIL AIR INLET: The coil fins will, over time, become clogged
with dirt, dust and other foreign matter. It is essential that the coil fins remain clear
for proper operation of the evaporator module assembly. Using a soft utility brush
and/or vacuum, remove any accumulated lint, dirt, dust and other foreign matter.
A small stiff brush such as a tooth brush can be used to break loose any caked on
dirt.

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6.4.1.2 EVAPORATOR HOUSING ASSEMBLY: The components that comprise the

evaporator housing assembly are the shroud and escutcheon . Over time, the
shroud and escutcheon may show signs of separating and this can cause the
evaporator module assembly to have less than optimal performance. If there are
signs of separation between the shroud and escutcheon, clean the separated
areas carefully with isopropyl alcohol to remove any dirt, dust, and other foreign
matter, to include the old RTV sealant. Refer to Repair (section 8) for resealing
procedures.
CAUTION: USE EXTREME CARE TO PREVENT DAMAGE OR BENDING TO THE BLOWER WHEEL
FRAME AND/OR BLADES.
6.4.1.3 BLOWER ASSEMBLY: The components that comprise the blower assembly are
the blower motor, blower scroll and blower wheel. Over time, these components
can become dirty causing the assembly to have less than optimal performance. It
is essential that this assembly remains free and clear of all dirt, dust, and foreign
matter. In an effort to ensure that the blower assembly is free and clear,
disassembly may be required (refer to disassembly, section 5). Using a soft utility
brush, vacuum, and/or towels (or other tools that may be required), remove all dirt,
dust, and foreign matter from the blower wheel and from the inside of the blower
scroll. After cleaning procedure is accomplished, refer to Assembly (section 9).
6.4.1.4 CONDENSATE DRAIN: The condensate drain can become clogged with dirt, dust
and foreign matter over time. It is essential that the drain remain free and clear of
foreign matter or performance will be less than optimal. Use a small brush or other
suitable cleaning tool to ensure that all foreign matter is removed from the drain.
6.4.1.5 WATER DEFLECTOR: The water deflector can become clogged with dirt, dust
and foreign matter over time. It is essential that the deflector remain free and clear
of foreign matter or performance will be less than optimal. Use a small brush or
other suitable cleaning tool to ensure that all foreign matter is removed from the
deflector.
6.4.1.6 EXPANSION VALVE: The expansion valve should be free from dirt, dust and
foreign matter. Use a brush or towel to clean.

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CHECK (INSPECTION SCHEDULE)
TASK 21-00-09-21-801
7.0 R-134a AIR CONDITIOING SYSTEM COMPONENT – INSPECTION SCHEDULE
SUBTASK 21-00-09-21-001
7.1 Compressor Drive Module and Condenser Blower Inspection Schedule:
WARNING: MAKE INSPECTION EVERY 300 HOURS LOGGED ON AIRFRAME HOUR METER. CHECK
HOUR METER ON COMPRESSOR DRIVE MODULE FOR MANDATORY BRUSH REPLACEMENT
SCHEDULE
NOTE: This is the recommended visual inspection schedule for the Compressor Drive Module and
Condenser Blower Assembly. Adherence to this schedule will ensure that all components of the assembly
are in accordance with the manufacturer’s specifications and is necessary to detect structural failure,
deterioration or damage, and to determine the need for corrective action.
7.1.1 If any component listed in this schedule requires cleaning, refer to Cleaning Procedure
(Section 6).
7.1.2
If any component listed in this schedule requires repair and/or replacement, refer to Repair
(Section 8).
Component Type Inspection Unit
Operating
Hours
Drive belt/pulley/cover Visually inspect for wear, nicks, cracks or looseness, and proper tracking. 500
Realign & tension and/or replace as required.
Inspect belt cover for cracks or other damage.
Compressor shaft seal Visually inspect for leaks (excessive oil spray) 500
Condenser outlet and fan Visually inspect condenser outlet and fan shroud for signs of cracking, 500
shrouds separation between shroud and condenser coil.
Condenser coil Visually inspect condenser coil for damage or dirt accumulation. 500
Visually inspect, clean and comb coil fins.
Inspect for leakage.
Inspect plumbing for damage weathering and wear
Visually inspect return bends for nicks, dents, cracks, or other damage..
Electrical wiring Visually inspect wiring for insulation damage, replace as required. 500
Drive motor Visually inspect drive motor commutator for wear.(See Illustration 4.5) 500
Internal contamination inspection
Motor bearing inspection (refer to Special Procedures, Section 12) 500
Drive Motor Brushes Replace Brushes Mandatory every

800 hours
Receiver dryer assembly Inspect for leakage. 500
Inspect plumbing for damage, weathering, and wear.
Verify mounting hardware is secure.
Motor insulation resistance Refer to Special Procedures, Section 12.3 500
check
Table 3.5 Compressor Condenser Inspection and Replacement

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Excellent Condition
Commutator is still bright and shows little sign of wear.
Figure 3.3: Commutator Excellent Condition Example

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Serviceable Condition
Shows some signs of wear and carbon build up
Figure 3.4: Commutator Serviceable Condition Example

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Unserviceable Condition
Shows excessive pitting and chipping on commutator
Figure 3.5: Commutator Unserviceable Condition Example

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SUBTASK 21-00-09-21-002
7.2 Evaporator Module inspection schedule:
NOTE: This is the recommended visual inspection schedule for the Evaporator Module Assembly.
Adherence to this schedule will ensure that all components of the assembly are in accordance with the
manufacturer’s specifications and is necessary to detect structural failure, deterioration or damage, and to
determine the need for corrective action.
7.2.1 If any component listed in this schedule requires cleaning, refer to Cleaning Procedure
(Section 6).
7.2.2 If any component listed in this schedule requires repair and/or replacement, refer to Repair
(Section 8).
Component Type Inspection Required Times

*Evaporator Coil Assembly Inspect refrigerant plumbing for leakage 12 Months
Inspect coil fins for cleanliness and damage
Inspect cold air ducting for leaking cracks or damage
Evaporator housing Assembly Inspect seam between shroud assembly and 12 Months
*Shroud Assembly escutcheon for signs of separation and condensate
*Escutcheon leakage.
*Water Deflector Inspect for cleanliness and damage/integrity.
Inspect condensate drain, making sure hole is clear
and secure.
Blower Assembly Inspect for cleanliness and damage/integrity 12 Months
*Blower Motor Verify that blower wheel is clean and operates vibration
*Blower Wheel free.
*Blower Scroll
Expansion Valve Inspect for cleanliness and damage/integrity 12 Months
Table 3.6 Evaporator Inspections

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REPAIR
TASK 21-00-09-30-801
8.0 R-134a AIR CONDITIONING SYSTEM COMPONENT – REPAIR PROCEDURES
SUBTASK 21-00-09-99F-012
8.1 General:
8.1.1 Refer to Illustrated Parts Listing (IPL) for figure/item numbers (Section 11).
SUBTASK 21-00-09-30-001
8.2 Compressor Drive Module Repair Procedures:
8.2.1 The following components may require periodic repair and/or replacement (refer to the
Inspection Schedule in Section 7 for mandatory time intervals) (refer to Figure 10001):
 Drive Belt/Cover/Pulley
 Drive Motor/Brushes
 Compressor Assembly
 Compressor Shaft Seal
 Electrical Wiring
8.2.1.1 DRIVE BELT/COVER/PULLEYS: The drive belt and the associated pulleys will,
over time, become worn or damaged, or may simply be out of alignment. It is
essential that the drive belt and the pulleys are in excellent condition for proper
operation of the Compressor Drive Module assembly. If the drive belt edges are
showing signs of wearing or if cracking is noticed, it should be replaced. If the
motor drive pulley is showing signs of wearing, both on the pulley teeth and pulley
flanges, it should be replaced. If belt cover is cracked or damaged in any way, it
should be replaced. If assembly is out of alignment, system will need to be aligned
and tensioned. Refer to Disassembly (Section 5) and Assembly (Section 9).
Contact Enviro Systems customer service to order new components.

