12037 N Highway 99

Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
[Link]

OPERATING, SERVICING, AND COMPONENT

MAINTENANCE MANUAL

WITH ILLUSTRATED PARTS LIST

(GM06-101)

CESSNA 525

R-134a AIR CONDITIONING SYSTEM COMPONENTS:

1) COMPRESSOR CONDENSER MODULE ASSEMBLY, PART # 1134400-17 or 1134400-31

CESSNA PART # 99122459-1 or 9912459-8

2) FORWARD EVAPORATOR MODULE ASSEMBLY, PART # 1134820-13

CESSNA PART # 9912459-9

3) AFT EVAPORATOR MODULE ASSEMBLY, PART # 1134820-14

CESSNA PART # 9912459-10

ATA SPECIFICATION 21-00-05

COPYRIGHT  2006 ORIGINAL ISSUE
21-00-05
JULY 5/ 2006
ENVIRO SYSTEM INC. SEPTEMBER 01, 2011
 12037 N Highway 99
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Phone (405) 382-0731
Fax (405) 382-0737
[Link]
Component Maintenance Manual

RECORD OF REVISIONS

REV DESCRIPTION OF CHANGE DATE APPROVAL

- Original Release of Rewrite with Brushless Motor 07/05/06 TB
Info
A Section [Link] IS “Hold the inductive sensor 08/31/06 TB
approximately 1 cm (0.4 in) above the
magnet….” WAS “above the magnet” bulleted at
bottom of list.
Updated Figure 3 and Cross-References in
[Link].8 and
[Link].10.
Corrected References to “Section 7.0”
1. Section [Link].3 WAS “…as described
in section 7.0” IS “…at the time intervals
described in section 7.0.”
2. Section [Link].5 WAS “Section 7.0” IS
“Section 4.1.3 and 4.1.4.”
3. Section [Link].8 WAS “Section 7.0” IS
“Section 4.0”
Section [Link], the “…in paragraph 8.2…”
Replaced with “… in paragraph [Link]…”
Section [Link] the “…per section 5.0…”
Replaced with “…per section 3.5…”
Added notes specifying brushless motors are
not a direct replacement for brushed motors,
Section 5.4, 7.2.3 and 7.2.4
Corrected grammatical/spelling/typographical
errors

B Typo error Page 5 – Was “my” is “may” 9/13/06 TB

Added obsolete evaporator part numbers to
Table 1
Added motor part number section 4.2 heading

1 Updated entire manual using ATA Spec 2200 as 6/11/07 BH

guide. Changed name of manual to “Operating,
Servicing, and Component Maintenance Manual
with Illustrated Parts List (GM06-101) Cessna
525”. Show revisions numerically per ATA Spec
2200.

See Next Page

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REV DESCRIPTION OF CHANGE DATE APPROVAL

2 Added into IPL attaching hardware for several 8/24/07 BH
components
3 Added in procedures on removing and installing 10/25/07 BH
Power Relay and inserted new IPL calling out
Power Relay.
4 Page 10008, Figure 10003, item # 10….. 1/16/08 BH
changed 1133210-23 to 1133210-7 (correct
motor).
Figure 1….Changed to reflect correct
measurement
Was…new length .875 in, min length .440 in
Is…….new length .895 in, min length .395
5 Added references to “thread sealant primer 3/12/08 BH
Loctite 7471” throughout the manual.
6 Updated Storage, Section 14. Updated 5/5/08 BH
information concerning cold weather operations
under General and System Off Season/On
Aircraft Functional Testing.
7 Title Page…changed Compressor Condenser 6/26/08 BH
Module Assembly Cessna P/N 9912459-1 to
Cessna P/N 9912459-8.
8 IPL Compressor Drive Module listed the motor 2/5/09 BH
brush/shunt as “1251171-6”. Changed to
“1251171”.
9 Add SB 11-101 Add Cond. Comp. 1134400-17 5/31/11 BH
IPL 10001-10 reference SB11-101 . IPL Figure
10001 item -150and 10002 item -140 Qty of
Brushes changed from 4 to 1. Table 2 Add
RL100E to Consumable List Add Section 4.0
Schematics and Wiring Diagrams Renumber
Subsequent sections
Change and label Table 3.5 & 3.6 to corrected
schedule hours and months. Remove Section
3.4 Drive Motor Brush Testing. Delete Figure 3
Brush Length Section 7 add Figure 4.3, 4.4 and
4.5, commutator wear examples. Section
[Link]: change verbiages to reflect replacement
of brushes and add Caution referring to
commutator wear condition examples. Renumber
subsequent figures. Remove IPL item numbers
from Sections 2 thru 10.
See Next Page

