Oscmm Pilatus Pc12 (R-134a) Ata 21-00-23 Rev 10

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
http://www.enviro-ok.com
Component Maintenance Manual
OPERATING, SERVICING, AND COMPONENT
MAINTENANCE MANUAL
WITH ILLUSTRATED PARTS LIST
PILATUS PC12
R-134a AIR CONDITIONING SYSTEM COMPONENTS:
1) COMPRESSOR CONDENSER MODULE ASSEMBLY, PART # 1134400-53

(Supersedes 1134400-13, 1134400-56), 1134400-59
2) EVAPORATOR MODULE ASSEMBLY, PART # 1134200-60 (L) /-61 (R) /-63 (C)
(Supersedes 1134200-42, L /-43. C&R)
ATA SPECIFICATION 21-00-23
Copyright © 2017 Original Release

ATA 21-00-23
January 2008
12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
RECORD OF REVISIONS
REV DESCRIPTION OF CHANGE DATE APPROVAL
ORIGINAL RELEASE 1/4/08 BH
1 Updated Storage, Section 14. Updated information concerning 5/5/08 BH
cold weather operations under General and System Off
Season/On Aircraft Functional Testing.
2 Page 10003, Figure 10001, Fig. Item 40A…was 1134162…is 7/7/08 BH
1134160
3 Delete page 2002 Subtask 21-00-23-99-002 9/22/08 BH
This removes wiring diagram Figure 3, and removes 4.2 “Wiring
Schematic” and 4.2.1 “The following electrical schematic shows
the system components and how they interrelate to each other”.
Renumber subsequent figures 4 and 5 and references to those
figures.
Revises Note above table 3 to remove reference to Figure 3
Wiring Schematic.
4 Correct refrigerant oil specification in SEC. 13.1.2 was BVM100 08/17/10 BH
is RL100H refrigerant oil.
5 IPC Delete item – 51 was AS568A-011 O-ring 11/04/10 BH
6 Title Page P/n 1134400-53 Supersedes 1134400-13 Table 2 08/16/11 BH
add RL100E to consumables as alternative. Also add to list in
SEC. 13.1.2. IPL Change all AN960 washer# to equivalent Nas
#. Add SB11-102. IPL Figure 10001 Add P/N 1134400-53 add
item 10C replacement motor. IPL Item -21A Brush qty. was 4 is
1 (set) Delete Sec. 3.4 and Figure1 Brush replacement wear
details Renumber subsequent Add new Figure 3.3, 3.4, and
3.5. Section 8.2.1.2: change verbiages to reflect replacement
of brushes and add CAUTION referring to commutator wear
condition examples. Change and Label Table 3.5 and 3.6.
Section 12.4.1 was Motor bearing will be inspected every 800-
1000 operational hours. Is Motor bearing will be inspected
according to Section 7 Inspection Schedule Table 3.5.Sec
12.5.1 was Compressor Bearing will be inspected every 1000-
1500 operational hours IS Compressor bearing will be inspected
according to Section 7 Inspection Schedule Table 3.5.
Remove IPL item numbers from Sections 2 thru 10.
Continued Next Page

NOTE: Check Enviro Systems Inc. web site to verify current revision. www.enviro-ok.com
Copyright © 2017 ATA 21-00-23

Page |2 Revision 10 June 1, 2017
12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
REV DESCRIPTION OF CHANGE-Continued DATE APPROVAL

7 SEC 9.2.6 replace belt tensioning instructions for use with Gates 11/11/11 BH
Sonic Meter. Replace Fig 4 with detail of meter use. Add new
Table 4 tensioning information. Renumber Table 5 was Table 4
Typical Operating Values SEC 13.3.3 add refrigerant charge to
rd
this section and omit table 5. Table 3.5 change 3 column title
from Service Hours to Unit Operating Hours IPC indicate part
numbers in detail list for motor and fan of -13 config. ITEM 50C
was 1134192-1 is 1134192-13, ITEM 60A deleted was
1250232-4
8 SEC 1.3 Table 1 Added row 2 .25-28 SET SCREW 4/19/12 BS
EVAPORATOR BLOWER WHEEL 12-15 IN-LBS, changed
torque values for 6-32 SCREW was 7-9 IN-LBS is 8-10 IN-LBS,
changed torque values for 10-32 SCREW/BOLT was 60-75 IN-
LBS is 20-25 IN-LBS, changed ¼-28-UNF torque values was
135-185 IN-LBS is 50-70 IN-LBS, changed 5/16-24UNF was
270-360 IN-LBS is 100-140 IN-LBS, changed 3/8-24UNF torque
values was 270-360 IN-LBS is 160-190 IN-LBS
9 • Section 2.3.1 Added (Superseded by 1134400-53) 1/21/14 BS
• Section 2.3.2 Added (1134400-13/-53)
• Section 11 Figure 10001, 10001-10C, Was: 1134104-5
Is: 1134104-6
• Section 11 Figure 10001, 50C Was: 1134192-13 Is:
1134192-1 (Superseded by 1134192-15)
• SEC. 9.2.4 Added instructions to replace drive motor
with incorporated thermal fuse
10 - Updated drive motor brush removal an installation procedures. 6/1/17 BS
- Remove references of SB11-102
- Added 1134400-56 configuration to title page
- Added note to IPL Figure 10001 for -56 configurations to be
returned for update to -53
- Minor formatting and spelling corrections
- Table 3.6 removed note to remove and replace blower motor
between 4900 – 5100 hours.
- Section 14.4.2 removed reference to General Motors Service
Bulletin 83-12-21
- Added 1134400-59 Configuration
- Removed Section 10.2.4.4.1 through 10.2.2.4.4 describing
procedures for replacing an 1134104-1 motor with an 1134104-
6 motor.
- Removed Section 13.6 Motor brush seating procedure
- Updated Table 2 Consumable Products to include Pilatus part
number where applicable and to specify Enviro part number.

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
RECORD OF TEMPORARY REVISIONS
REV DESCRIPTION OF CHANGE DATE APPROVAL

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
LIST OF SERVICE BULLETINS
SERVICE DESCRIPTION DATE

BULLETIN # RELEASED

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
LIST OF EFFECTIVE PAGES
CHAPTER / SECTION PAGE DATE CHAPTER / SECTION PAGE DATE

All All 5/5/08
ALL All 7/7/08
All All 9/22/08
All All 08/17/10
All All 11/04/10
All All 08/15/11
All All 11/11/11
All All XX/XX/2017

12037 N Highway 99
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Phone (405) 382-0731
Fax (405) 382-0737
TABLE OF CONTENTS
RECORD OF TEMPORARY REVISIONS ........................................................................................................... 4

LIST OF SERVICE BULLETINS ......................................................................................................................... 5
LIST OF EFFECTIVE PAGES ............................................................................................................................. 6
TABLE OF CONTENTS ...................................................................................................................................... 7
LIST OF ILLUSTRATIONS ................................................................................................................................. 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: ......................................................................................... 11
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 Condenser Module Assembly Testing Procedures .................................................. 18
3.3 Evaporator Module Assembly Testing Procedures ........................................................................ 18
3.4 System Leak Check Testing Procedure: .......................................................................................... 19
3.5 Fault Isolation (Trouble Shooting): ................................................................................................... 21
SCHEMATIC AND WIRING DIAGRAMS .......................................................................................................... 25
4.0 R-134A AIR CONDITIONING SYSTEM SCHEMATIC AND WIRING DIAGRAMS ............................ 25
4.1 R-134A Refrigerant Flow Schematic: ................................................................................................ 25
DISASSEMBLY ................................................................................................................................................. 26
5.0 R-134A AIR CONDITIONING SYSTEM COMPONENT - DISASSEMBLY ......................................... 26
5.1 General:................................................................................................................................................ 26
5.2 Compressor Condenser Module Disassembly Procedures ........................................................... 27
5.3 Evaporator Module Assembly Disassembly Procedures ............................................................... 33
CLEANING ........................................................................................................................................................ 34
6.0 R-134A AIR CONDITIONING SYSTEM COMPONENT – CLEANING PROCEDURES ..................... 34
6.1 General:................................................................................................................................................ 34
6.2 Compressor Condenser Module Cleaning Procedures: ................................................................. 35
6.3 Evaporator Module Assembly Cleaning Procedures: ..................................................................... 36
CHECK (INSPECTION SCHEDULE) ................................................................................................................ 37
7.0 R-134A AIR CONDITIOING SYSTEM COMPONENT – INSPECTION SCHEDULE .......................... 37
7.1 Compressor Condenser Module Assembly Inspection Schedule: ................................................ 37
7.2 Evaporator Module Assembly Inspection Schedule: ...................................................................... 42
REPAIRS ........................................................................................................................................................... 43
8.0 R-134A AIR CONDITIONING SYSTEM COMPONENT – REPAIR PROCEDURES .......................... 43
8.1 General:................................................................................................................................................ 43
8.2 Compressor Condenser Module Repair Procedures: ..................................................................... 43
8.3 Evaporator Module Assembly Repair Procedures: ......................................................................... 46

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
ASSEMBLY ....................................................................................................................................................... 48
9.0 R-134A AIR CONDITIONING SYSTEM COMPONENT - ASSEMBLY ............................................... 48
9.1 General:................................................................................................................................................ 48
9.2 Compressor Condenser Module Assembly Procedures ................................................................ 49
9.3 Evaporator Module Assembly Procedures ...................................................................................... 64
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT .......................................................................................... 66
10.0 SPECIAL TOOLS/EQUIPMENT........................................................................................................... 66
10.1 General:................................................................................................................................................ 66
ILLUSTRATED PARTS LIST ............................................................................................................................ 68
11.0 R-134A AIR CONDITIONING SYSTEM COMPONENT ILLUSTRATED PARTS LISTING ............... 68
11.1 Introduction: ........................................................................................................................................ 68
SPECIAL PROCEDURES ................................................................................................................................. 78
12.0 SPECIAL PRODECURES .................................................................................................................... 78
12.1 Expansion Valve Alignment:.............................................................................................................. 78
12.2 Balancing Multiple Evaporators: ....................................................................................................... 80
12.3 Motor Insulation Resistance Check: ................................................................................................. 80
12.4 Motor Bearing Inspection: ................................................................................................................. 81
12.5 Compressor Bearing Inspection: ...................................................................................................... 81
12.6 Compressor Oil Level Check: ............................................................................................................ 82
SERVICING ....................................................................................................................................................... 83
13.0 R-134A AIR CONDITIONING SYSTEM SERVICING PROCEDURES ............................................... 83
13.1 General:................................................................................................................................................ 83
13.2 Evacuating the system (R-134A): ...................................................................................................... 84
13.3 Charging the system (R-134A): ......................................................................................................... 84
13.4 Flushing The System (R-134A): ......................................................................................................... 85
STORAGE ......................................................................................................................................................... 87
14.0 COMPRESSOR CONDENSER MODULE ASSEMBLY STORAGE PROCEDURES......................... 87
14.1 General:................................................................................................................................................ 87
14.2 System Long Term Shelf Storage: .................................................................................................... 87
14.3 System Off-Season/On-Aircraft Functional Tests: .......................................................................... 88
14.4 General System Component Storage procedures: ......................................................................... 88