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8.2.1.2 DRIVE MOTOR BRUSHES: Drive motor brushes can, over time, become worn or
damaged. It is essential that the drive motor brushes remain in excellent condition
for proper operation of the compressor condenser module assembly. They must
be replaced according to the inspection schedule in Section 7. Refer to
Disassembly (Section 5) and Assembly (Section 9).
CAUTION: INSPECT THE COMMUTATOR FOR EXCESSIVE OR UNEVEN WEAR. THE COMMUTATOR
SHOULD HAVE A BURNISHED APPEARANCE WITH LIGHT FILMING. IF THE COMMUTATOR IS BLACK,
BURNED, PITTED, GROOVED, OR EXCESSIVELY WORN, THE MOTOR SHOULD BE REPLACED OR
REBUILT. IF THE DEPTH OF THE MICA UNDERCUT REMAINING ON THE COMMUTATOR IS LESS
THAN .020 INCH THE MOTOR SHOULD ALSO BE REPLACED. (See Illustration 4.3 THRU 4.5 in Section 7
for examples)
8.2.1.3 COMPRESSOR ASSEMBLY: The compressor and pulley can, over time, become
dirty and shows signs of wear and/or damage. It is essential that the compressor
and its pulley remain in excellent condition for proper operation of the Compressor
Drive Module assembly. Check the pulley condition as per 8.2.1.1. If there is
damage to the pulley, it should be replaced. Check the compressor shaft seal as
per 8.2.1.4. If a leak is detected and it is excessive, the compressor should be
replaced. If there is visible damage to the compressor housing, the compressor
should be removed and replaced. Refer to Disassembly (Section 5) and Assembly
(Section 9). Contact Enviro Systems customer service.
8.2.1.4 COMPRESSOR SHAFT SEAL: Over time, the compressor shaft seal may show
signs of excessive oil spray and this can cause the Compressor Drive Module
assembly to have less than optimal performance. If excessive oil spray is
observed, the compressor should be replaced. Refer to Disassembly (Section 5)
and Assembly (Section 9). Contact Enviro Systems customer service to order new
compressor.
NOTE: If the compressor has not been operated for 30-60 days or more, the dynamic shaft seal may indicate
a small leak due to the absence of oil on the dynamic seal surface. Operation of the system should eliminate
this type of leak. If not, proceed with removal and replacement procedures.
8.2.1.5 ELECTRICAL WIRING: The electrical wiring can, over time, become worn and
damaged. If the wiring insulation is showing signs of abrasion or damage of any
other kind, replace wiring as required
SUBTASK 21-00-09-30-002
8.3 Receiver Dryer Assembly Repair Procedures:
8.3.1.1 RECEIVER DRYER ASSEMBLY: The receiver dryer assembly can, over time,
become damaged. The component can also become contaminated due to
damaged, opened, cracked, or ruptured lines or hoses. If the receiver dryer shows
signs of damage, the receiver dryer should be removed and replaced. If the
receiver dryer has been contaminated, it must be removed and replaced (refer to
Disassembly, Section 5 and Assembly, Section 9). Contact Enviro Systems
customer service to order a new receiver dryer.
SUBTASK 21-00-09-30-003

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8.4 Condenser Blower Assembly Repair Procedures

 Vane Axial Blower Assembly
 Shroud Assembly
8.4.1.1 VANE AXIAL BLOWER ASSEMBLY: The vane axial blower motor and fan
assembly is a balanced assembly and cannot be removed and replaced in the
field. If there is damage to this assembly in any way, remove the entire vane axial
blower assembly (refer to Disassembly, Section 5 and Assembly, Section 9) and
return to Enviro Systems for repair or replacement. Contact Enviro System
customer service.
8.4.1.2 SHROUD ASSEMBLY: The shroud assembly can, over time, show signs of
cracking and separation between the shroud and the condenser coil assembly.
This can cause the condenser blower assembly to have less than optimal
performance. If the shroud is separating, refer to Disassembly (Section 4) for
removal of shroud. Then refer to Cleaning (Section 6). After insuring that the
seam between the shroud and condenser has been cleaned according to the
cleaning procedures (Section 6), apply a new bead of RTV and reinstall shrouds
(refer to Assembly, Section 9). Allow RTV to cure for a minimum of 24 hours
before operating system. If the shrouds are cracked or are damaged in any other
way, the shrouds should be replaced (refer to Disassembly, Section 5 and
Assembly, Section 9). Contact Enviro Systems customer service to order new
components.
8.4.1.3 CONDENSER COIL ASSEMBLY: The condenser coil fins can, over time, become
clogged with dirt, dust, and other foreign matter. The component can also become
damaged. The coil return bends can, over time, become dented, cracked, or can
start leaking. It is essential that the condenser coil as well as the coil bends
remain clear and undamaged for proper operation of the condenser blower
assembly. Refer to Cleaning (Section 6) for proper cleaning procedures. If coil
fins are bent, use a fin comb and try straightening the fins. If fins and coil return
bends are excessively damaged, the entire condenser blower assembly must be
removed (refer to Disassembly, Section 5 and Assembly, Section 9) and sent to
Enviro Systems for repair. Contact Enviro Systems customer service

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SUBTASK 21-00-09-30-004
8.5 Evaporator Module Repair Procedures:
 Evaporator Coil
 Evaporator Housing Assembly
 Blower Assembly
 Condensate Drain (part of Evaporator Housing Assembly)
 Water Deflector
8.5.1.1 EVAPORATOR COIL: The evaporator coil fins can, over time, become clogged
with dirt, dust, and other foreign matter. The component can also become
damaged. The coil return bends can, over time, become damaged. Dents, nicks,
cracks, and other damage can cause less than optimal performance. It is
essential that the condenser coil remain clear and undamaged for proper operation
of the evaporator module assembly. Refer to Cleaning (Section 6) for proper
cleaning procedures. If coil fins are bent, use a fin comb and try straightening the
fins. If fins are excessively damaged or the return bends are excessively
damaged, the entire evaporator module assembly must be removed (refer to
Disassembly, Section 5) and sent to Enviro Systems for repair. Contact Enviro
Systems customer service.
8.5.1.2 EVAPORATOR HOUSING ASSEMBLY: The components that comprise the

evaporator housing assembly are the shroud and escutcheon. Over time, the
shroud and escutcheon may show signs of separating and this can cause the
evaporator module assembly to have less than optimal performance. After
insuring that the seam between the shroud and escutcheon has been cleaned
according to the cleaning procedures (Section 6), apply a new bead of RTV and
smooth. Allow RTV to cure for a minimum of 24 hours before operating system. If
housing assembly is damaged in any way other than seam separation, the entire
Forward Evaporator Module Assembly must be removed and sent to Enviro
Systems for repair. Contact Enviro Systems customer service.
CAUTION: USE EXTREME CARE TO PREVENT DAMAGE OR BENDING TO THE BLOWER WHEEL
FRAME AND/OR BLADES.
8.5.1.3 BLOWER ASSEMBLY: The components that comprise the blower assembly are
the blower motor, blower scroll and blower wheel. Over time, these components
can become dirty or damaged causing the assembly to have less than optimal
performance. Occasionally damage will occur to unit that requires repair and/or
replacement of one or more of the assembly components.