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Component Maintenance Manual

REV DESCRIPTION OF CHANGE DATE APPROVAL

10 IPL Fig 10002 item 10 add 1134105-1 reference 09/01/11 BH
[Link] 12.4.1 was Motor bearing will
be inspected every 500 operational hours. Is
Motor bearing will be inspected according to
Section 7 Inspection Schedule Table 3.5

NOTE: Check Enviro Systems Inc. web site to verify current revision [Link]

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RECORD OF TEMPORARY REVISIONS

REV DESCRIPTION OF CHANGE DATE APPROVAL

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Revisions
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LIST OF SERVICE BULLETINS

SERVICE DESCRIPTION DATE

BULLETIN # RELEASED
11-101 Add Motor Thermal Fuse 05/12/2011

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LIST OF EFFECTIVE PAGES

CHAPTER / SECTION PAGE DATE CHAPTER / SECTION PAGE DATE

All All 6/11/7
ALL ALL 10/25/07
All All 1/16/08
All All 3/12/08
All All 5/5/08
All All 6/26/08
All All 2/5/09
All All 05/31/11
All All 09/01/11

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TABLE OF CONTENTS

RECORD OF REVISIONS...................................................................................................................................1
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..................................................................................................................................................9
1.0 MANUAL INTRODUCTION....................................................................................................................9
1.1 General introduction (How to Use): ....................................................................................................9
1.2 Acronyms, Abbreviations, and Symbols:.........................................................................................10
1.3 Standard Torque Values: ...................................................................................................................11
1.4 Documents required:..........................................................................................................................11
1.5 Consumable Products:.......................................................................................................................11
DESCRIPTION AND OPERATION ...................................................................................................................12
2.0 R-134a AIR CONDITIONING SYSTEM ...............................................................................................12
2.1 General:................................................................................................................................................12
2.2 System Description and Operation:..................................................................................................13
2.3 System Component Description and Operation:.............................................................................14
TESTING AND FAULT ISOLATION .............................................................................................................1001
3.0 R-134a AIR CONDITIONING SYSTEM COMPONENT ...................................................................1001
3.1 General:............................................................................................................................................1001
3.2 Compressor Condenser Module Assembly testing procedures: ..............................................1001
3.3 Forward / Aft Evaporator Module Assembly testing procedures ..............................................1002
3.4 System Leak Check testing procedure: .......................................................................................1002
3.5 Fault Isolation (trouble shooting): ................................................................................................1005
SCHEMATIC AND WIRING DIAGRAMS......................................................................................................2001
4.0 R-134a AIR CONDITIONING SYSTEM ...........................................................................................2001
4.1 R-134a Refrigerant Flow Schematic: ............................................................................................2001
4.2 R-134a System Electrical Schematic: ...........................................................................................2001
DISASSEMBLY .............................................................................................................................................3001
5.0 R-134a AIR CONDITIONING SYSTEM COMPONENT ...................................................................3001
5.1 General:............................................................................................................................................3001
5.2 Compressor Condenser Module disassembly procedures:.......................................................3001
5.3 Forward / Aft Evaporator Module disassembly procedures: .....................................................3004
CLEANING ....................................................................................................................................................4001
6.0 R-134a AIR CONDITIONING SYSTEM COMPONENT ...................................................................4001
6.1 General:............................................................................................................................................4001
6.2 Compressor Condenser Module cleaning procedures:..............................................................4002
6.3 Forward and Aft Evaporator Module cleaning procedures: .......................................................4003
CHECK (INSPECTION SCHEDULE) ............................................................................................................5001
7.0 R-134a AIR CONDITIOING SYSTEM COMPONENT – INSPECTION SCHEDULE ......................5001
7.1 Compressor Condenser Module inspection schedule: ..............................................................5001
7.2 Forward and Aft Evaporator Module inspection schedule:........................................................5001
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REPAIR..........................................................................................................................................................6001
8.0 R-134a AIR CONDITIONING SYSTEM COMPONENT ...................................................................6001
8.1 General:............................................................................................................................................6001