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
LIST OF ILLUSTRATIONS
Figure 1 R-134A Refrigerant Flow Schematic ............................................................................................... 25

Figure 3.3: Commutator Excellent Condition Example ............................................................................... 39
Figure 3.4: Commutator Serviceable Condition Example .......................................................................... 40
Figure 3.5: Commutator Unserviceable Condition Example ...................................................................... 41
Figure 4 Belt Tensioning Reference .............................................................................................................. 61
Figure 10001 Compressor Condenser Module Assembly 1134400-53 ....................................................... 69
Figure 10001 Compressor Condenser Module Assembly (1134400-53) Details ....................................... 70
Figure 10001 Compressor Condenser Module Assembly (1134400-53) Details ....................................... 71
Figure 10002 Evaporator Module Assembly 1134200-42 (L) /-43 (C,R) ...................................................... 74
Figure 10002 Evaporator Module Assembly (1134200-42/-43) Details ....................................................... 75
Figure 10003 Evaporator Module Assembly 1134200-60/-61/-63 (-60 Shown) ........................................... 76
Figure 10003 Evaporator Module Assembly (1134200-60/-61/-63) Details ................................................. 77
LIST OF TABLES
Table 1 Standard Torque Values .................................................................................................................... 12

Table 2 Consumable Products ....................................................................................................................... 12
Table 3 Trouble Shooting List ........................................................................................................................ 22
Table 3.5 Compressor Condenser Module Inspection Schedule ................................................................ 37
Table 3.6 Forward and Aft Evaporator Module Inspection Schedule ......................................................... 42
Table 4 Gates Sonic Tension Meter Data ...................................................................................................... 61
Table 5 Typical Operating Values................................................................................................................... 79

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
INTRODUCTION
TASK 21-00-23-99F-801
1.0 MANUAL INTRODUCTION
SUBTASK 21-00-23-99F-001
1.1 General introduction (How to Use):
1.1.1 This operating, servicing and component maintenance manual (OSCMM) covers the
requirements for field servicing the R-134A air conditioning system for the Pilatus PC12
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.

P a g e | 10 Revision 10 June 1, 2017
12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
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 21-00-23-99F-002
1.2 Acronyms, Abbreviations, and Symbols:
• 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

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
SUBTASK 21-00-23-99F-003
1.3 Standard Torque Values:

TYPE FASTENER DESCRIPTION/LOCATION TORQUE
.25-28 SET SCREW ALL OTHER LOCATIONS 40-50 IN LBS
.25-28 SET SCREW EVAPORATOR BLOWER WHEEL 12-15 IN LBS
6-32 SCREW AN500-6-6, MS35265-30/-43, MS35206- 8-10 IN-LBS
228, ALL LOCATIONS
8-32 SCREW AN500-A8-6, MS35265-45, ALL 12-15 IN-LBS
LOCATIONS
10-32 SCREW/BOLT ALL LOCATIONS 20-25 IN-LBS
M10X1.2525MM COMPRESSOR BOLT 175-200 IN LBS
¼-28-UNF ALL LOCATIONS 50-70 IN-LBS
5/16-24UNF ALL LOCATIONS 100-140 IN-LBS
3/8-24UNF AN6-10A, AN6-14A, ALL LOCATIONS 160-190 IN-LBS
5/8-18 PLUMBING RECEIVER DRYER INLET/DISCHARGE 132-156 IN-LBS
CONNECTIONS PORT
7/8-14 PLUMBING COMPRESSOR SUCTION PORT 252-324 IN-LBS
CONNECTIONS
¾-16 PLUMBING COMPRESSOR DISCHARGE PORT 180-240 IN LBS
CONNECTIONS
7/16-20 PLUMBING EXPANSION VALVE INLET PORT 100-140 IN LBS
CONNECTIONS
¾-16 PLUMBING EXPANSION VALVE OUTLET PORT 270-350 IN LBS
CONNECTIONS
Table 1 Standard Torque Values
SUBTASK 21-00-23-99F-004
1.4 Documents required:

• Illustrated Parts Listings (IPL) (included with this manual)
• Pilatus PC12 Aircraft Maintenance Manual
SUBTASK 21-00-23-99F-005
1.5 Consumable Products:

ENVIRO PART DESCRIPTION REMARKS/ALTERNATE PILATUS PART
NUMBER NUMBER
11602 SEALANT RTV BLACK RTV 103 P08-045
7471 THREAD SEALANT PRIMER LOCTITE 7471
569 THREAD SEALANT LOCTITE 569
RL-100H POE REFRIGERANT OIL R-134A P10-021
Table 2 Consumable Products
12037 N Highway 99
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Phone (405) 382-0731
Fax (405) 382-0737
DESCRIPTION AND OPERATION
TASK 21-00-23-99F-802
2.0 R-134A AIR CONDITIONING SYSTEM DESCRIPTION AND OPERATION
SUBTASK 21-00-23-99F-006
2.1 General:
2.1.1 The air conditioning system installed on the Pilatus PC12 Aircraft is not considered a
primary flight system. However, an air conditioning system does perform the important
function of providing passenger and flight crew comfort during aircraft movement on the
ground and while in flight. 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.

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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.
SUBTASK 21-00-23-99F-007
2.2 System Description and Operation:
2.2.1 The cabin cooling system installed in the Pilatus PC12 Aircraft operates using a closed
vapor cycle concept using refrigerant R-134A as the heat absorption media. The R-134A
air conditioning system cools the aircraft in a similar manner as systems found in an
automobile or home. 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. An example of a
system is shown in Figure 1 (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.

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
SUBTASK 21-00-23-99F-008
2.3 System Component Description and Operation:
2.3.1 The R-134A air conditioning system installed on the Pilatus PC12 Aircraft uses the following
major system components:
• Compressor Condenser Module Assembly 1134400-13
1134400-53 Supersedes-13
1134400-56 Limited Serial Numbers
1134400-59 Improved Brush Life
• Evaporator Module Assembly 1134200-42 (L) / -43 (C&R)
Superseded by 1134200-60 (L)/-61 (R)/-63 (C)
2.3.2 The COMPRESSOR CONDENSER MODULE ASSEMBLY (PN 1134400-13/-53/-56/-59)

has a rated cooling capacity of 17,350 BTUH when operating with the other components in
the Pilatus PC12 Aircraft at an ambient temperature of 95°F OAT. Under this condition, the
nominal current draw is 100 AMPS at 28 VDC.
2.3.3 The Compressor Condenser Module Assembly is packaged to meet the aircraft installation
requirements and contains the following major components (refer to Figure 10001):
• Compressor Drive Motor (10C)
• Compressor Assembly (40A)
• Condenser Coil (120A)
• Receiver Dryer Assembly (50C)
• Binary Pressure Switch (60A)
2.3.3.1 COMPRESSOR DRIVE MOTOR: The compressor drive motor has a double-ended
shaft and operates on 27.5 VDC power with a rated current draw of 115 AMPS max.
One output shaft drives the R-134A compressor and the other end drives the motor
cooling fan. The motor design power is 3.2 HP at 5000-5250 RPM and 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
shaft is supported on high speed ball bearings for reliability and friction reduction.
2.3.3.2 COMPRESSOR ASSEMBLY: The compressor assembly contains an R-134A

compressor and 5.01 inch pitch diameter pulley assembly. The compressor also
features a six piston wobble plate design as well as anti-slugging features that
eliminate the need for a suction trap/accumulator. The compressor has a light-weight
aluminum housing. The pulley assembly is designed for a high strength, positive grip
240L100 timing belt and contains a radial bearing to assure no side loads are
transmitted into the compressor input shaft. The assembly is designed for continuous
operation.

12037 N Highway 99
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Phone (405) 382-0731
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2.3.3.3 CONDENSER COIL ASSEMBLY: The condenser coil assembly is a copper tube and
aluminum fin configuration with 6061-T6 aluminum support brackets. The coil heat
rejection is 30,400 BTUH based on a 95°F ambient day. Condenser cooling airflow
and coil sizes are based on the design cooling capacity and compressor input
horsepower. This assembly requires airflow of 900 CFM for proper operation.
2.3.3.4 RECEIVER DRYER ASSEMBLY: The receiver-dryer assembly consists of a

refrigerant container, Schrader valve, high pressure charging port and a binary
pressure switch. The receiver-dryer is constructed of aluminum alloy and contains a
standpipe, wire filter, and desiccant. 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.
2.3.3.5 BINARY PRESSURE SWITCH: The binary pressure switch performs two major
functions. The first function prevents the R-134A compressor from operating if the
system charge is lost or the ambient temperature is too low. The second function
stops the compressor from operating if the head pressure increases to an unsafe
level. The high pressure cutout is at 275-335 PSIG on rise and the low pressure
cutout is at 15-29 PSIG falling.
2.3.4 The EVAPORATOR MODULE ASSEMBLY (PN 1134200-60/-61/-63, Supersedes 1134200-

42/-43) has a rated cooling capacity of 7000 BTUH at an ambient air temperature of 80° F
(db), and 50% RH (relative humidity). The assembly provides an air flow of 225 CFM (cubic
feet per minute) in order to maintain these performance specifications.
2.3.5 The Evaporator Module Assembly is packaged to meet the aircraft installation requirements
and contains the following major components (refer to Figure 10002/10003):
• Coil Assembly
• Blower Motor
• Blower Wheel
• Blower Scroll
• Expansion Valve
• Evaporator Housing
2.3.5.1 COIL ASSEMBLY: The evaporator coil assembly contains the evaporator coil,
mounting hardware, and refrigerant plumbing connections. The coil is constructed of
copper tube and aluminum fins with aluminum support brackets made of 6061-T6
Aluminum. The assembly receives its air (return air) from the suction created by the
blower assembly. This air is conditioned and returned to the cabin.