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8.5.1.3.1 If blower motor wheel is damaged, such as having bent or cracked blades,
removal and replacement is required. Refer to Disassembly (Section 5) for
removal procedures. Refer to Assembly (Section 9) for installation procedures.
After completing the removal and installation of the new blower wheel, perform
functional check (Section 3). Contact Enviro Systems customer service to
order new blower wheel.
8.5.1.3.2 If blower motor scroll is damaged in any way, the entire Forward Evaporator
Module Assembly must be removed and sent to Enviro Systems for repair.
Contact Enviro Systems customer service.
8.5.1.3.3 If blower motor is damaged or is not operating to specifications, removal and

replacement is required. Refer to Disassembly (Section 5) for removal. Refer
to Assembly (Section 9) for installation. After completing the removal and
installation of the new blower motor, perform functional check (Section 3).
Contact ENVIRO Systems customer service to order a new motor or to return
entire assembly.
8.5.1.4 CONDENSATE DRAIN: The condensate drain (part of the housing assembly)
can, over time, become damaged. It is essential that the drain remains in
excellent condition for proper operation of the evaporator module assembly. If the
condensate drain is damaged, the entire Forward Evaporator Module Assembly
must be removed and sent to Enviro Systems for repair. Contact Enviro Systems
customer service.
8.5.1.5 WATER DEFLECTOR: The water deflector can, over time, become damaged. It
is essential that the deflector remains in excellent condition for proper operation of
the evaporator module assembly. If the water deflector is damaged, the entire
Forward Evaporator Module Assembly must be removed and sent to Enviro
Systems for repair. Contact Enviro Systems customer service.

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ASSEMBLY
TASK 21-00-09-40-801
9.0 R-134a AIR CONDITIONING SYSTEM COMPONENT - ASSEMBLY
SUBTASK 21-00-09-99F-013
9.1 General:
9.1.1 Refer to Illustrated Parts Listing (IPL) during assembly procedures for figure/item numbers
(Section 11).
9.1.2 Gain access to the Compressor Drive Module, Condenser Blower Assembly, or Evaporator
Module (refer to the aircraft maintenance manual for removal of access panels and other
hardware that might need to be removed)
9.1.4 After assembly of any component requiring installation of refrigerant plumbing or hoses,
charge refrigerant system (refer to Servicing, Section 13).
NOTE: A functional test should be performed any time one or more components are removed and replaced.
Prior to starting functional test, ensure that all components of the assembly are installed. Refer to Test and
Fault Isolation Section 3.
9.1.5 Tools, fixtures, equipment, or consumable items required
 Gates Sonic Belt Tension Meter
 Small ‘rare earth” magnet
 Tape
 Straight edge
 Measuring device
 Shop air, 40 PSIG max
 Micrometer
 Scribe or wire hook
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 Inspection mirror
 Thermometer, 0-150°F
 Flash light or service lamp
 R-134a service manifold and gauge set
 R-134a electronic leak detector
 R-134a refrigerant cylinder
 Leak check fluid (soapy)
 Thread sealant primer
 Thread sealant
 Dry nitrogen, regulated
SUBTASK 21-00-09-40-001
9.2 Receiver Dryer Assembly Procedures:
9.2.1 Assembly of Receiver Dryer
9.2.1.1 Position receiver dryer on motor support bracket and attach with mounting clamps.
9.2.1.2 Connect pressure switch electrical wiring (if applicable).
SUBTASK 21-00-09-40-002
9.3 Compressor Drive Module Assembly Procedures
9.3.1 Assembly of Drive Motor Brushes (refer to Figure 3 for details)
CAUTION: ENSURE THAT MOTOR COMMUTATOR IS CLEAR OF ANY CONTAMINATION AND THAT
ALL CARBON DUST IS REMOVED.
CAUTION: DO NOT ALLOW BRUSH SPRING TO SNAP AGAINST THE BRUSH OR BRUSH DAMAGE
MAY RESULT.
9.3.1.1 Ensure that brushes have not exceeded the time limit listed in Check Inspection
Schedule (Section 7).
9.3.1.2 Lift brush spring and slide brush into brush rack. Verify that brush direction is
against commutator.
9.3.1.3 Seat new brushes according to Special Procedures, Section 12. All new brushes
must be seated to ensure proper motor operation and/or performance.

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CAUTION: APPLY THREAD SEALANT SPARINGLY TO MALE FITTING THREADS STAYING CLEAR OF
FIRST 2-3 THREADS.
9.3.1.4 Twist the shunt leads 180˚ so that the wires cross at the center of the brush as
close to the brush as possible (see below) This is to ensure the shunt leads do not
prevent the brush from traveling through the brush rack.
9.3.1.5 Attach brush shunt wire terminal to brush rack using attaching screw. Verify the
shunt wire terminal is positioned so that the wires exit inward towards the center of
the motor (see below). Apply a drop of thread sealant to screw.

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9.3.1.6 Using a tongue depressor, route brush shunt leads down the side of the brush rack
to allow for brush wear and to prevent shorting to the brush cover or motor
housing. (see below)
9.3.1.7 Install brush cover screen and secure with attaching screws and washers (refer to
table 1, section 1.3 for torque specifications). Safety wire screws in place.
9.3.1.8 Run system for a minimum of 15 minutes to seat brushes and check motor
operation.

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9.3.2 Assembly of Fan

NOTE: The 1134608-1 fan blade and 1250124-1 spacer have been replaced with the 1134608-3 fan
blade and 1250124-3 spacer. For the initial replacement to the new fan blade and spacer, kit part
number K1134608-3 should be purchased. This kit includes fan blade, spacer, washer, and retaining
nut.
9.3.2.1 1134608-1 Fan Blade (Obsolete) (see illustrated parts list)
9.3.2.1.1 Slide 1134608-1 fan assembly and 1250124-1 spacer

onto motor shaft.
FIRST 2-3 THREADS.
9.3.2.1.2 Apply a drop of thread sealant to the set screw thread.

Tighten fan assembly set screw (refer to table 1,
Section 1.3 for torque specifications), insuring that the
screw is located on flat part of motor shaft.
9.3.2.1.3 Tighten motor shaft retaining nut and washer.
9.3.2.2 1134608-3 Fan Blade (see illustrated parts list)
9.3.2.2.1 If replacing the 1134608-1 fan blade with the 1134608-3

fan blade, procurement of kit part number K1134608-3
is required.
9.3.2.2.2 Slide the spacer onto the motor shaft.
9.3.2.2.3 Thread the fan blade onto the motor shaft with the Hex
outward.
9.3.2.2.4 Torque fan blade to 20 in.-lbs.
9.3.2.2.5 Install the washer and nut onto the motor shaft. Torque
the nut to 240 in.-lbs.