8.2 Compressor Condenser Module repair procedures: ..................................................................6001
8.3 Forward and Aft Evaporator Module repair procedures:............................................................6001
ASSEMBLY ...................................................................................................................................................7001
9.0 R-134a AIR CONDITIONING SYSTEM COMPONENT ...................................................................7001
9.1 General:............................................................................................................................................7001
9.2 Compressor Condenser Module assembly procedures .............................................................7001
9.3 Forward / Aft Evaporator Module assembly procedures:...........................................................7006
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT......................................................................................9001
10.0 SPECIAL TOOLS/EQUIPMENT.......................................................................................................9001
10.1 General:............................................................................................................................................9001
ILLUSTRATED PARTS LIST ......................................................................................................................10001
11.0 R-134a AIR CONDITIONING SYSTEM COMPONENT .................................................................10001
11.1 Introduction: ..................................................................................................................................10001
SPECIAL PROCEDURES ...........................................................................................................................11001
12.0 SPECIAL PRODECURES ..............................................................................................................11001
12.1 Expansion valve alignment:.........................................................................................................11001
12.2 Balancing multiple evaporators: .................................................................................................11002
12.3 Motor Insulation Resistance Check:...........................................................................................11003
12.4 Motor Bearing Inspection: ...........................................................................................................11003
12.5 Motor Brush Seating Procedure: ................................................................................................11004
12.6 Compressor Oil Level Check:......................................................................................................11004
SERVICING .................................................................................................................................................14001
13.0 R-134a AIR CONDITIONING SYSTEM SERVICING PROCEDURES ..........................................14001
13.1 General:..........................................................................................................................................14001
13.2 Evacuating the system (R-134a): ................................................................................................14001
13.3 Charging the system (R-134a): ....................................................................................................14002
13.4 Flushing the system (R-134a):.....................................................................................................14003
STORAGE ...................................................................................................................................................15001
14.0 COMPRESSOR CONDENSER MODULE ASSEMBLY STORAGE PROCEDURES...................15001
14.1 General:..........................................................................................................................................15001
14.2 System Long Term Shelf Storage: ..............................................................................................15001
14.3 Internal Pressures: .......................................................................................................................15001
14.4 System Off Season Functional Tests: ........................................................................................15001

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LIST OF ILLUSTRATIONS

Figure 1 R-134a refrigerant Flow Schematic.............................................................................................2001

Figure 2 Electrical Schematic .....................................................................................................................2001
Figure 4 Brush Removal Details.................................................................................................................3003
Figure 4.3: Commutator Excellent Condition Example...........................................................................5001
Figure 4.4: Commutator Serviceable Condition Example ......................................................................5002
Figure 4.5: Commutator Unserviceable Condition Example ..................................................................5003
Figure 5 Belt Tensioning Reference...........................................................................................................7006
Figure 10001 Compressor Condenser Module Assembly 1134400-17.................................................10002
Figure 10001 Compressor Condenser Module Assembly Details ........................................................10003
Figure 10001 Cont. Compressor Condenser Module Assembly Details..............................................10004
Figure 10002 Compressor Condenser Module Assembly 1134400-31.................................................10005
Figure 10002 Compressor Condenser Module Assembly Details ........................................................10006
Figure 10002 Cont. Compressor Condenser Module Assembly Details..............................................10007
Figure 10003 Forward Evaporator Module Assembly 1134820-13........................................................10008
Figure 10003 Forward Evaporator Module Assembly Details ...............................................................10009
Figure 10004 Aft Evaporator Module Assembly 1134820-14.................................................................10010
Figure 10004 Aft Evaporator Module Assembly Details ........................................................................10011