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Phone (405) 382-0731
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2.3.5.2 BLOWER MOTOR: The blower motor operates on 28 VDC with a rated current draw
of 10 AMP and has a design RPM of 5250-6250. The blower motor is a brushless
design with an integrated controller and was selected for its efficiency, excellent
controllability, long life and low vibration at high speeds. The motor has two speeds,
low speed designed for the heating recirculation requirement and high speed
designed for maximum system cooling. It was designed for continuous operation.
2.3.5.3 BLOWER WHEEL: The blower wheel is the component that is used in concert with
the blower motor and provides for the movement of air. It is made of lightweight
aluminum that provides superior strength and durability.
2.3.5.4 BLOWER SCROLL: The blower scroll is constructed of high impact, fire retardant,
self-extinguishing, and corrosion resistant, lightweight polycarbonate material (Lexan
F-6000). It is nickel plated to give it superior strength and durability qualities. The
blower scroll has successfully passed blower wheel containment testing.
2.3.5.5 EXPANSION VALVE: The expansion valve is an automatic 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.
2.3.5.6 EVAPORATOR HOUSING: The evaporator housing is constructed of high impact, fire
retardant, self-extinguishing, and corrosion resistant, lightweight polycarbonate
material (Lexan F-6000).

12037 N Highway 99
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Phone (405) 382-0731
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TESTING AND FAULT ISOLATION
TASK 21-00-23-70-801
3.0 R-134A AIR CONDITIONING SYSTEM COMPONENT – TESTING AND FAULT ISOLATION
SUBTASK 21-00-23-99F-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 21-00-23-70-001
3.2 Compressor Condenser Module Assembly Testing Procedures

(refer to Figure 10001):
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 Condenser
Module (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:
3.2.1.1 Verify that system is running smoothly and that there is no excessive noise and/or
vibration coming from the assembly.
3.2.1.2 Verify that the system is cooling properly.
3.2.2 If there is excessive noise and/or vibration coming from the Compressor Condenser Module
assembly or the system is not cooling, refer to Fault Isolation, Section 3.6, 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.
SUBTASK 21-00-23-70-002
3.3 Evaporator Module Assembly Testing Procedures

3.3.1 Verify blower motor operation in both low and high speed positions using cockpit mounted
selector switch.
3.3.2 While blower motor is operating in both positions, listen carefully for the following:

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Phone (405) 382-0731
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3.3.2.1 Verify that there is a distinct and noticeable change in sound of blower motor when
changing from low to high speed positions. This indicates that the cockpit selector
switch is functioning properly and that the blower motor is responding accordingly.
3.3.2.2 Verify that there is a smooth transition when changing from low to 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 Fault Isolation, Section 3.6, 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. If not, the expansion valve(s) might need
aligning. Refer to Special Procedures, Section 12, for Expansion Valve Alignment
procedures.
NOTE: If a failure has occurred to the evaporator module assembly, a fault LED light will sometimes
illuminate inside the blower motor (1134200-60/-61/-63 evaporators only) and may be seen through the vent
cap/screen on the side of the motor. If technician observes the fault LED light, component must be removed
and replaced (refer to Disassembly, Section 5 and Assembly, Section 9).
SUBTASK 21-00-23-70-003
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
3.4.3 Special Tools and/or Equipment Required:

• Gaseous dry nitrogen, regulated source (0-500 psig)
• R-134A refrigerant charging manifold with gauges and hoses (low pressure gauge, 0-300
PSIG), (high pressure gauge, 0-600 PSIG)
• Leak check fluid (soap solution), (Spec MS-SNOOP-GAL)
• Assorted hand tools
• Hand and eye protection
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• Thread sealant primer, PN 7471 (Loctite)

• Thread sealant, PN 569 (Loctite)
• Hose adapter (1/2 in. male acme to ¼ in. female flare)
3.4.3.1 Remove, if required, all panels, doors, shrouds, etc, to gain access to
system/component being leak checked (refer to aircraft maintenance manual).
3.4.3.2 Remove, if required, any enclosures or access doors to expose all tubing, hoses,
fittings, etc. to the system components.
3.4.3.3 Verify all plumbing connections are tight.
3.4.3.4 Verify that power is removed from aircraft. If it is not practical to remove aircraft
power, technician must pull and collar applicable circuit breakers.
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.
3.4.3.5 Remove service port caps from the A/C system. Service ports are located on the
compressor.
3.4.3.6 Close all manifold gauge valves and verify hose connections are tight.
3.4.3.7 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.
3.4.3.8 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: APPLY NITROGEN PRESSURE SLOWLY DURING THIS PROCEDURE OR DAMAGE TO
SYSTEM COULD RESULT.
CAUTION: DO NOT EXCEED 200 PSIG NITROGEN PRESSURE DURING PROCEDURE OR DAMAGE TO
EXPANSION VALVE WILL RESULT.
3.4.3.9 Slowly regulate nitrogen source to a pressure of 200 PSIG maximum.
3.4.3.10 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.

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3.4.3.11 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 applied.
3.4.3.12 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.
3.4.3.13 Apply Loctite 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
3.4.3.14 Apply a light coating of R-134A refrigerant oil to flare and/or O-ring to prevent metal
galling or O-ring damage.
3.4.3.15 Tighten joints as required to stop leaks (refer to Table 1, Section 1.3 for torque
values).
CAUTION: VENT SYSTEM PRESSURE VERY SLOWLY TO ASSURE COMPRESSOR OIL IS NOT
VENTED WITH THE NITROGEN. DO NOT LET AIR ENTER THE SYSTEM.
3.4.3.16 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.
3.4.3.17 Close manifold valve.
3.4.3.18 System is now ready for charging (refer to Servicing, Section 13).
SUBTASK 21-00-23-81-001
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.

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Phone (405) 382-0731
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NOTE: Refer to Refrigerant Flow (Figure 1), 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 3. Replace
failed
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 Drive motor temp switch failed 10 Replace motor
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 Evaporator
9. Evaporator blower failed 9. Replace Evaporator
10. Evaporator blows 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 Evaporator
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
F. No Low Evap. Fan speed 1. Failed switch 1. Replace

(Hi Speed Ok)
2. Failed resistor 2. Replace Evaporator
3. Failed relay 3. Replace

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G. 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
H. 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
I. Evaporator Module Coil 1. No air flow 1. Turn fan on

Freezing
2. Expansion valve failed or 2. Remove debris or replace
clogged
3. Expansion valve setting low 3. Reset to obtain 26-30 psig
suction pressure
J 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
K Fault LED Light Illuminated 1. Numerous evaporator failures 1. Replace evaporator module
Inside Evaporator Motor Vent can cause this indication. assembly
Cap/Screen (1134200-60/-61/-63)

12037 N Highway 99
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Phone (405) 382-0731
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SCHEMATIC AND WIRING DIAGRAMS
21-00-23-99-801
4.0 R-134A AIR CONDITIONING SYSTEM SCHEMATIC AND WIRING DIAGRAMS
SUBTASK 21-00-23-99-001
4.1 R-134A Refrigerant Flow Schematic:
4.1.1 The following schematic shows an air conditioning system and its associated components
as well as the flow of the R-134A refrigerant.
Figure 1 R-134A Refrigerant Flow Schematic

12037 N Highway 99
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DISASSEMBLY
TASK 21-00-23-00-801
5.0 R-134A AIR CONDITIONING SYSTEM COMPONENT - DISASSEMBLY
SUBTASK 21-00-23-99F-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 system component or components requiring disassembly (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).

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NOTE: Do not disassemble the parts unnecessarily.
5.1.6 Refer to Illustrated Parts Listing (IPL) for figure/item numbers (Section 11).
5.1.7 Tools, fixtures, equipment, or consumable items required:

• Small hand tools and socket set
• Scribe or wire hook
• Volt or OHM meter (digital)
• Shop air, 40 PSIG max
• Respiration mask
SUBTASK 21-00-23-00-001
5.2 Compressor Condenser Module Disassembly Procedures

5.2.1 Removal of Receiver Dryer (50C)
5.2.1.1 Verify that system refrigerant charge has been recovered (refer to Servicing, Section
13)
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 Cap receiver dryer (if reusing) and plumbing connections immediately.
5.2.1.6 Loosen receiver dryer attaching clamp and carefully slide receiver dryer from
mounting bracket.
5.2.2 Removal of Belt Cover (80C)
5.2.2.1 Remove 4 belt cover attaching screws and washers (2 located at bottom, right cover,
2 located at top, mid cover).
5.2.2.2 Loosen 2 attaching bolts and washers (left side).
5.2.2.3 Carefully slide belt cover from assembly.
5.2.3 Removal of Drive Belt (90C) and Pulley (21C)

CAUTION: DO NOT BEND OR TWIST THE DRIVE BELT EXCESSIVELY DURING REMOVAL OR
DAMAGE MAY RESULT.
5.2.3.1 Remove belt cover per 5.2.2.

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5.2.3.2 Slightly loosen the compressor mounting bolts.
5.2.3.3 Loosen drive motor pulley set screws.
5.2.3.4 Slide upper compressor in towards drive motor, slide drive pulley and belt from motor
shaft, while at the same time sliding the drive belt off the compressor pulley.
5.2.4 Removal of Compressor Assembly (40A)
5.2.4.1 Remove belt cover, drive belt, and drive pulley per 5.2.2 and 5.2.3.
5.2.4.2 Disconnect refrigerant lines from compressor plumbing ports.
5.2.4.3 Cap compressor ports and refrigerant lines immediately.
5.2.4.4 Remove compressor mounting bolts and washers.
5.2.4.5 Carefully lift compressor from mounting bracket.
5.2.5 Removal of Condenser Coil (120A)
5.2.5.1 Remove receiver dryer per 5.2.1.
5.2.5.2 Remove two nuts and washers retaining receiver dryer bracket to condenser coil and
remove bracket.
5.2.5.3 Disconnect plumbing lines from the compressor. Immediately cap both sides of the
connection.
5.2.5.4 Remove tube clamps on both condenser tubes.
5.2.5.5 Cut safety wire and remove 7 screws and washers securing condenser support
bracket and remove condenser support bracket from assembly.
5.2.5.6 Cut safety wire and remove 8 screws and washers securing condenser to base
support.
5.2.5.7 Slide condenser coil/shroud assembly off of unit.
5.2.5.8 If replacing condenser coil, remove shrouds from coil per 5.2.8 and 5.2.9.
5.2.6 Removal of Drive Motor (10C)
5.2.6.1 Remove belt cover, drive pulley, belt, compressor and condenser coil per 5.2.2, 5.2.3,
5.2.4 and 5.2.5.
5.2.6.2 Remove fan beginning with step 5.2.7.2.
5.2.6.3 Remove all cable ties used to secure wiring to motor.