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9.3.3 Assembly of Fan Shroud
9.3.3.1 Slide fan shroud onto motor assembly and attach using fan shroud clamp.
9.3.4 Assembly of Drive Motor
CAUTION: TAKE EXTREME CARE WHEN INSTALLING DRIVE MOTOR ONTO ASSEMBLY OR DAMAGE
TO FAN OR FAN SHROUD COULD OCCUR.
9.3.4.1 Reconnect motor electrical leads. Observe correct motor lead polarity when
making connections. Secure with cable ties and route to prevent chaffing.
9.3.4.2 Position drive motor in motor support bracket and install bolt and turn buckle
hardware (refer to table 1, section 1.3 for torque specifications).
9.3.5 Assembly of Compressor
9.3.5.1 Position compressor on mounting bracket and attach with bolts and washers (refer
to Table 1, Section 1 for torque specifications). Install turn buckle hardware but do
not tighten (tighten only after tensioning has been accomplished).
9.3.5.3 Apply 1-2 drops of thread sealant on compressor discharge port threads.
CAUTION: TAKE EXTREME CARE NOT TO GET REFRIGERANT OIL ON FITTING THREADS
9.3.5.4 Apply a thin film of refrigerant oil to compressor discharge port flare surface.
9.3.5.5 Connect condenser fitting to compressor discharge port and tighten (refer to table
1, section 1.3 for torque specifications).

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9.3.5.7 Apply 1-2 drops of thread sealant on receiver dryer inlet port threads.
9.3.5.8 Apply thin film of refrigerant oil to O-ring and install on condenser fitting.
9.3.5.9 Connect condenser fitting to receiver dryer and tighten (refer to table 1, section 1.3
for torque specifications).
9.3.6 Assembly of Drive Belt and Pulley
9.3.6.1 Verify key is installed and motor is free to rotate. Place drive belt (5MR-535-25)
over motor drive pulley and slide belt onto compressor pulley while sliding motor
pulley onto motor shaft.
9.3.6.2 Belt should be tensioned (refer to Figure 5) and tested utilizing Gates Sonic
Tension Meter to ranges shown (refer to Figure 6). Securely tighten tensioner’s
attachment hardware to include installing turn buckle locking device when proper
tension is achieved. Follow the procedure outlined below.
CAUTION: DO NOT OVER TENSION BELT. IMPROPER BELT TRACKING AND BELT / MOTOR DAMAGE
MAY RESULT.
9.3.6.2.1 Gates Sonic Tension meter method: (Required

Method)
 Input the following information into the Meter:
 Weight: 3.2 g/m/mm
 Width: 25 mm
 Span: 147 mm
9.3.6.2.2 In A Quiet/Non Windy Environment – Cord

Sensor
9.3.6.2.3 Push the measure button on the meter, hold the cord sensor approximately 1
cm (0.4 in) above the belt at the midway point between the pulleys.
 Lightly strum the belt with finger to induce a vibration.
 Record the results in Hz or Newton’s
 Repeat 3 times (or more if necessary) to verify consistent readings
9.3.6.2.4 In A Noise Filled Environment – Inductive

Sensor
CAUTION: REMOVE THE TAPE AND MAGNET FROM BELT BEFORE PROCEEDING.
9.3.6.2.5 Tape the Small Magnet in the mid-span of the belt; push the measure button
on the meter. Hold the inductive sensor approximately 1 cm (0.4 in) above
the magnet

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9.3.6.2.6 Lightly strum the belt with finger to induce a vibration.

 Record the results in Hz or Newton’s (N)
 Repeat 3 times (or more if necessary) to verify consistent readings
9.3.6.3 Rotate compressor by hand through several revolutions and verify belt tracking.
Readjust as required.
9.3.6.4 Secure drive pulley by tightening drive pulley set screws (refer to table 1, section
1.3 for torque specifications).
9.3.6.5 Tighten and secure compressor mounting bolts, washers, and lock nuts (refer to
table 1, section 1.3 for torque specifications).
9.3.7 Assembly of Hour Meter
9.3.7.1 Return wire connections to correct locations on back of hour meter.
9.3.7.2 Attach hour meter to bracket (2 screws, 2 nuts on backside). Wire tie as
necessary
9.3.7.3 Attach motor wire clamp (1 screw) and electrical mounting assembly (4 screws, 4
nuts on bottom of unit).
9.3.8 Assembly of Power Relay
9.3.8.1 Carefully slide power relay into position and attach using mounting hardware.
9.3.8.2 Connect electrical connections and install boots for protection.
9.3.9 Assembly of Belt Cover
9.3.9.1 Position belt cover on assembly and attach with screws (refer to table 1, section
1.3 for torque specifications).

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Figure 5 Belt Tensioning Reference
Tensioning Information: (Sonic Tension Meter 507C, www.gates.com)
New Belt Used Belt

Min Max Min Max
Belt Frequency: (Hz) 137 143 114 122

Sonic Tension Meter: (N) 12 136 86 99
Table 4 Gates Sonic Tension Meter Data

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SUBTASK 21-00-09-40-003
9.4 Evaporator Module assembly procedures
9.4.1 Assembly of Blower Motor/ Wheel
9.4.1.1 Position blower wheel on blower motor shaft. Ensure that there is a gap of 0.20”
between motor and back of blower wheel.
FIRST 2-3 THREADS.
9.4.1.2 Apply a drop of thread sealant to the set screw threads. Tighten set screw (refer
to table 1, Section 1 for torque specifications), insuring that the screw is located on
flat part of motor shaft.
9.4.1.3 Sparingly apply a thin bead of RTV to blower motor mounting plate.
9.4.1.4 Carefully install blower motor/wheel into blower motor scroll and attach with blower
motor attachment screws and flat washers. Refer to table 1, Section 1 for torque
specifications.
9.4.1.5 Ensure that blower wheel does not hit or rub against blower scroll by rotating
wheel by hand, and verifying sufficient clearance.
9.4.1.6 Connect blower motor to electrical power and perform a functional test (Section 3).
Wire hookup is as follows (refer to Table 5):
Black Ground
Orange +28 VDC, Hi Speed
Red +28 VDC, Low Speed
Table 5 Blower Motor Electrical Connections
9.4.2 Assembly of Expansion Valve
FIRST 2-3 THREADS.
9.4.2.2 Set new valve adjustment screw to same position as failed valve.
9.4.2.3 Apply 1-2 drops of thread sealant to threads of expansion valve and to evaporator
header nut threads.
CAUTION: TAKE EXTREME CARE NOT TO GET REFRIGERANT OIL ON FITTING THREADS.