LIST OF TABLES

Table 1 Standard Torque Values ....................................................................................................................11

Table 2 Consumable Products .......................................................................................................................11
Table 3 Trouble Shooting List ....................................................................................................................1005
Table 3 Trouble Shooting List ....................................................................................................................1006
Table 3 Trouble Shooting List ....................................................................................................................1007
Table 3.5 Compressor Condenser Module inspection schedule ............................................................5001
Table 3.6 Forward and Aft Evaporator Module inspection schedule .....................................................5001
Table 4 Gates Sonic Tension Meter Data ..................................................................................................7006
Table 5 Blower Motor Electrical Connections...........................................................................................7007
Table 6 Typical Operating Values.............................................................................................................11001
Table 7 Refrigerant Charge .......................................................................................................................14002

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INTRODUCTION

TASK 21-00-05-99F-801

1.0 MANUAL INTRODUCTION

SUBTASK 21-00-05-99F-001

1.1 General introduction (How to Use):

1.1.1 This operating, servicing and component maintenance manual (CMM) covers the
requirements for field servicing the R-134a air conditioning system for the Cessna 525,
Aircraft. This document includes component descriptions, servicing, maintenance, inspection
requirements and 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:

[Link] WARNING: Discloses vital information in order to prevent injury or death while
performing the maintenance procedure.

[Link] CAUTION: Discloses vital information in order to prevent damage to the

equipment during the maintenance procedure.

[Link] NOTE: Discloses more information that will help perform a step of the procedure
or refers to a different procedure.

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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.
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.

SUBTASK 21-00-05-99F-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

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SUBTASK 21-00-05-99F-003

1.3 Standard Torque Values:

TYPE FASTENER DESCRIPTION/LOCATION TORQUE

.25-28 SET SCREW ALL LOCATIONS 40-50 IN-LBS
6-32 SCREW ALL LOCATIONS 8-10 IN-LBS
8-32 SCREW ALL LOCATIONS 12-15 IN-LBS
10-32 SCREW ALL LOCATIONS 20-25 IN-LBS
¼-28-UNF ALL LOCATIONS 50-70 IN-LBS
5/16-24UNF ALL LOCATIONS 100-140 IN-LBS
3/8-24UNF ALL LOCATIONS 160-190 IN-LBS
3/8 PLUMBING CONNECTIONS RECEIVER DRYER INLET PORT 130-160 IN-LBS
½ PLUMBING CONNECTIONS COMPRESSOR DISCHARGE PORT 300-400 IN-LBS
½ PLUMBING CONNECTIONS COIL HEADERS 250-325 IN LBS

Table 1 Standard Torque Values

SUBTASK 21-00-05-99F-004

1.4 Documents required:

 Illustrated Parts Listings (IPL) (included with this manual)

SUBTASK 21-00-05-99F-005

1.5 Consumable Products:

PART NUMBER DESCRIPTION REMARKS

11602 SEALANT RTV BLACK
7471 THREAD SEALANT PRIMER LOCTITE
569 THREAD SEALANT LOCTITE
N7649 LOCTITE PRIMER
RL100H or RL100E EMKARATE ESTER REFRIGERANT OIL
R134a REFRIGERANT

Table 2 Consumable Products

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DESCRIPTION AND OPERATION

TASK 21-00-05-99F-802

2.0 R-134a AIR CONDITIONING SYSTEM

SUBTASK 21-00-05-99F-006

2.1 General:

2.1.1 Air conditioning systems installed on aircraft are not considered a primary flight system.
However, an air conditioning system does perform the important function of providing
passenger and flight crew comfort during aircraft movement on the ground or while in flight.
Aircraft air conditioning systems not only provide effective passenger cooling, but must also
maintain a high level of reliability to minimize aircraft downtime due to unscheduled repairs.