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CAUTION: DO NOT ALLOW MOTOR TO FALL ON POWER RELAY DURING THIS PROCEDURE OR
DAMAGE MAY RESULT.
5.2.6.4 Remove motor mounting bolts and washers from motor support bracket.
CAUTION: TAKE EXTREME CARE WHEN REMOVING DRIVE MOTOR FROM ASSEMBLY OR DAMAGE
TO COIL COULD OCCUR.
5.2.6.5 Carefully slide motor sideways from assembly and set beside unit.
5.2.6.6 Disconnect power cables from power relay and mark for later identification.
5.2.7 Removal of Fan
5.2.7.1 Remove condenser coil per 5.2.5
5.2.7.2 Remove motor shaft retaining nut and washer.
5.2.7.3 Loosen fan hub set screw(s).
5.2.7.4 Slide fan assembly motor shaft.
5.2.8 Removal of Fan Shroud
5.2.8.1 Remove condenser coil per 5.2.5.
5.2.8.2 Remove remaining 3 shroud mounting screws, washers, and nuts.
5.2.8.3 Cut RTV between shroud and coil using a putty knife.
5.2.8.4 Carefully remove shroud from assembly.
5.2.9 Removal of Outlet Shroud
5.2.9.1 Remove four shroud mounting screws, washers, and nuts.
5.2.9.2 Cut RTV between shroud and coil using a putty knife.
5.2.9.3 Carefully remove shroud from assembly.
5.2.10 Removal of Power Relay (10B)
5.2.10.1 Disconnect electrical connections and mark for later identification.
5.2.10.2 Remove relay mounting hardware and carefully slide relay from assembly.
5.2.11 Removal of Hour Meter (140C)
5.2.11.1 Disconnect electrical terminals from hour meter and mark for later identification.

12037 N Highway 99
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5.2.11.2 Remove attaching screws, washers, and nuts.
5.2.11.3 Carefully slide hour meter from receiver dryer bracket.
5.2.12 Removal of Drive Motor Brushes
5.2.12.1 Locate and remove the safety wire and screws securing the brush cover.

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5.2.12.2 Remove the Brush Cover
5.2.12.3 Disconnect the brush shunt wire terminals.

12037 N Highway 99
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5.2.12.4 With a 90° pick, lift brush spring and remove the worn brushes from the brush
guides.
5.2.12.5 Upon removal, ensure that no FOD remains in the brush guide that may prevent
smooth brush travel upon reassembly. If brush guide is deformed or damaged, the
motor must be replaced.
Edges should be smooth and clean, no nicks or FOD that may prevent smooth brush travel

12037 N Highway 99
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Phone (405) 382-0731
Fax (405) 382-0737
SUBTASK 21-00-23-00-002
5.3 Evaporator Module Assembly Disassembly Procedures

(Refer to Figure 10002/10003):
5.3.1 Removal of Evaporator Module Assembly
5.3.1.1 Refer to aircraft maintenance manual for removal of Evaporator Module Assembly.
5.3.2 Removal of Blower Motor/Blower Wheel (FIG. 10003, 10/20B)
5.3.2.1 Disconnect power leads and mark for later identification.
5.3.2.2 Remove upper motor attachment screws and washers.
5.3.2.3 Remove lower motor attachment screws, spacers, washers and clamp.
5.3.2.4 Remove attachment nuts and washers securing drip tray to escutcheon.
5.3.2.5 Carefully slide drip away from evaporator.

CAUTION: USE EXTREME CARE TO PREVENT DAMAGE OR BENDING OF BLOWER WHEEL DURING
REMOVAL OF MOTOR AND WHEEL.
5.3.2.6 Cut RTV between blower motor and scroll using a putty knife.
5.3.2.7 Carefully slide blower motor/wheel from scroll.
5.3.2.8 Carefully remove blower wheel from motor shaft by loosening wheel set screw.
5.3.3 Removal of Expansion Valve (FIG. 10002, 10), (FIG. 10003, 60A)
5.3.3.1 Disconnect refrigerant plumbing lines and cap off immediately.
5.3.3.2 Remove expansion valve from evaporator fitting and cap off fitting immediately.
5.3.4 Removal of Air Filter (FIG. 10002, 20), (FIG. 10003, 70D)
5.3.4.1 Carefully pull air filter from evaporator. Air filter is secured to evaporator with Velcro.

12037 N Highway 99
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CLEANING
TASK 21-00-23-10-801
6.0 R-134A AIR CONDITIONING SYSTEM COMPONENT – CLEANING PROCEDURES
SUBTASK 21-00-23-99F-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 Condenser Module or Evaporator Module Assembly (refer
to the aircraft maintenance manual for removal of access panels and other hardware that
might need to be removed)

12037 N Highway 99
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Phone (405) 382-0731
Fax (405) 382-0737
SUBTASK 21-00-23-10-001
6.2 Compressor Condenser Module Cleaning Procedures:
6.2.1 The following components of the Compressor Condenser Module will require periodic
cleaning (refer to the Inspection Schedule in section 7 for time intervals). This is in no way
an all-encompassing list. 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 Condenser Module Assembly

• Condenser Coil
• Fan/Outlet Shroud
6.2.1.1 COMPRESSOR CONDENSER MODULE ASSEMBLY: Over time, the Compressor

Condenser 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 motor brushes, commutator should be cleaned with compressed air
blast to remove any carbon dust or contaminants
6.2.1.2 CONDENSER COIL: Over time, the Condenser Coil will become dirty and require
general cleaning. It is essential that the assembly remain clean to ensure proper
operation and optimal performance. 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 coil. 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.
6.2.1.3 FAN/OUTLET SHROUD: The shroud, over time, can show signs of separating from
the coil. If separation is noticed, refer to Disassembly, Section 5 and Repair, Section
9. After shroud has been removed from coil assembly, clean the mating surfaces
carefully with isopropyl alcohol to remove any dirt, dust, and other foreign matter, to
include the old RTV sealant. For resealing, refer to Repair, Section 8 and Assembly,
Section 9.

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
SUBTASK 21-00-23-10-002
6.3 Evaporator Module Assembly Cleaning Procedures:
6.3.1 The following components of the Evaporator Module Assembly will require periodic cleaning
(refer to the Inspection Schedule in section 7 for time intervals) (refer to Figure
10002/10003):
• Evaporator Coil Air Inlet
• Evaporator Coil Air Inlet Air Filter
• Evaporator Housing Assembly
• Condensate Drain (part of Evaporator Housing Assembly)
• Expansion Valve
CAUTION: USE EXTREME CARE TO PREVENT DAMAGE OR BENDING OF COIL FINS
6.3.1.1 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.
6.3.1.2 EVAPORATOR COIL AIR INLET AIR FILTER: The air filter will, over time, become
clogged with dirt, dust and other foreign matter. It is essential that the air filter remain
clear for proper operation of the evaporator module assembly. Carefully remove air
filter from evaporator assembly and use a soft utility brush and/or vacuum to remove
any accumulated lint, dirt, dust and other foreign matter. If air filter shows signs of
deterioration, replace filter (refer to Disassembly, Section 5 and Assembly, Section 9).
6.3.1.3 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.
6.3.1.4 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.
6.3.1.5 EXPANSION VALVE: The expansion valve should be free from dirt, dust and foreign
matter. Use a brush or rag to clean.

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
CHECK (INSPECTION SCHEDULE)
TASK 21-00-23-21-801
7.0 R-134A AIR CONDITIOING SYSTEM COMPONENT – INSPECTION SCHEDULE
SUBTASK 21-00-23-21-001
7.1 Compressor Condenser Module Assembly Inspection Schedule:

NOTE: This is the recommended visual inspection schedule for the Compressor Condenser 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.
7.1.1 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 Inspect for wear, nicks, cracks or looseness, and proper tracking. 600
Realign & tension and/or replace as required.
Inspect belt cover for cracks or other damage.
Compressor/Shaft seal Inspect for leaks (excessive oil spray) 600
Bearing inspection
Condenser fan/outlet Inspect condenser shrouds for signs of cracking, separation between 600
shrouds shrouds and condenser coil.
Condenser coil Inspect condenser coil for damage or dirt accumulation. 600
Inspect, clean and comb coil fins. Inspect for leakage.
Inspect plumbing for damage weathering and wear
Inspect return bends for nicks, dents, cracks, or other damage.
Electrical wiring Inspect wiring for insulation damage, replace as required. 600
Drive. motor Inspect drive motor commutator for wear. (Refer to figures 3.3 – 3.5 for 600
serviceable determination)
Internal contamination inspection
Motor insulation resistance check (refer to Special Procedures, Section 13)
Inspect brush holders for looseness, damage from arcing, heat distortion or
cracks.
Motor bearing inspection (refer to Special Procedures, Section 13)
Drive Motor Brushes Replace Brushes Mandatory every
(Except 1134400-59) 500 hours
Drive Motor Brushes Inspect brush length and determine wear rate 600
(1134400-59 Only) Replace Brushes if wear rate exceeds recommendations in Section 7.1.3
Receiver dryer assembly Inspect for leakage. Inspect plumbing for damage, weathering, and wear. 600
Verify mounting hardware is secure
Hour Meter Inspect for proper operation and damage. 600
Table 3.5 Compressor Condenser Module Inspection Schedule

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
7.1.3 Brush Inspection (1134400-59 Only)
7.1.3.1 Determine how many hours the installed brushes have accumulated since new. If the
compressor condenser module was installed new and the motor and/or brushes have
never been replaced, then the hours shown on the compressor/condenser hour meter
may be used.
7.1.3.2 If hours on installed brushes are unknown, the brush depth measurement from 7.1.3.3
cannot exceed 0.10 inches.
7.1.3.3 To calculate remaining brush life, use following method. Calculations should be based
on the shortest brush length.
Step 1:
Measure depth in inches from the top of the brush guide to the top of the brush and
use in the following equation to calculate the Wear Rate.
(Measured Depth + 0.03)

Wear Rate =
Hours
Step 2:
Calculate the remaining Usable Length of brush using the following equation.
Usable Length = 0.5 - (Measured Depth + 0.03)
Step 3:
Calculate the Remaining Brush Life in hours using the following equation.
Usable Length
Remaining Brush Life = ≥ 700
Wear Rate
7.1.3.4 If Remaining Brush Life is less than 700 hours, brushes or motor must be replaced.

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
7.1.4 Commutator Inspection

Inspect commutator per following figures for excessive or uneven wear. The commutator
should have a burnished appearance with light filming. If the commutator is black, burned,
pitted, grooved, or excessively worn, the motor should be replaced. If the commutator
brush wear grove depth exceeds 0.015”, the motor should be replaced.
7.1.4.1 Commutator in excellent condition is still bright and shows little sign of wear.
Figure 3.3: Commutator Excellent Condition Example

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
7.1.4.2 Commutator in serviceable condition shows some signs of wear and carbon film.
Figure 3.4: Commutator Serviceable Condition Example

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
7.1.4.3 Commutator in unserviceable condition shows excessive pitting and chipping on

commutator.
Figure 3.5: Commutator Unserviceable Condition Example

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
SUBTASK 21-00-23-21-002
7.2 Evaporator Module Assembly Inspection Schedule:

NOTE: This is the recommended visual inspection schedule for the Evaporator Module Assembly.
Adherence to this schedule will ensure that all components of the assembly are in accordance with the
manufacturer’s specifications and is necessary to detect structural failure, deterioration or damage, and to
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 Forward and Aft Evaporator Module Inspection Schedule

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
REPAIRS
TASK 21-00-23-30-801
8.0 R-134A AIR CONDITIONING SYSTEM COMPONENT – REPAIR PROCEDURES
SUBTASK 21-00-23-99F-012
8.1 General:
8.1.1 Refer to Illustrated Parts Listing (IPL) for figure/item numbers (Section 12).
SUBTASK 21-00-23-30-001
8.2 Compressor Condenser 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
• Receiver Dryer
• Fan / Outlet Shroud
• Condenser Coil
• Hour Meter

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
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 Condenser 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.
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). The commutator on the armature must be in serviceable condition to
maintain proper operation. See Section 7 for inspection criteria.
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 Condenser 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 .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 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 Condenser 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.