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9.4.2.4 Apply thin film of refrigerant oil to expansion valve flare surface and a very small
amount to the O-rings to prevent damage.
9.4.2.5 Connect expansion valve to coil header fitting. Refer to table 1, Section 1 for
torque specifications.
9.4.2.6 Route expansion valve bulb line along evaporator escutcheon and attach bulb to
evaporator coil outlet header. Bulb should be located on header at 3 O’clock
position.
9.4.2.7 Cover bulb with insulation and secure with tie straps 2 places.
9.4.2.8 Leak check per Testing and Fault Isolation, Section 3.5 and then evacuate and
charge system per Servicing, Section 13.
SUBTASK 21-00-0940-004-
9.5 Condenser Blower Assembly Procedures
9.5.1 Assembly of Shroud Assembly
9.5.1.1 Ensure that shroud assembly and coil assembly mounting surface areas are
thoroughly clean and free of any dirt or other foreign matter (refer to Cleaning,
Section 6).
9.5.1.2 Apply a thin bead of RTV sealant on the shroud mounting surface and install,
insuring correct orientation (refer to Repair, Section 8).
CAUTION: DO NOT OVER TORQUE SCREWS, OR DAMAGE TO THE SHROUD AND COIL MAY
RESULT.
9.5.1.3 Install mounting hardware (refer to table 1, Section 1 for torque specifications).
9.5.2 Assembly of Condenser Blower
9.5.2.1 Apply a small bead of RTV sealant on the condenser shroud and install the vane
axial blower insuring the orientation of the wires are correctly positioned.
CAUTION: DO NOT OVER-TORQUE MOUTING SCREWS OR THREAD DAMAGE MAY RESULT.
9.5.2.2 Install all mounting screws and washers and torque (refer to Standard Torque
Values, Section 1.3).
9.5.2.3 Rotate blower wheel to ensure there is no rubbing and that the blower outlet is free
of all foreign matter and obstructions.
9.5.2.4 Connect motor wiring, then connect power leads to condenser blower and perform
functional test per Testing and Fault Isolation, Section 3.2.
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT

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TASK 21-00-09-99F-803
10.0 SPECIAL TOOLS/EQUIPMENT
SUBTASK 21-00-09-99F-014
10.1 General:
10.1.1 This section describes the necessary tools and test equipment required to perform
maintenance, functional testing, troubleshooting, and repair procedures. Equivalent test
equipment may be substituted only if it meets the listed equipment specifications.
 Regulated Shop Air 40 PSIG
 Fin comb SK1250101-13
 Miscellaneous hand tools and socket set
 Shop vacuum with soft utility brush
 Gates Sonic Tension Meter 507C (www.gates.com)
 Vacuum pump, air or electric 0-30 in.hg.
 Gaseous dry Nitrogen, regulated source 0-500 PSIG
 Reclaim/Recycle Cart (R-134a) (Robinair model # 342000) (preferred) or R-134a refrigerant
charging manifold with gauges and hoses.
 Thread sealant primer Loctite 7471
 Thread sealant Loctite 569
 Loctite primer N7649
 RTV sealant 11602 Black
 Hose adapter 1/2 in. male ACME to 1/4 in. female flare
 Leak check fluid soap solution
 Refrigerant oil contact Enviro for proper oil type
 External or aircraft power source 200 amp.
 Inspection mirror
 Thermometer 0-150°F
 Flashlight or service lamp
 Refrigerant R-134a or R-12
 Kent-More Flush Adapter J42939
 Small “rare earth” magnet
 Tape
 Straight Edge
 Measuring Device
 Micrometer
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 Scribe or Wire Hook

 Volt-OHM Meter

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ILLUSTRATED PARTS LIST
TASK 21-00-09-98-801
11.0 R-134a AIR CONDITIONING SYSTEM COMPONENT ILLUSTRATED PARTS LISTING
SUBTASK 21-00-09-99F-015
11.1 Introduction:
11.1.1 This Illustrated Parts Listing (IPL) is intended for use during testing and isolation,
disassembly, cleaning, check (inspection), repair, assembly, and issuing the replaceable
equipment components as well as in identification of new and reclaimed parts.
11.1.2 This IPL includes illustrations of the Compressor Drive Module, Condenser Blower
Assembly, and the Evaporator Module Assembly to be used during the procedures outlined
previously.
11.1.3 This IPL includes figure and item numbers to call out specific components. Each
component will be assigned an item number. Items listed but not shown are identified by a
dash preceding the item number. The figure refers to the exploded view of the equipment.
11.1.4 This IPL includes a part number for each component called out in the illustration that is a
field replaceable component.
11.1.5 This IPL includes nomenclature for each component that helps with identification.
11.1.6 This IPL includes units per assembly for each component called out in the illustration that is
a field replaceable component.

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Figure 10001 Compressor Drive Module Assembly 1133610-4

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Replacement motor cooling fan blade (K1134608-3)

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1134608-1 (Obsolete) 1134608-3
Obsolete vs. Replacement Fan Blade Comparison

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FIG. ITEM PART NUMBER NOMENCLATURE UNITS ASSY.

10001-10 1134146-6 MOTOR ASSEMBLY 1
10A 1134228-1 POWER RELAY 1
11A 10-32X3/8IHW SCREW 2
12A 409-1032Z LOCK NUT 2
13A MS25171-3 LARGE BOOT 1
11 1133087-2 TURN BUCKLE ASSEMBLY 1
-12 MS21042-5 LOCK NUT 1
-13 NAS 1149D0563J FLAT WASHER (AN960JD516) 2
-14 AN5-32A BOLT 1
-15 AN4-14A BOLT 2
-16 NAS1149D0463H FLAT WASHER (AN960D416) 4
-17 1133617-1 SPACER 4
-18 MS21256-1 TURN BUCKLE LOCKING DEVICE 1
-19 MS21042-2 LOCKING NUT 2
20 1134247-3 DRIVE PULLEY 1
30 1133618-1 BELT COVER 1
31 NAS1149F0363P FLAT WASHER ALTERNATE (AN960-10) 1
32 MS35207-262 SCREW 1
-33 MS32506-230 SCREW 2
40 5MR-535-25 DRIVE BELT 1
50 1133130-7 COMPRESSOR ASSEMBLY 1
-51 AN6-31A BOLT 1
-52 MS35333-42 LOCK WASHER 1
-53 AN5-32A BOLT 1
-54 AN5-33A BOLT 1
-55 MS35333-41 FLAT WASHER 2
-56 1133633-2 COMPRESSOR CLEVIS 1
60 1134609-1 FAN SHROUD 1
61 QS100M60H CLAMP 1
70 (OBS) 1134608-1 MOTOR FAN (OBSOLETE) N/P
71 NAS1149F0663P FLAT WASHER (AN960-616) 1
72 21FK-624 LOCK NUT 1
73 (OBS) 1250124-1 ALUMINUM SPACER` N/P
74 1134608-3 MOTOR FAN (Superseded 1134608-1) 1
75 1250124-3 ALUMINUM SPACER (Superseded 1250124-1) 1
76* K1134608-3 Kit containing items 71, 72, 74, 75 1
-80 1251171-6 MOTOR BRUSH/ SHUNT (SET CONTAINS 4 1
BRUSH PAIRS)
Figure 10001 Compressor Drive Module Assembly Details
- ITEMS NOT ILLUSTRATED N/P ITEMS NOT PROCURABLE

* Use this kit when replacing the stamped aluminum fan blade with the machined fan blade.