2.1.2 In order to ensure component reliability and achieve a long service life for which the system is
designed, periodic inspection and preventive maintenance must be performed. Failure to
complete periodic inspections, service, or maintenance schedules may reduce product life
and potentially void manufacturer’s warranty.

2.1.3 Inspections, servicing, and/or maintenance schedules are presented in the following sections.
This will ensure component and/or system reliability and performance are maintained when
performed at the specified intervals.

WARNING: SERVICE TECHNICIANS ARE ADVISED TO OBSERVE STANDARD SAFETY

PRECAUTIONS, SUCH AS WEARING PERSONAL SAFETY GEAR, TO PREVENT INJURY WHILE
PERFORMING SERVICE TO THE UNIT. LIQUID REFRIGERANT CAN CAUSE FROSTBITE AND/OR
BLINDNESS.
WARNING: PROPER VENTILATION IS REQUIRED. KEEP REFRIGERANTS AND OILS AWAY FROM
OPEN FLAMES. REFRIGERANTS CAN PRODUCE POISONOUS GASSES IN THE PRESENCE OF A
FLAME. WORK IN A WELL VENTILATED AREA AND AVOID BREATHING REFRIGERANT /LUBRICANT
VAPOR MIST IF ACCIDENTAL DISCHARGE OCCURS.
WARNING: AVOID USE OF COMPRESSED AIR. DO NOT INTRODUCE COMPRESSED AIR OR
OXYGEN INTO AN AIR CONDITIONING SYSTEM OR REFRIGERANT CONTAINER. R-134A IN THE
PRESENCE OF AIR OR OXYGEN ABOVE ATMOSPHERIC PRESSURE MAY FORM A COMBUSTIBLE
MIXTURE.

2.1.4 Do not discharge R-134a refrigerant into the atmosphere. Although its ozone depletion
potential is zero, it can have an effect on global warming. In the United States recovery and
recycling are mandated by the Clean Air Act.

2.1.5 Refrigerant recovery/recycling service equipment must be approved for use with R-134a
refrigerant. Recycling machines must be approved by Underwriters Laboratories (UL) and
meet SAE standard J2210 and SAE standard J2099 for refrigerant purity.
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SUBTASK 21-00-05-99F-007

2.2 System Description and Operation:

2.2.1 The cabin cooling system installed in the Cessna Model 525 Aircraft operates using a closed
vapor cycle concept using refrigerant R-134a as the heat absorption media. The R-134a air
conditioning system cools the aircraft in a similar manner as systems found in an automobile
or home. However, aircraft air conditioning systems contain components which are designed
to be light weight, compact, provide high performance, and provide the ability to operate at
extreme altitudes and ambient temperatures.

2.2.2 The concept of air conditioning a room, cabin or cockpit is straight forward. Examples of a
system as well as an electrical schematic for a typical system are shown in Figures 1 and 2.
Refrigerant is the media which absorbs and rejects the room or cabin heat. By continuous
recirculation of the warm cabin air, heat is absorbed in the evaporator module(s) and is
rejected to the outside through the system condenser. When the system is turned on, the
electric motor drives the R-134a compressor at a constant speed and capacity which
compresses the R-134a refrigerant gas to a high pressure. The hot, high pressure gas then
passes through the condenser coil where it is cooled and condensed into a warm liquid at
constant pressure. The warm liquid is then routed into a receiver-dryer container where the
liquid and any remaining gas are separated and any moisture is absorbed. The warm, dry
liquid is then directed to the evaporator module expansion valve where the high pressure
liquid is expanded to a low pressure. The expansion process creates a super cool gas which
passes through the evaporator coil and absorbs heat from the warm cabin air passing over
the coils. The warm low pressure refrigerant then enters the R-134a compressor where the
process starts all over again. In addition to cooling the cabin air, a refrigerant type system
also removes a large percentage of the moisture in the air as well as removing dust and
pollen particles in the air. Thus, the system conditions the air as well as cooling it. As a safety
feature, the unit is also equipped with a binary pressure switch. This switch prevents the unit
from operating if the discharge pressure becomes excessively high. The switch also prevents
the unit from operating if the internal pressure is very low due to leakage or low ambient
temperatures.