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
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
8.2.1.6 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, it 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
8.2.1.7 Fan / Outlet Shroud

The fan / outlet shrouds can, over time, show signs of cracking and separation
between the shrouds and the condenser. This can cause the compressor condenser
module assembly to have less than optimal performance. If the shrouds are
separating, refer to Disassembly (Section 5) for removal. Then refer to Cleaning
(Section 5). After insuring that the seam between the shrouds and condenser have
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, they should be replaced. Contact Enviro Systems
customer service to order new components.
8.2.1.8 Condenser Coil

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 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. 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
compressor condenser module assembly must be removed (refer to Disassembly,
Section 5) and sent to Enviro Systems for repair. Contact Enviro Systems customer
service.
8.2.1.9 Hour Meter

The hour meter can, over time, become damaged or show signs of improper
operation. If the hour meter is damaged or not operating correctly, remove and
replace (refer to Disassembly, Section 5 and Assembly, Section 9).

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
SUBTASK 21-00-23-30-002
8.3 Evaporator Module Assembly Repair Procedures:
8.3.1 The following components may require periodic repair and/or replacement (refer to the
Inspection Schedule in Section 8 for mandatory time intervals) (refer to Figure
10002/10003):
• Evaporator Coil
• Evaporator Housing Assembly
• Blower Assembly
• Condensate Drain (part of Evaporator Housing Assembly)
• Expansion Valve
8.3.1.1 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 evaporator coil remain clear and
undamaged for proper operation. 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 coil assembly must be removed (refer to Disassembly, Section 5) and sent
to Enviro Systems for repair. Contact Enviro Systems customer service.
8.3.1.2 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 coil 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 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.
8.3.1.3 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.

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
8.3.1.3.1 If blower motor wheel is damaged, such as having bent or cracked blades,
removal and replacement is required (1134200-60/-61/-63 only). 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.
8.3.1.3.2 If blower motor scroll is damaged in any way, the entire Evaporator Module
Assembly must be removed and sent to Enviro Systems for repair. Contact
8.3.1.3.3 For the blower motor, if the Evaporator Module Assembly is P/N 1134200-42
(L) /-43 (C,R), removal and replacement of the entire evaporator module
assembly is required (refer to aircraft maintenance manual), as maintenance
of the evaporator blower motor is no longer supported. Contact Pilatus for
replacement evaporator. If Pilatus cannot support a replacement for the
1134200-42/-43 evaporator, contact Enviro Systems for replacement.
Replacement evaporator will be 1134200-60 (L)/-61(R)/-63 (C) and is not
compatible with older evaporator 1134200-42/-43. Therefore, if aircraft has
evaporator 1134200-42/-43 that has failed (left or right side), both the left and
right side evaporators must be changed together. The left and right
evaporators must all be either 1134200-42/-43 or 1134200-60(L)/-61(R), not a
combination of the two. After completing the removal and installation of the
new evaporator module assembly, perform functional check (Section 3).
8.3.1.3.4 If the Evaporator Module Assembly is 1134200-60/-61/-63 and blower motor is

damaged or is not operating to specifications, motor will need to be removed
and replaced (refer to Disassembly, Section 5 and Assembly, Section 9).
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 component.
8.3.1.4 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 coil assembly. If the condensate drain is damaged, the
entire assembly must be removed and sent to Enviro Systems for repair. Contact
8.3.1.5 Expansion Valve

The expansion valve can, over time, become damaged and/or not operate correctly. If
the expansion valve shows signs of damage or does not function properly, remove
and replace (refer to Disassembly, Section 5 and Assembly, Section 9).

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
ASSEMBLY
TASK 21-00-23-40-801
9.0 R-134A AIR CONDITIONING SYSTEM COMPONENT - ASSEMBLY
SUBTASK 21-00-23-99F-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 Condenser Module and Evaporator Module Assembly (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.

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
9.1.5 Tools, fixtures, equipment, or consumable items required

• Gates Sonic Tension Meter 508C or equivalent
• Inspection mirror
• Thermometer, 0-150°F
• Flash light or service lamp
• Leak check fluid (soapy), (MS-SNOOP-GAL)
• Thread sealant primer
• Thread sealant
• Dry nitrogen, regulated (0-300 PSIG)
SUBTASK 21-00-23-40-001
9.2 Compressor Condenser Module Assembly Procedures

9.2.1 Assembly of Drive Motor Brushes (refer to IPL for details)
CAUTION: IT IS EXTREMELY IMPORTANT THAT THE BRUSH SHUNT WIRES DO NOT CONTACT THE
MOTOR HOUSING OR BRUSH COVER. THE MOTOR BRUSH SHUNT WIRES CARRY ALL OF THE
REQUIRED POSITIVE CURRENT FOR THE MOTOR TO OPERATE, THE MOTOR HOUSING IS/MAY BE
GROUNDED. ALLOWING THE SHUNT WIRES TO CONTACT THESE SURFACES WILL CAUSE A DIRECT
SHORT AND COULD CAUSE PREMATURE FAILURE OR OTHER DAMAGE.
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.

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
9.2.1.1 Ensure the brush guide interior is free of debris and the surfaces are smooth to
allow for proper brush travel.
9.2.1.2 Prepare each brush by guiding the brush lead across the top of the brush as
shown below.

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
9.2.1.3 Ensure that brush lead does NOT extend out past the edge of the brush as shown
below. This will cause the brush not to pass through the brush guide properly.
9.2.1.4 The brushes must be formed to the curvature of the commutator prior to full load
operation. To form the brushes, cut a 1.5” X ~ 7.5” strip of 200 grit garnet
sandpaper. Cut 2 pieces of 3M 40PR Utility Tape (or equivalent non residue
leaving), put one piece on each side (rough and smooth) of one end of the
sandpaper, the tape on the rough side must be longer to attach to the commutator.
CAUTION: Garnet sand paper MUST be used for this process.
9.2.1.5 Feed the sandpaper through the opening near the brush guide and tape the paper
to the commutator with the rough side facing out. Rotate the motor shaft to “wind”
the sandpaper around the commutator in the normal direction of motor rotation,
CCW as viewed from brush end of motor (the sandpaper should overlap enough to
cover the tape).

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
9.2.1.6 Using a 90° scribe, lift the brush tension spring to allow brush installation. Insert
brushes into slots ensuring that the curvature of the brush matches the armature.
Brushes should slide in brush guides freely without restriction. After insertion of
the brush, do not allow the spring to slap against the brush as this can cause
damage to the brush resulting in premature failure.
CAUTION: Do NOT overextend the brush spring farther than necessary to install the
brush as this can change the spring tension.

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
9.2.1.7 Rotate the motor through 5 revolutions in the CCW direction as viewed from the
brush end.
9.2.1.8 Raise the brushes approximately half way and allow the spring to hold the brush in
this position by pressing against the side of the brush.
9.2.1.9 Remove the sandpaper and use compressed air to remove any remaining carbon
dust and other debris.

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
9.2.1.10 Lower the brushes back into position on the commutator.

9.2.1.11 Attach field winding leads and brush shunt wires to the terminals as shown. Place
the brush shunt terminal on the top of the other terminals. Orient the tab of the
shunt terminal such that the wires exit away from the brushes. Torque brush shunt
wire mounting hardware to 15 IN-LBS.

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
9.2.1.12 Install the fan blade per Section 9.2.4

9.2.1.13 Install the motor into the Compressor Condenser Module Assembly per Section
9.2.5
9.2.1.14 Operate the motor for 1 hour without the belt installed (no load). After 1 hour the
brushes must be checked for proper seating as illustrated below. If the brushes
are not fully seated after 1 hour of operation, the motor must be operated for
another hour and continued until the brushes are fully seated.
Note: Operating the motor without fully seated brushes does not allow for efficient current
transfer and will cause higher heat and current loads and will reduce motor life.
9.2.1.15 Once the brushes are fully seated, route the brush shunt leads as shown in the
following illustrations.

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
Note: The Brush Shunt Wires shall locate in the slot of the brush guide as shown above; this will
ensure the brush travel will not be inhibited by improper shunt wire routing. Proper shunt wire
routing for 2 brush locations shown below.

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
9.2.1.16 Reinstall the brush cover and screws. Use safety cable or wire to secure the
brush cover in place.

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
9.2.1 Assembly of Drive Motor (10C)

CAUTION: TAKE EXTREME CARE WHEN INSTALLING DRIVE MOTOR ONTO ASSEMBLY OR DAMAGE
TO COIL OR FAN SHROUD COULD OCCUR.
9.2.1.1 Set motor near unit and connect motor power wires to the relay and ground bolt.
9.2.1.2 Carefully slide drive motor into position.
9.2.1.3 Install 8 mounting bolts finger tight only. Install upper compressor mounting bracket at
this time as shown in IPL.
9.2.1.4 Tighten all motor mounting bolts except the 2 bolts used to secure the belt cover per
Table 1.
9.2.1.5 Connect electrical harness.
9.2.1.6 Install fan per 9.2.2.
9.2.1.7 Install compressor assembly per 9.2.3.
9.2.1.8 Install drive motor belt and pulley per 9.2.4.
9.2.1.9 Install belt cover per 9.2.5.
9.2.1.10 Install fan shroud, outlet shroud and condenser coil per 9.2.6, 9.2.7 and 9.2.8.
9.2.1.11 Install receiver dryer per 9.2.9
9.2.1.12 Safety wire screws in place.
9.2.2 Assembly of Fan
9.2.2.1 Slide fan assembly onto motor shaft against shoulder.

CAUTION: APPLY THREAD SEALANT SPARINGLY TO THREADS OF SET SCREW(S) STAYING CLEAR
OF FIRST 2-3 THREADS.
9.2.2.2 Apply a drop of thread sealant to the set screw thread. Tighten fan assembly set
screw lightly insuring that the screw is located on flat part of motor shaft.
9.2.2.3 Install flat washer and retaining nut and tighten nut and torque per Table 1.
9.2.2.4 Tighten set screw per Table 1.
9.2.2.4.1 On 1134400-59 only – Install second set screw and fully tighten both fan set
screws.