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Figure 10002 Condenser Blower Assembly 1134620-5

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1-10 1134620-5 CONDENSER ASSEMBLY
20 CONDENSER COIL ASSEMBLY N/P
30 1134619-1 SHROUD ASSEMBLY 1
40 NAS1149F0332P WASHER FLAT (AN960-10L) 8
50 409-1032Z LOCKNUT 4
60 10-32X500IH SCREW (PURCHASE 10-32X1/2IH) 4
65 10-32X375IH SCREW (PURCHASE 10-32X3/8IHW) 4
70 1250435-10 FAN VANE AXIAL 1
80 NAS620-10 WASHER FLAT 6
90 NAS1351-3-10P SCREW CAP 6
Figure 10002 Condenser Blower Assembly Details
- ITEMS NOT ILLUSTRATED

N/P ITEMS NOT PROCURABLE

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Figure 10003 Evaporator Module Assembly 1133300-1

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10003-10 1133210-1 BRUSHLESS DC MOTOR 1

20 1250219-6 BLOWER WHEEL 1
30 BLOWER SCROLL N/P
40 SHROUD N/P
50 ESCUTCHEON N/P
60 1134417 EXPANSION VALVE 1
61 AS4407D0808 90° SWIVEL FITTING 2
62 1250284-1 REDUCER FITTING 1
63 1134419-1 SPRING CLIP 1
70 NAMEPLATE N/P
110 NAS1149FN832P FLAT WASHER 4
120 8-32X5/8IHS SCREW 4
Figure 10003 Evaporator Module Assembly Details
- ITEMS NOT ILLUSTRATED

N/P ITEMS NOT PROCURABLE

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SPECIAL PROCEDURES
TASK 21-00-09-82-801
12.0 SPECIAL PRODECURES
SUBTASK 21-00-09-82-001
12.1 Motor Insulation Resistance Check:
12.1.1 After the inspection of the commutator, a quick check of the motor insulation resistance
should be performed. This check may be done with or without the brushes installed, but the
power leads must be removed from the motor during this procedure.
12.1.2 Gain access to the Compressor Drive Module, Forward Evaporator Module, or Aft
Evaporator Module (refer to the aircraft maintenance manual for removal of access panels
and other hardware that might need to be removed)
12.1.4 With OHM meter positive lead connected to the motor positive terminal and the other lead
connected to motor case (grnd), measure and record resistance. Resistance value must be
equal to or greater than 10,000 OHM’s. If less, the motor should be replaced.
SUBTASK 21-00-09-20-001
12.2 Motor Bearing Inspection:
12.2.1 Motor bearing will be inspected according to Section 7 Inspection Schedule Table 3.5.
12.2.2 Gain access to the Compressor Drive Module, Forward Evaporator Module, or Aft
Evaporator Module (refer to the aircraft maintenance manual for removal of access panels
and other hardware that might need to be removed)
12.2.4 Remove brush cover (on some systems, removal of power leads is required prior to brush
cover removal, tag positive terminal).
12.2.5 Remove brushes from guides and remove belt from motor pulley (refer to Disassembly,
Section 5).
12.2.6 Rotate motor shaft by hand to ensure freedom of movement. Visually inspect bearing for
sign of overheating or loss of lubrication using an inspection mirror.
12.2.7 If bearings rotate smoothly and are good, reinstall belt and brushes (refer to Assembly,
Section 9). Check belt alignment and tensioning (refer to Assembly, Section 9).

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SUBTASK 21-00-09-82-002
12.3 Motor Brush Seating Procedure:
12.3.1 Cut 4” long by 1.5 “ wide strip of 400-500 grit paper and place, with rough side out, on motor
commutator. Secure one end of the paper to the commutator with masking tape in a
manner such that the taped end will lead in the direction of shaft rotation (CCW looking at
fan end). The other end will remain loose and overlap the taped end. Raise each brush
momentarily while rotating the shaft until the taped end passes under each brush. After the
grit paper is properly located tight against the commutator and encompasses all brush
surface area, carefully rotate the armature by hand in the normal direction of rotation until a
full seat is obtained on each new brush. Three to four rotations is generally adequate.
CAUTION: EXCESSIVE SEATING IS NOT ADVISED OR BRUSH LIFE MAY BE REDUCED.
12.3.2 Remove grit paper and blow out all the carbon dust and other contamination from
commutator and brush area.
SUBTASK 21-00-09-20-002
12.4 Brush Shunt Wire Routing
12.4.1 Un-Acceptable Shunt Wire routing
Notice the shunt wires are lying over the brush rack and the terminal is positioned so that
the wires are exiting towards the brush.

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12.4.2 Acceptable Shunt Wire routing

CAUTION: CAREFULLY LAY BRUSH SHUNT LEADS IN A POSITION WHICH WILL PREVENT ANY
POSSIBLE SHORTING PROBLEMS. LEADS MUST EASILY FOLLOW BRUSH AND SPRING MOVEMENT
AS WEAR OCCURS. IMPROPER LEAD PLACEMENT MAY RESULT IN MOTOR DAMAGE.
Notice the shunt wires are crossed so the wires will not “hang” on the edge of the brush rack
and the terminal is positioned so that the wires exit towards the center of the motor.
12.5 Compressor Oil Level Check:

NOTE: Checking compressor oil quantity is only required if an excessive amount of oil is observed due to
leaking or the system has been vented quickly thereby causing a loss of oil. An oil check can only be made
with the system vented.
12.5.1 When replacing the compressor, use the following procedure to add required oil to system.
12.5.2 Drain and measure oil from new compressor (7 oz).
12.5.3 Drain and measure oil from failed compressor. Record quantity in ounces.
CAUTION: DO NOT OVERFILL COMPRESSOR WITH OIL OR SYSTEM PERFORMANCE WILL BE
AFFECTED.
12.5.4 Add new oil to the new compressor in the amount measured from the failed compressor.