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SUBTASK 21-00-05-99F-008

2.3 System Component Description and Operation:

2.3.1 The R-134a air conditioning system on the Cessna Model 525 uses the Compressor
Condenser Module Assembly (PN 1134400-17 or1134400-31), the Forward Evaporator
Module Assembly (PN 1134820-13), and the Aft Evaporator Module Assembly (PN 1134820-
14).

2.3.2 The COMPRESSOR CONDENSER MODULE ASSEMBLY (PN 1134400-17 or 1134400-31)

has a rated cooling capacity of 16,500 (BTUH) when operating with the other components in
the Cessna 525 Aircraft at an ambient temperature of 95° F (db) and 50% RH (relative
humidity). 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
 Condenser Fan
 Compressor Assembly
 Condenser Coil
 Receiver Dryer Assembly
 Binary Pressure Switch

[Link] COMPRESSOR DRIVE MOTOR: The compressor drive motor has a double-
ended shaft and operates on 28 VDC power with a current draw of 106 AMPS
max. One output shaft drives the R134a compressor and the other end drives the
motor cooling fan. The motor design power is 3.2 HP at 5500 RPM. The motor is
specially designed to provide a high starting torque to overcome the compressor
startup requirements. The motor is a brush commutated, permanent magnet
design and was selected for its efficiency, excellent controllability, long life, and
low vibration. The motor shaft is supported on high speed ball bearings for
reliability and friction reduction.

[Link] COMPRESSOR ASSEMBLY: The compressor assembly contains an R134a

compressor and 5.01 inch pitch diameter pulley assembly. The compressor
incorporates a six-piston swash plate design. The compressor also features anti-
slugging features that eliminate the need for a suction trap/accumulator. The
compressor displacement is 5.0 cubic inches/rev. and has a light weight aluminum
housing. The pulley assembly is designed for a positive grip .375 pitch timing belt
and contains a radial bearing to assure no side loads are transmitted into the
compressor input shaft.

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[Link] CONDENSER COIL ASSEMBLY: The condenser coil assembly is a copper tube
and aluminum fin configuration with 6061-T6 aluminum support brackets. The
required coil heat rejection is 25,000 BTUH and usually based on a 95°F ambient
day. Condenser cooling airflow and coil sizes are based on the design cooling
capacity and compressor input horsepower. The coil working pressure is up to
1500 PSIG.

[Link] 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 steel and contains a
standpipe, wire filter, desiccant and a sight glass for observing refrigerant charge.
The receiver dryer assembly is provided with a corrosion resistant baked enamel
finish. The receiver volume is approximately 40 cubic inches and can store up to
1.8 pounds of refrigerant at 240 PSIG. The Schrader valve located in the
container inlet port allows for the binary pressure switch to be removed without
venting the system refrigerant charge. A lightweight aluminum receiver dryer is
also available.

[Link] BINARY PRESSURE SWITCH: The binary pressure switch performs two major
functions. The first function prevents the R134a 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 355-412 PSIG and resets at 8530 PSIG below
opening pressure. The low side is set to close on rising pressure of 25-35 PSIG
and opens on decreasing pressure of 25-35 PSIG. Electrical contacts are rated at
3.5 amps at 28 VDC.

[Link] CONDENSER FAN: A seven blade, 9.0 inch diameter fan, supplies the condenser
cooling air. The fan is constructed of glass filled nylon and mounted using a 6061-
T6 aluminum hub. The fan provides 900 CFM at 0.5 in.w.g. static pressure.