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
9.2.3 Assembly of Compressor
9.2.3.1 Position compressor in mounting bracket and install 3 mounting bolts. Finger tighten
bolts only.
9.2.3.2 Rotate upper compressor towards drive motor. Tighten mounting hardware only after
tensioning and alignment have been accomplished (refer to installation of drive belt
and pulley, 9.2.4).
9.2.3.4 Apply 1-2 drops of thread sealant on compressor discharge threads.

CAUTION: TAKE EXTREME CARE NOT TO GET REFRIGERANT OIL ON FITTING THREADS
9.2.3.5 Apply a thin film of refrigerant oil to compressor discharge port flare surfaces.
9.2.3.6 Connect condenser fitting to compressor discharge port and tighten per Table 1.
9.2.4 Assembly of Drive Belt and Pulley
9.2.4.1 Place drive belt over motor drive pulley and slide belt onto compressor pulley while
sliding motor pulley onto motor shaft.
9.2.4.2 Position motor pulley to align belt with compressor pulley. Tighten belt by rotating
compressor in mounting bracket.
9.2.4.3 Belt must be tensioned and tested utilizing Gates Sonic Tension Meter to ranges
shown (refer to Figure 4). Securely tighten attachment hardware when proper tension
is achieved. Follow the procedure outlined below.
9.2.4.3.1 Verify all the compressor mounting hardware is slightly tight and belt properly
aligned.
CAUTION: DO NOT OVER TENSION BELT. IMPROPER BELT TRACKING AND BELT / MOTOR DAMAGE
MAY RESULT.
9.2.4.3.2 Rotate compressor away from motor to increase belt tension and tighten
upper compressor mounting bolt.
9.2.4.3.3 Input the following information into the Gates Sonic Tension meter.
• Weight: 3.2 g/m
• Width: 25 mm
• Span: 147 mm
9.2.4.3.4 In A Quiet/Non Windy Environment connect microphone sensor.

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
9.2.4.3.5 Push the measure button on the meter, hold the sensor approximately 1 cm
(0.4 in) above the belt at the midway point between the pulleys.
• 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
9.2.4.3.6 In A Noise Filled Environment, if microphone sensor fails to produce accurate

readings, connect inductive sensor.
CAUTION: REMOVE THE TAPE AND MAGNET FROM BELT BEFORE PROCEEDING.
9.2.4.3.7 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
• 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
9.2.4.4 Rotate compressor by hand through several revolutions and verify belt tracking.
Readjust as required.
9.2.4.5 Apply Loctite to drive pulley set screws and tighten (refer to table 1, section 1.3 for
torque specifications).
9.2.4.6 Tighten and secure compressor mounting bolts and washers (refer to table 1,
section 1.3 for torque specifications).

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
Figure 4 Belt Tensioning Reference

Tensioning Information: (Sonic Tension Meter 508C, www.gates.com)
New Belt Used Belt

Min Max Min Max
Belt Frequency (Hz) 132 139 111 118
Sonic Tension Meter (N) 122 134 85 97
Table 4 Gates Sonic Tension Meter Data
9.2.5 Assembly of Belt Cover
9.2.5.1 Position belt cover on assembly and attach 2 fasteners at lower cover, attach 2
fasteners at upper mid cover just inside belt cover opening. Install 2 mounting bolts
on side of assembly used to secure drive motor (refer to table 1, section 1.3 for
9.2.6 Assembly of Fan Shroud
9.2.6.1 After insuring that the shroud/coil mating surfaces have been cleaned in accordance
with section 6, apply a 1/8 inch bead of RTV to fan/outlet shroud/coil mating surface.
CAUTION: DO NOT TIGHTEN FAN SHROUD MOUNTING SCREWS UNTIL MOTOR AND FAN HAVE
BEEN INSTALLED. TIGHTEN ONLY AFTER INSURING THAT THERE IS MINIMUM 0.050” BLADE TIP
CLEARANCE BETWEEN THE BLADE AND THE SHROUD AROUND THE ENTIRE CIRCUMFERENCE.
9.2.6.2 Install receiver dryer mounting bracket prior to tightening shroud mounting bolts.
12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
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9.2.6.3 Attach fan shroud to coil with mounting bolts, washers and nuts (refer to table 1,
Section 1.3 for torque specifications).
9.2.7 Assembly of Outlet Shroud
9.2.7.1 After insuring that the shroud/coil mating surfaces have been cleaned in accordance
with section 6, apply a 1/8 inch bead of RTV to outlet shroud/coil mating surface.
9.2.7.2 Attach fan / outlet shroud to coil with mounting bolts, washers and nuts (refer to table
1, Section 1.3 for torque specifications).
9.2.8 Assembly of Condenser Coil
9.2.8.1 Attach condenser fan shroud and outlet shroud to coil per 9.2.6 and 9.2.7.
9.2.8.2 Attach condenser coil to base support using 8 screws and washers. Torque per Table
1 and apply safety wire or cable.
9.2.8.3 Attach condenser support bracket with 7 screws and washers. Torque per Table 1 and
apply safety wire or cable.
9.2.8.4 Using a wire brush and cleaning solvent, completely remove old thread sealant from
compressor connection threads. Apply a thin layer of thread sealant primer to male
fitting threads.
9.2.8.5 Apply 1-2 drops of thread sealant on compressor fitting threads.

9.2.8.6 Apply a thin film of refrigerant oil to fitting flare surfaces.
9.2.8.7 Connect condenser fitting to compressor and tighten per Table 1.
9.2.8.8 Install receiver dryer per 9.2.9.
9.2.8.9 Secure condenser lines to condenser support bracket and base mounting bracket with
clamps as was removed.
9.2.9 Assembly of Receiver Dryer
9.2.9.1 Carefully slide receiver dryer into mounting clamp and tighten clamp.
CAUTION: APPLY THREAD SEALANT SPARINGLY TO THREADS STAYING CLEAR OF FIRST 2-3
THREADS.
9.2.9.3 Apply 1-2 drops of thread sealant on receiver dryer inlet port threads.
12037 N Highway 99
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Phone (405) 382-0731
Fax (405) 382-0737
9.2.9.4 Apply thin film of refrigerant oil to flare and connect condenser fitting to receiver dryer
and tighten (refer to table 1, section 1.3 for torque specifications).
9.2.10 Assembly of Power Relay
9.2.10.1 Carefully slide power relay into position and attach using mounting hardware.
9.2.10.2 Connect electrical connections and install boots for protection.
9.2.11 Assembly of Hour Meter
9.2.11.1 Carefully slide hour meter into hour meter opening and secure with attaching
hardware (refer to table 1, Section 1.3 for torque specifications).
9.2.11.2 Connect electrical terminals.
9.2.12 Assembly of Compressor Condenser Module Assembly
9.2.12.1 Refer to aircraft maintenance manual for installation of compressor condenser module
assembly.

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
SUBTASK 21-00-23-40-002
9.3 Evaporator Module Assembly Procedures

(refer to Figure 10002/10003):
9.3.1 Assembly of Expansion Valve (FIG. 10002, 10), (FIG. 10003, 60A)
9.3.1.1 Set new valve adjustment screw to same position as failed valve.
CAUTION: APPLY THREAD SEALANT SPARINGLY TO MALE FITTING THREADS STAYING CLEAR OF
FIRST 2-3 THREADS.
9.3.1.3 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.
9.3.1.4 Apply thin film of refrigerant oil to expansion valve flare surface and a very small
amount to the O-rings to prevent damage.
9.3.1.5 Connect expansion valve to coil header fitting. Refer to table 1, Section 1 for torque
specifications.
9.3.1.6 Leak check per Testing and Fault Isolation, Section 3.5 and then evacuate and charge
system per Servicing, Section 13.
9.3.2 Assembly of Air Filter (FIG. 10002. 20), (FIG. 10003, 70D)
9.3.2.1 Remove old Velcro from evaporator coil.
9.3.2.2 Apply new Velcro (hook side) along top and bottom of evaporator coil inlet.
9.3.2.3 Apply new Velcro (loop side) along top and bottom of filter.
9.3.2.4 Install new filter into position ensuring Velcro is securely mated.
9.3.3 Assembly of Blower Motor/Wheel (FIG. 10003, 10/20B)
9.3.3.1 Position Blower Wheel on motor shaft. Ensure that there is a 0.25 inch gap between
motor and back of blower wheel.
9.3.3.2 Tighten set screw, ensuring that set screw is located on flat of motor shaft (refer to
table 1, Section 1.3 for torque specifications).
9.3.3.3 Apply RTV to motor and scroll mating surfaces.

CAUTION: USE EXTREME CARE TO PREVENT DAMAGE OR BENDING OF BLOWER WHEEL DURING
INSTALLATION OF MOTOR AND WHEEL.
12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
9.3.3.4 Slide motor/blower wheel into scroll and attach with upper motor screws and washers.
9.3.3.5 Attach drip tray to motor with lower motor attachment screws and washers, ensuring
that spacers and clamp have been installed properly (refer to table 1, Section 1.3 for
9.3.3.6 Secure drip tray onto escutcheon with nuts and washers.
9.3.3.7 Connect power leads.

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT
TASK 21-00-23-99F-803
10.0 SPECIAL TOOLS/EQUIPMENT
SUBTASK 21-00-23-99F-014
10.1 General:
10.1.1 This section describes the necessary tools and test equipment required to perform
maintenance, functional testing, troubleshooting, and repair procedures. 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
• 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 (low pressure gauge, 0-300 PSIG), (high pressure
gauge, 0-600 PSIG).
• Thread sealant primer Loctite 7471
• Thread sealant Loctite 569
• RTV sealant 11602 Black
• Hose adapter 1/2 in. male ACME to 1/4 in. female flare
• Leak check fluid soap solution (Spec MS-SNOOP-GAL)
• Refrigerant oil RL-100S
• External or aircraft power source 200 amp.
• Thermometer 0-150°F
• Flashlight or service lamp
• Refrigerant R-134A
• Kent-More Flush Adapter J42939
• Small “rare earth” magnet
• Tape
12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
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• Straight Edge
• Measuring Device
• Micrometer
• Scribe or Wire Hook
• Volt-OHM Meter
• Gates Sonic Tension Meter 508C or equivalent

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
ILLUSTRATED PARTS LIST
TASK 21-00-23-98-801
11.0 R-134A AIR CONDITIONING SYSTEM COMPONENT ILLUSTRATED PARTS LISTING
SUBTASK 21-00-23-99F-015
11.1 Introduction:
This Illustrated Parts Listing (IPL) is intended for use during testing and isolation, disassembly, cleaning,
check (inspection), repair, assembly, and issuing the replaceable equipment components as well as in
identification of new and reclaimed parts. This IPL includes
• Illustrations of the Compressor Condenser Module and Evaporator Module Assembly to be
used during the procedures outlined previously.
• Figures 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.
• A part number for each component called out in the illustration that is a field replaceable
component.
• Nomenclature for each component helps with identification.
• Units per assembly for each field replaceable component called out in the illustration. N/P
designates non–procurable items.