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SERVICING
TASK 21-00-09-60-801
13.0 R-134a AIR CONDITIONING SYSTEM SERVICING PROCEDURES
SUBTASK 21-00-09-99F-016
13.1 General:
13.1.1 Reclaiming the system (R-134a) refrigerant charge is required on systems before system
removal, after an accidental line break, component failure or when the system has
excessive leaks. Due to the chemical nature of the refrigerant, every precaution must be
taken to protect the service person from accidental exposure to the refrigerant. Follow all
service precautions previously outlined.
WARNING: ONLY R-134a REFREFRIGERANT IS APPROVED FOR USE IN THIS AIR CONDITIONING
SYSTEM. ANY OTHER REFRIGERANT COULD CREATE A HAZARD TO BOTH THE AIRCRAFT AND
SERVICE PERSONNEL.
13.1.2 Tools, fixtures, equipment, or consumable items required:
 Vacuum pump, air or electric (0-30 in.h.g.)
 Refrigerant, R-134a
 R-134a charging manifold with gauges and hoses
 Thermometer, 0-150° F
 Adjustable inspection mirror
 Service light or flash light
 Shop towels
 RL100S Emkarate Ester refrigerant oil
 External or aircraft power source, 200 amp.
 Reclaim/ Recycle Cart (R-134a)
 Hose adapter (1/2 in, male acme to ¼ female flare)
SUBTASK 21-00-09-60-001
13.2 Evacuating The System (R-134a):
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NOTE: The system must be evacuated for a minimum of 45 minutes to remove air and moisture which can
cause the system to have less than optimal performance.
13.2.1 Gain access to the Compressor Drive Module (refer to the aircraft maintenance manual for
removal of access panels and other hardware that might need to be removed)
13.2.3 If required perform leak check procedure.
13.2.4 Connect certified reclaim charging and recycle cart manifolds to system service ports.
13.2.5 Open both valves and reclaim and recycle the systems refrigerant charge (refer to the
reclaim equipment manufacturer’s instruction manual for recovery unit handling and
operation).Once the refrigerant is reclaimed and recycled apply vacuum on the system for
approximately 30 minutes. System vacuum should attain 25-27 in. hg. in 10 to 15 minutes.
Allow pump to hold a vacuum (29 to 30 in. hg.) for 15 minutes
CAUTION: ANY CHANGE IN VACUUM PRESSURE OR FAILURE TO ACHIEVE A SYSTEM PRESSURE
OF 29 INCHES HG VACUUM INDICATES THE PRESENCE OF A PLUMBING LEAK. REPEAT LEAK
CHECK PROCEDURE AND LOCATE AND FIX ALL LEAKS.
CAUTION: EXCESSIVE WATER AND/OR AIR IN THE SYSTEM WILL CAUSE PRESSURE TO RISE AND
EXPANSION VALVE TO FREEZE UP.
13.2.6 System in now ready for refrigerant charging.
SUBTASK 21-00-09-60-002
13.3 Charging The System (R-134a):
WARNING: SYSTEM DAMAGE CAN OCCUR FROM OVERCHARGING OR UNDERCHARGING THE
SYSTEM TO THE SPECIFIED AMOUNT OF REFRIGERANT.
13.3.3 Charging the system with refrigerant is required on a new system installation or when
“topped off”, the proper method is to recover the existing charge and charge with the
appropriate mass of refrigerant. Refer to the reclaim/recycle equipment manufacturer’s
instruction manual for recovery unit handling and operation. Refrigerant charges for the
system are as follows in Table 6.
Aircraft Model Refrigerant Charge (lbs.)

Cessna 510 Mustang 2.5 + - 0.1
Table 6 Refrigerant Charge

13.3.4 After refrigerant charging, ensure system is operating according to the typical operating
values as outlined in table 7 below.
Outside Air Temperature Suction Pressure Discharge Pressure

(Deg F) (PSIG) (PSIG)
60-70 28 125 - 140
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80 30 170 ±10
95 31 210 ± 10
105 32 237 ± 10
Table 7 Typical Operating Values
SUBTASK 21-00-09-60-003
13.4 Flushing The System (R-134a):
13.4.1 System flushing is required only when the system has experienced a catastrophic failure of
the compressor or receiver drier. In addition, examination of the system refrigerant lubricant
should be performed during component replacement. If this examination shows lubricant
particulate contamination or unusual oil discoloration, a complete system flush is
recommended.
WARNING: KEEP REFRIGERANTS AND OILS AWAY FROM OPEN FLAMES. REFRIGERANTS CAN
PRODUCE POISONOUS GASSES IN THE PRESENCE OF A FLAME. WORK IN A WELL VENTILATED
AREA AND AVOID BREATHING REFRIGERANT /LUBRICANT VAPOR MIST IF ACCIDENTAL
DISCHARGE OCCURS
WARNING: REFRIGERANT RECOVERY/RECYLE SERVICE EQUIPMENT MUST BE APPROVED FOR
USE WITH R-134a REFRIGERANT. RECYCLING MACHINES MUST BE APPROVED BY
UNDERWRITERS LABORATORIES (UL) AND MEET SAE STANDARD J2210 AND SAE STANDARD J2099
FOR REFRIGERANT PURITY.
WARNING: DO NOT INTRODUCE COMPRESSED AIR OR OXYGEN INTO AN AIR CONDITIONING
SYSTEM OR REFRIGERANT CONTAINER. R-134a IN THE PRESENCE OF AIR OR OXYGEN ABOVE
ATMOSPHERIC PRESSURE MAYFORM A COMBUSTABLE MIXTURE.
CAUTION: ENVIRO SYSTEMS INC. DISCOURAGES THE USE OF ALL OTHER FLUSHING AGENTS DUE
TO THE DIFFICULTY OF ASSURING THAT ALL THE SOLVENT HAS BEEN REMOVED. FLUSH AGENTS
REMAINING IN THE SYSTEM RESULT IN POOR COMPRESSOR LUBRICATION AND PREMATURE
COMPONENT FAILURE. IT HAS BEEN FOUND THAT RESIDUAL AMOUNTS OF FLUSH AGENTS MAY
ACT AS CORROSIVES AND AFFECT THE INTEGRITY OF SEALS, O-RINGS, AND OTHER
COMPONENTS.
13.4.4 Connect certified reclaim charging and recycle cart manifolds to system service ports
(ensure reclaim cart is properly grounded) and recover remaining refrigerant (refer to the
reclaim equipment manufacturer’s instruction manual for recovery unit handling and
operation).
13.4.5 Remove expansion valve and install fittings and hoses to close loop after valve removal.
13.4.6 Remove the receiver dryer and install a jumper hose between the open ports.
13.4.7 Apply power to recovery unit and run for a minimum of 15 minutes.
13.4.8 Check for leaks during flushing process. If leaks are detected, stop machine and repair
leaks before continuing.
13.4.9 Confirm that recovery unit shuts down at the end of the selected recovery time.

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13.4.10 Turn power off at the recovery unit and remove from the aircraft.
CAUTION: ALWAYS USE PROTECTIVE COVERINGS AND/OR PROTECTIVE CAPS ON OPEN OR
EXPOSED HOSES, PLUMBING, ETC. THIS WILL ENSURE THAT THE COMPONENT STAYS FREE DIRT,
DUST, OR ANY OTHER FOREIGN MATTER.
13.4.11 Reconnect the lines to the compressor (refer to Assembly, Section 9)
13.4.12 Remove fittings and hoses and re-install the expansion valve (refer to Assembly, Section 9)
13.4.13 Remove jumper hoses from receiver dryer ports and install a new receiver dryer (refer to
Assembly, Section 9)
13.4.14 Perform a system leak check (refer to Test and Fault Isolation, Section 3, System Leak
Check, Section 3.3)
13.4.15 Perform system refrigerant charge (refer to Servicing, Section 13)
13.4.16 Verify system performance (refer to Test and Fault Isolation, Section 3.1)