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
Figure 10001 Compressor Condenser Module Assembly 1134400-53

Supersedes 1134400-13 and 1134400-56 – All three configurations shown here

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
FIG. ITEM PART NUMBER NOMENCLATURE UNITS ASSY.

10001-10C 1134104-1 DC MOTOR (-13 CONFIG ONLY) 1
See note below* DC MOTOR ASSEMBLY (-56 CONFIG ONLY) NP
1134104-6 DC MOTOR ASSEMBLY (-53 CONFIG) 1
11A 5/16-24X3/4H UPPER/LOWER BOLT 2
12A MS35333-41 FLAT WASHER 2
14A NAS1149F0563P FLAT WASHER (AN960-516) 2
15A 5/16-24X3/4H UPPER BOLT 1
16A MS35333-41 UPPER FLAT WASHER 1
17A 5/16-24X3/4H LOWER DRIVE MOTOR BOLT 1
18A MS35333-41 LOWER DRIVE MOTOR FLAT WASHER 1
20A MS35333-41 FLAT WASHER 2
MOTOR BRUSH (SET CONTAINS 4 BRUSH
-21 1251171 1
PAIRS)
10B 1250128 POWER RELAY 1
-11B ¼-28X1/2H BOLT 1
-12B ¼-28X1H BOLT 1
-13B 21FK-428 NUT 2
-14B MS35333-40 FLAT WASHER 1
-15B AN345-416 NUT 1
-16B NAS1149F0463P FLAT WASHER (AN960-416) 4
-17B MS25171-3 LARGE BOOT 3
-18B MS25171-1 SMALL BOOT 2
21C 1250146-5 DRIVE PULLEY 1
-30 1134170-5 FAN BLADE (-53 CONFIG) 1
1134170 FAN BLADE (-13 CONFIG ONLY) 1
-31 ¼-28X5/16B SET SCREW 1
-32 NAS1149F0663P FLAT WASHER (AN960-616) 3
-33 21FK-624 NUT 1
40A 1134160 COMPRESSOR ASSEMBLY 1
-41 M10-1.2525MM BOLT 3
Figure 10001 Compressor Condenser Module Assembly (1134400-53) Details
Supersedes 1134400-13 and 1134400-56 – All configurations shown here
- ITEMS NOT ILLUSTRATED

N/P ITEMS NOT PROCURABLE
* For units that are the 1134400-56 configuration- when a motor requires service, the entire compressor
condenser module must be removed and returned to get upgraded to 1134400-53 or 1134400-59.

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
UNITS
FIG. ITEM PART NUMBER NOMENCLATURE
ASSY.
-42A 10MM SPLIT WASHER 3
-43 1134125-3 MANIFOLD ASSEMBLY 1
-44 AS568-013-HNBR-70 O-RING 1
-44 1134125-4 MANIFOLD ASSEMBLY 1
-45 901V212-10 O-RING TO FLARE ADAPTER 1
-46 AS568-015-HNBR-70 O-RING 1
50C 1134192-1 RECEIVER DRYER (Superseded by 1134192-15) 1
RECEIVER DYRER (Supersedes 1134192-1)
1134192-15 1
w/pressure switch
60A 1250232-4 BINARY PRESSURE SWITCH 1
70C QS100M36H CLAMP 2
80C 1134199 BELT COVER 1
-81 6-32X1/2IHS SCREW 4
90C 240L100 DRIVE BELT 1
100A 1134510 OUTLET SHROUD 1
-101 10-32X3/8IHW BOLT 4
-102 NAS1149F0332P FLAT WASHER (AN960-10L) 4`
-103 409-1032Z LOCK NUT 4
110A 1134509 FAN SHROUD 1
-111 10-32X1/2H BOLT (RECEIVER DRYER BRACKET SIDE) 3
-112 NAS1149F0332P FLAT WASHER (AN960-10L) 3
-113 409-1032-Z LOCK NUT 3
-114 10-32X3/8IHW BOLT 3
-115 NAS1149F0332P FLAT WASHER (AN960-10L) 3
-116 409-1032Z LOCK NUT 3
120A CONDENSER COIL ASSEMBLY N/P
130A 1134502-1 CONDENSER BRACKET 1
-131 MS35265-28 SCREW 4
-132 NAS1149FN632P FLAT WASHER (AN960-6) 4
-133 MS35265-43 SCREW 3
140C 1250703-3 HOUR METER 1
-141 AN500-A8-6 SCREW 2
-143 409-632Z LOCK NUT 2
150A RECEIVER DRYER BRACKET N/P
Figure 10001 Compressor Condenser Module Assembly (1134400-53) Details
Supersedes 1134400-13 and 1134400-56 – All Configurations shown here


12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
1134400-59 Compressor Condenser Module Assembly

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737

1 1134104-9 28VDC Motor Assembly 1
Item Not Shown 1251171-11 Motor Brush Set (Contains 4 Brush Pairs) 1
2 1260970 Fan Assembly 1
3 1134502-2 Condenser Support Bracket 1
4 1134509-6 Condenser Fan Shroud 1
1134400-59 Compressor Condenser Module Assembly Details
This table lists the differences between the 1134400-59 and other assemblies
Refer to Table 10001 for all other parts

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
Figure 10002 Evaporator Module Assembly 1134200-42 (L) /-43 (C,R)

(Superseded by 1134200-60, L /-61, R /-63, C)

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737

10002-10 1134218 EXPANSION VALVE (-42) 1
1134218-1 EXPANSION VALVE (-43) 1
20 1250540-11 AIR FILTER 1
-21 190940 VELCRO (HOOK) (2.6 FT.) 1
-22 190911 VELCRO (LOOP) (2.6 FT.) 1
30 BLOWER MOTOR N/P
40 SHROUD N/P
50 ESCUTCHEON N/P
Figure 10002 Evaporator Module Assembly (1134200-42/-43) Details


12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
Figure 10003 Evaporator Module Assembly 1134200-60/-61/-63 (-60 Shown)

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737

10003-10B 1133210-16 BRUSHLESS DC MOTOR (-60) 1
1133210-15 BRUSHLESS DC MOTOR (-61) 1
1133210-17 BRUSHLESS DC MOTOR (-63) 1
20B 1250219-1 BLOWER WHEEL (-60) 1
1250219-2 BLOWER WHEEL (-61/-63) 1
30C BLOWER SCROLL N/P
40A SHROUD N/P
50A ESCUTCHEON N/P
60A 1134218 EXPANSION VALVE (-60) 1
1134218-1 EXPANSION VALVE (-61/-63) 1
70D 1250540-11 AIR FILTER 1
-71 190940 VELCRO (HOOK) (2.6 FT.) 1
-72 190911 VELCRO (LOOP) (2.6 FT.) 1
80B ¼-28X25 SET SCREW 1
90B 4259 SPACER 2
100B NAS1096-2-10 SCREW (8-32XX5/8) 2
110B MS35333-38 LOCK WASHER 4
120B NAS1096-2-20 SCREW (8-32X1-1/4) 2
130B NAS1149FN832P FLAT WASHER (AN960-8) 1
140B CLN3/16 CLAMP 1
150A 1250823-5 DRIP TRAY (-60) 1
1250823-4 DRIP TRAY (-61/-63) 1
Figure 10003 Evaporator Module Assembly (1134200-60/-61/-63) Details


12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
SPECIAL PROCEDURES
TASK 21-00-23-82-801
12.0 SPECIAL PRODECURES
SUBTASK 21-00-23-82-001
12.1 Expansion Valve Alignment:
12.1.1 The expansion valve is set at the factory, but there may be times when it must be adjusted
to assure proper refrigerant flow at the desired evaporating temperature; for example,
excessive pressure drop for long suction line runs. Any adjustment must not affect typical
suction and discharge pressures as outlined in Table 5.

• Micrometer
• Volt-OHM meter (digital)
• Respiration mask
• External aircraft power source
• Thermometer, 0-150° F
• Flashlight or service lamp
• R-134A service manifold and gauge set

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
• Verify that system leak check and refrigerant charging has been performed and system is
operating at typical values as outlined in table 5.
Outside Air Temperature Suction Pressure Discharge Pressure

(Deg F) (PSIG) (PSIG)
60-70 28 125 - 140
80 30 170 ± 10
95 31 210 ± 10
105 32 237 ± 10
Table 5 Typical Operating Values
12.1.3 Gain access to the Evaporator Coil Assembly (refer to the aircraft maintenance manual for
removal of access panels and other hardware that might need to be removed)
12.1.4 Remove all shrouds, covers or enclosures which prevent access to the evaporator
expansion valve adjustment knob.
12.1.5 Remove expansion valve protective cap.
12.1.6 Verify that inlet to evaporator coil and blower ducting are free of any contamination or
restrictions which could alter air flow. If components are dirty, refer to Cleaning, Section 7.
12.1.7 Verify the blower speed switch is in the high position.
12.1.8 Verify R-134A manifold gauges and hoses are connected to the compressor service valves
and system is operating normally.
12.1.9 Close cabin and cargo doors and allow system to operate for 5 minutes.
12.1.10 Record compressor suction and discharge pressures and evaporator air inlet and outlet
temperatures.
NOTE: Typical temperature difference of evaporator inlet and outlet air is 25±5°F.
12.1.11 If the suction pressure is above the typical values outlined Table 5, the expansion valve
must be turned CCW in ½ revolution increments. Wait 2-5 minutes for valve to stabilize,
until desired value is obtained, or outlet temperature is the lowest possible.
12.1.12 If suction pressure is lower than typical values outlined Table 5, the expansion valve must
be turned CW in accordance with the same procedure discussed in previous paragraph.
12.1.13 Allow system to operate for 5-10 minutes after expansion valve adjustment to verify setting.

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
SUBTASK 21-00-23-82-002
12.2 Balancing Multiple Evaporators:
12.2.1 If system contains multiple evaporator modules, balancing of evaporators must be

accomplished for refrigerant flow between evaporators to achieve equal evaporator air
outlet temperatures. If system does not contain multiple evaporators, shut system off and
replace all shrouds, enclosures, ducting, as required and remove charging/measurement
equipment.
12.2.2 Gain access to all system evaporator’s. Measure and record outlet air temperatures.
12.2.3 Adjust the expansion valve on the evaporator with the highest outlet air temperature ¼
revolution in a CW direction. This will increase the refrigerant flow and reduce the outlet air
temperature.
12.2.4 Adjust the remaining evaporator(s) with a lower outlet air temperature ¼ revolution CCW.
12.2.5 Allow system to stabilize, recheck the evaporator outlet temperatures and repeat adjustment
procedure if required. Evaporator outlet temperatures should be within 1-3° of each other.
NOTE: Proper evaporator balancing should not result in a change of the compressor suction pressure. Verify
system pressures are typical values as shown in table 5.
12.2.6 If the evaporator’s outlet temperature is equal and the suction pressure is typical, then
servicing is complete. Shut system off and replace all shrouds, enclosures, ducting, as
required and remove charging/measurement equipment. If not, repeat adjustment
procedure until temperatures are equal and suction pressure is typical.
SUBTASK 21-00-23-82-003
12.3 Motor Insulation Resistance Check:
12.3.1 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.
12.3.2 Gain access to the Compressor Condenser Module (refer to the aircraft maintenance
manual for removal of access panels and other hardware that might need to be removed)
12.3.4 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.

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
SUBTASK 21-00-23-20-001
12.4 Motor Bearing Inspection:
12.4.1 Motor bearing will be inspected according to Section 8 Inspection Schedule Table 3.5 to
ensure that premature seizure does not occur.
12.4.4 Remove brush cover (on some systems, removal of power leads is required prior to brush
cover removal, tag positive terminal).
12.4.5 Remove brushes from guides and remove belt from motor pulley (refer to Disassembly,
Section 5).
12.4.6 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.
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.
12.4.7 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).
SUBTASK 21-00-23-20-002
12.5 Compressor Bearing Inspection:
12.5.1 Compressor bearing will be inspected according to Section 7 Inspection Schedule Table 3.5
to ensure that premature seizure does not occur.
manual for removal of access panels and other hardware that might need to be removed).
12.5.4 Rotate compressor pulley by hand to ensure freedom of movement and to ensure that the
pulley is not showing signs of loosening. Visually inspect bearing for sign of overheating or
loss of lubrication using an inspection mirror.
12.5.5 If bearings rotate smoothly and are in otherwise good condition, perform belt alignment and
tensioning (refer to Assembly, Section 9).

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
SUBTASK 21-00-23-20-003
12.6 Compressor Oil Level Check:

NOTE: Checking compressor oil quantity is only required if an excessive amount of oil is observed due to
leaking or the system has been vented quickly thereby causing a loss of oil. An oil check can only be made
with the system vented.
12.6.1 When replacing the compressor, use the following procedure to add required oil to system.
12.6.2 Drain and measure oil from new compressor (5 oz).
12.6.3 Drain and measure oil from failed compressor. Record quantity in ounces.
CAUTION: DO NOT OVERFILL COMPRESSOR WITH OIL OR SYSTEM PERFORMANCE WILL BE
AFFECTED.
12.6.4 Add new oil to the new compressor in the amount measured from the failed compressor.
Only RL100H or RL100E oils are approved for this system.

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
SERVICING
TASK 21-00-23-60-801
13.0 R-134A AIR CONDITIONING SYSTEM SERVICING PROCEDURES
SUBTASK 21-00-23-99F-016
13.1 General:
13.1.1 Reclaiming the system (R-134A) refrigerant charge is required on systems before system
removal, after an accidental line break, component failure or when the system has
excessive leaks. 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: DUE TO THE EVER INCREASING NUMBER OF ALTERNATE REFRIGERANTS BEING
INTRODUCED ON THE MARKET, EXTREME CARE MUST BE TAKEN TO PREVENT THEIR USE IN THIS
SYSTEM. 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.

• 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
• RL100H or RL100E refrigerant oil
• External or aircraft power source, 200 AMPS.
• Reclaim/ Recycle Cart (R-134A)

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
• Hose adapter (1/2 in, male acme to ¼ female flare)
SUBTASK 21-00-23-60-001
13.2 Evacuating the system (R-134A):

NOTE: The system must be evacuated for a minimum of 45 minutes to remove air and moisture which can
cause the system to have less than optimal performance.
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 an additional15 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 21-00-23-60-002
13.3 Charging the system (R-134A):

WARNING: SYSTEM DAMAGE CAN OCCUR FROM OVERCHARGING OR UNDERCHARGING THE
SYSTEM TO THE SPECIFIED AMOUNT OF REFRIGERANT.
technician must pull and collar applicable circuit breakers

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
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 charge for the Pilatus PC12 system is 2.0 lbs.
SUBTASK 21-00-23-60-003
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
13.4.2 Enviro recommends flushing R-134A systems using only R-134A refrigerant.
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.
13.4.5 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).
13.4.6 Remove expansion valve and install fittings and hoses to close loop after valve removal.
12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
13.4.7 Remove the receiver dryer and install a jumper hose between the open ports.
13.4.8 Apply power to recovery unit and run for a minimum of 15 minutes.
13.4.9 Check for leaks during flushing process. If leaks are detected, stop machine and repair
leaks before continuing.
13.4.10 Confirm that recovery unit shuts down at the end of the selected recovery time.
13.4.11 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.
13.4.12 Reconnect the lines to the compressor (refer to Assembly, Section 9)
13.4.13 Remove fittings and hoses and re-install the expansion valve (refer to Assembly, Section 9)
13.4.14 Remove jumper hoses from receiver dryer ports and install a new receiver dryer (refer to
Assembly, Section 9)
13.4.15 Perform a system leak check (refer to Test and Fault Isolation, Section 3, System Leak
Check, Section 3.3)
13.4.16 Perform system refrigerant charge (refer to Servicing, Section 13)
13.4.17 Verify system performance (refer to Test and Fault Isolation, Section 3.1)

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
STORAGE
TASK 21-00-23-55-801
14.0 COMPRESSOR CONDENSER MODULE ASSEMBLY STORAGE PROCEDURES
SUBTASK 21-00-23-99F-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 21-00-23-55-001
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.

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
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.
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.
SUBTASK 21-00-23-55-002
14.3 System Off-Season/On-Aircraft 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.
SUBTASK 21-00-19-99F-019
14.4 General System Component Storage procedures:
14.4.1 This section defines the procedures and requirements necessary if any component is to be
stored and not installed onto the aircraft immediately. The component should be stored in a
manner that will protect it from damage and contamination in an effort to ensure component
reliability and achieve a long service life for which the component is designed
14.4.1.1 If component will be stored and not installed on the aircraft for any period of time, the
following preventive maintenance should be followed.
14.4.1.2 Component is packaged and shipped in a manner designed to keep it protected from
damage and/or contamination. Should the component not be installed in an aircraft
immediately, it is desirable that it remain sealed and packaged in the original Enviro
Systems container. This will ensure maximum protection during the storage period.
14.4.1.3 If the component is removed from the original packaging and is not installed on the
aircraft immediately, it is desirable that it be repackaged using the original Enviro
Systems packaging.
12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
14.4.1.4 If the component is removed from the original packaging and is not installed on the
aircraft immediately and the original packaging is not available for repackaging,
ensure that the component is packaged in the following manner.
14.4.1.5 Ensure duct or refrigerant openings are capped to further protect the component from
contamination.
14.4.1.6 Slide the evaporator module assembly into a durable clear plastic bag and seal air
tight. Ensure that a small desiccant bag is placed into bag prior to sealing. This will
aid in keeping the component moisture free.
14.4.1.7 It is desirable at this point, to place the covered and sealed evaporator module
assembly into a protective container such as a box to prevent damage.


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12037 N Highway 99

OPERATING, SERVICING, AND COMPONENT

WITH ILLUSTRATED PARTS LIST

R-134a AIR CONDITIONING SYSTEM COMPONENTS:

1) COMPRESSOR CONDENSER MODULE ASSEMBLY, PART # 1134400-53

ATA SPECIFICATION 21-00-23

Copyright © 2017 Original Release

Continued Next Page

Copyright © 2017 ATA 21-00-23

REV DESCRIPTION OF CHANGE-Continued DATE APPROVAL

Copyright © 2017 ATA 21-00-23

RECORD OF TEMPORARY REVISIONS

REV DESCRIPTION OF CHANGE DATE APPROVAL

Copyright © 2017 ATA 21-00-23

LIST OF SERVICE BULLETINS

SERVICE DESCRIPTION DATE

Copyright © 2017 ATA 21-00-23

LIST OF EFFECTIVE PAGES

CHAPTER / SECTION PAGE DATE CHAPTER / SECTION PAGE DATE

Copyright © 2017 ATA 21-00-23

RECORD OF TEMPORARY REVISIONS ........................................................................................................... 4

Copyright © 2017 ATA 21-00-23

Copyright © 2017 ATA 21-00-23

Figure 1 R-134A Refrigerant Flow Schematic ............................................................................................... 25

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

Copyright © 2017 ATA 21-00-23

1.0 MANUAL INTRODUCTION

1.1 General introduction (How to Use):

Copyright © 2017 ATA 21-00-23

1.2 Acronyms, Abbreviations, and Symbols:

• CMM Component Maintenance Manual

Copyright © 2017 ATA 21-00-23

1.3 Standard Torque Values:

1.4 Documents required:

1.5 Consumable Products:

DESCRIPTION AND OPERATION

2.0 R-134A AIR CONDITIONING SYSTEM DESCRIPTION AND OPERATION

Copyright © 2017 ATA 21-00-23

2.2 System Description and Operation:

Copyright © 2017 ATA 21-00-23

2.3 System Component Description and Operation:

2.3.2 The COMPRESSOR CONDENSER MODULE ASSEMBLY (PN 1134400-13/-53/-56/-59)

2.3.3.2 COMPRESSOR ASSEMBLY: The compressor assembly contains an R-134A

Copyright © 2017 ATA 21-00-23

2.3.3.4 RECEIVER DRYER ASSEMBLY: The receiver-dryer assembly consists of a

2.3.4 The EVAPORATOR MODULE ASSEMBLY (PN 1134200-60/-61/-63, Supersedes 1134200-

Copyright © 2017 ATA 21-00-23

Copyright © 2017 ATA 21-00-23

TESTING AND FAULT ISOLATION

3.2 Compressor Condenser Module Assembly Testing Procedures

3.2.1.2 Verify that the system is cooling properly.

3.3 Evaporator Module Assembly Testing Procedures

Copyright © 2017 ATA 21-00-23

3.4 System Leak Check Testing Procedure:

3.4.3 Special Tools and/or Equipment Required:

• Thread sealant primer, PN 7471 (Loctite)

3.4.3.3 Verify all plumbing connections are tight.

3.4.3.8 Connect yellow charging hose to a regulated dry nitrogen source

3.4.3.9 Slowly regulate nitrogen source to a pressure of 200 PSIG maximum.

Copyright © 2017 ATA 21-00-23

3.4.3.17 Close manifold valve.

3.5 Fault Isolation (Trouble Shooting):

Copyright © 2017 ATA 21-00-23

NOTE: Refer to Refrigerant Flow (Figure 1), Section 4.