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STORAGE
TASK 21-00-09-55-801
14.0 COMPRESSOR DRIVE MODULE ASSEMBLY STORAGE PROCEDURES
SUBTASK 21-00-09-99F-017
14.1 General:
14.1.1 This section defines the procedures and requirements necessary if the Compressor
assembly is to be stored and not installed onto aircraft immediately. In addition, this section
defines the procedures and requirements for operation on the aircraft during the cold winter
months when the system is not typically needed or used. These requirements are needed
to maintain a thin film of oil on the Compressor shaft dynamic seal to prevent leakage.
NOTE: If ambient temperature is below 50° F (10°C) the pressure switch is designed to keep the system from
operating and causing possible damage if operated for extended periods of time. In this case, it is
recommended that the aircraft be heated above this threshold to enable the system to operate.
CAUTION: OPERATION OF THE SYSTEM AT LOW AMBIENT TEMPERATURES FOR MORE THAN 15
MINUTES COULD RESULT IN MAJOR DAMAGE OF THE R-134A COMPRESSOR.
SUBTASK 21-00-09-55-001
14.2 System Long Term Shelf Storage:
14.2.1 If unit will be stored for periods in excess of 12 months, the following preventive
maintenance should be followed for the compressor. These procedures should be
performed at 12 months from MFG date on unit and every 6 months thereafter for a
maximum of 36 months.
NOTE: When installing unit with MFG date in excess of 12 months prior to installation date, verify record of
preventive maintenance. If no maintenance record exists, contact Enviro Systems Inc. prior to installation.
14.2.2 For internal pressures within a range of 5-15 PSIG, rotate compressor by hand through a
minimum of 10 revolutions.
14.2.3 For internal pressures below 5 PSIG, system should be pressurized to 15 PSIG using
regulated dry Nitrogen. After pressurizing the system, rotate the compressor by hand
through a minimum of 10 revolutions.
14.2.4 If the system does not have any detectable pressure, the compressor oil must be checked
for contamination using the following procedures:
14.2.4.1 Remove compressor oil plug and insert a clean tie strap into oil fill hole. Remove
the strap to inspect the oil. Oil should have a clear to amber color. If oil shows
specs of black or other contamination, compressor oil should be drained and
replaced.
14.2.4.2 Drain old oil into measuring cup to verify amount of oil being replaced.
CAUTION: ONLY AN ENVIRO APPROVED TYPE OF OIL MAY BE USED IN THIS TYPE OF
COMPRESSOR.
CAUTION: DO NOT OVERFILL COMPRESSOR WITH OIL OR SYSTEM PERFORMANCE WILL BE
AFFECTED.
Copyright © 2019 21-00-09
Page 75
May 2, 2019
12037 N. Highway 99
Seminole, OK 74868
Phone (405) 382-0731
14.2.4.3 Measure an equal amount of new oil and add to compressor. Install oil plug and
tighten.
14.2.4.4 Check system pressure per section 14.2. System is now ready for storage.
21-00-09-55-003
14.3 System Off Season Functional Tests:
NOTE: If ambient temperature is below 50° F (10°C), the pressure switch is designed to keep the system
from operating and causing possible damage if operated for extended periods of time. In this case, it is
recommended that the aircraft be heated above this threshold to enable the system to operate.
CAUTION: OPERATION OF THE SYSTEM AT LOW AMBIENT TEMPERATURES FOR MORE THAN 15
MINUTES CAN RESULT IN MAJOR DAMAGE OF THE R-134A COMPRESSOR.
14.3.1 During cold winter months, the system should be operated for 10-15 minutes every two
weeks to maintain a thin oil film on the compressor output shaft dynamic seal to prevent
shaft leakage.
14.3.2 Prior to turning on the air conditioning system (energizing the compressor drive), run
blowers on high speed for a minimum of 5 minutes. This will aid in warming the refrigerant
and bringing it up to an acceptable temperature enabling operation of the system.

Copyright © 2019 21-00-09
Page 76
May 2, 2019
12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
Component Maintenance Manual

Copyright © 2019 21-00-09
Page 15001
May 2, 2019

Enviro 21-00-09rev13

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12037 N.

OPERATING, SERVICING, AND COMPONENT

WITH ILLUSTRATED PARTS LIST

R-134a AIR CONDITIONING SYSTEM COMPONENTS:

1) COMPRESSOR DRIVE MODULE ASSEMBLY, PART # 1133610-4

2) CONDENSER BLOWER ASSEMBLY, PART # 1134620-5

3) EVAPORATOR MODULE ASSEMBLY, PART # 1133300-1

4) RECEIVER DRYER ASSEMBLY, PART # 1134275-1

5) CHECK VALVE PART # 1310150-2

ATA SPECIFICATION 21-00-09

Enviro Systems Original Release July 18, 2007

REV DESCRIPTION OF CHANGE DATE APPROVAL

Enviro Systems Original Release July 18, 2007

RECORD OF REVISIONS - Continued

REV DESCRIPTION OF CHANGE DATE APPROVAL

11 Added Section 12.4 / Modified Sections 5.3.9.6 and 9.3.1.4 to 11/5/13 BS

Enviro Systems Original Release July 18, 2007

13 Page 4 – added note that “Manuals must be obtained through 5/2/19 BS

Manuals must be obtained through Textron Aviation Technical

Enviro Systems Original Release July 18, 2007

RECORD OF TEMPORARY REVISIONS

REV DESCRIPTION OF CHANGE DATE APPROVAL

Enviro Systems Original Release July 18, 2007

LIST OF SERVICE BULLETINS

SERVICE DESCRIPTION DATE

Enviro Systems Original Release July 18, 2007

RECORD OF REVISIONS ................................................................................................................................... 2

Enviro Systems Original Release July 18, 2007

8.0 R-134a AIR CONDITIONING SYSTEM COMPONENT – REPAIR PROCEDURES........................... 41

Enviro Systems Original Release July 18, 2007

Figure 1 R-134a Refrigerant Flow Schematic................................................................................................ 24

Table 1 Standard Torque Values .................................................................................................................... 12

Enviro Systems Original Release July 18, 2007

1.0 MANUAL INTRODUCTION

1.1.5.2 CAUTION: Discloses vital information in order to prevent damage to the

 CMM Component Maintenance Manual

Enviro Systems Original Release July 18, 2007

TYPE FASTENER DESCRIPTION/LOCATION TORQUE

Table 1 Standard Torque Values

PART NUMBER DESCRIPTION REMARKS

Table 2 Consumable Products

Enviro Systems Original Release July 18, 2007

DESCRIPTION AND OPERATION

2.0 R-134a AIR CONDITIONING SYSTEM DESCRIPTION AND OPERATION

Enviro Systems Original Release July 18, 2007

Enviro Systems Original Release July 18, 2007

2.3.3.2 COMPRESSOR ASSEMBLY: The compressor assembly contains an R134a

Enviro Systems Original Release July 18, 2007

2.3.4 The CONDENSER BLOWER ASSEMBLY (PN 1134620-5) is designed to provide up to

2.3.5.2 SHROUD ASSEMBLY: The shroud assembly is constructed of .093, a high

Enviro Systems Original Release July 18, 2007

Enviro Systems Original Release July 18, 2007

TESTING AND FAULT ISOLATION

Enviro Systems Original Release July 18, 2007

3.4.2.3 Verify all plumbing connections are tight.

Enviro Systems Original Release July 18, 2007

3.4.2.8 Connect yellow charging hose to a regulated dry nitrogen source

3.4.2.9 Regulate nitrogen source to a pressure of 200 PSIG maximum.

3.4.2.13 Apply thread sealant on all male fitting threads sparingly.

Enviro Systems Original Release July 18, 2007

3.4.2.17 Close manifold valve.

B. Power On But System Will 1. Air conditioner breaker off 1. Turn on

Enviro Systems Original Release July 18, 2007