2.3.4 The FORWARD EVAPORATOR MODULE ASSEMBLY (PN 1134820-13) and AFT
EVAPORATOR MODULE ASSEMBLY (PN 1134820-14) are designed to provide 7,000
(BTUH) of cooling capacity with an ambient air inlet condition of 80° F (db) and 50% RH
(relative humidity). The evaporator blowers will provide 300 CFM (cubic feet per minute) with
a static pressure of 2.0 in.w.g. (inch of water gage) from aircraft ducting (discounting internal
evaporator pressure drop). The blowers are designed to be used in both the air conditioning
mode and as a recirculation mode during aircraft heating. The blowers contain two (2)
speeds. Low speed is designed for the aircraft heating mode which keeps the duct outlet
temperatures at a comfortable level. High speed is designed for the air conditioning mode
and is used for maximum system cooling.

2.3.5 Dual independent evaporators are used to provide dual zone temperature control. Either the
cockpit or cabin evaporator may be used independently depending on the cooling
requirement of either zone.

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2.3.6 The Forward and Aft Evaporator Module Assemblies are packaged to meet the aircraft
installation requirements and each contains the following major components (refer to Figure
10002 and 10003):
 Coil Assembly
 Blower Motor
 Blower Wheel
 Expansion Valve
 Evaporator Housing

[Link] COIL ASSEMBLY: The evaporator coil assembly contains the evaporator coil,
mounting hardware, rubber grommets and female flared fittings. The coil is
constructed of copper tube and aluminum fins with aluminum support brackets.
The coil is rated at 10,000 BTUH with an ambient air inlet condition of 74° F (db)
and 50% RH and an air flow of 300 CFM.

[Link] BLOWER MOTOR: The evaporator blower motor operates on 28 VDC with a
current draw of 16 A @ 300 CFM at 3.0 in.w.g. of static pressure (2.0 in.w.g. for
aircraft ducting and 1.0 in.w.g. for losses internal to the evaporator assembly).
The 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 (2) speeds, low speed designed for the heating recirculation
requirement and high speed designed for maximum system cooling. The motor
shaft is supported on high-speed ball bearings for reliability and friction reduction.

[Link] BLOWER WHEEL: The blower wheel is the component that is used in concert
with the blower motor and provides for the movement of air.

[Link] EXPANSION VALVE: The expansion valve is a thermostatic type with a

temperature sensing return gas line bulb. 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.

[Link] EVAPORATOR HOUSING: The evaporator housing and blower scroll are
constructed of high impact, fire retardant, self extinguishing, corrosion resistant,
lightweight polycarbonate material. The blower scroll has successfully passed
blower wheel containment testing.

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TESTING AND FAULT ISOLATION

TASK 21-00-05-70-801

3.0 R-134a AIR CONDITIONING SYSTEM COMPONENT

SUBTASK 21-00-05-99F-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 21-00-05-70-001

3.2 Compressor Condenser Module Assembly testing procedures:

3.2.1 Ensure that power is applied to the aircraft and that the air conditioning system is switched on
using the cockpit mounted selector switch. Gain access to the Compressor Condenser
Module (refer to the aircraft maintenance manual for removal of access panels and other
hardware that might need to be removed). Verify that the compressor condenser module
assembly is operating and perform the following:
 Verify that system is running smoothly and that there is no excessive noise and/or vibration
coming from the assembly.
 Verify that the system is cooling properly.

3.2.2 If there is excessive noise and/or vibration coming from the compressor condenser module
assembly or the system is not cooling, refer to the Disassembly procedures in section 5 and
Check (inspection) procedures in section 7. This will help in identifying whether one or more
components are dirty or damaged and are in need of repair or replacement.

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SUBTASK 21-00-05-70-002

3.3 Forward / Aft Evaporator Module Assembly testing procedures

3.3.1 Verify blower motor operation in both the low and high speed positions using cockpit mounted
selector switch.

3.3.2 While blower motor is operating in both low and high speed positions, listen carefully for the
following:
 There is a distinct and noticeable change in sound of blower motor when changing from low
to high speed positions. This indicates the cockpit selector switch is functioning properly and
the blower motor is responding accordingly.
 There is a smooth transition when changing from low to high speed positions, and there is no
excessive noise or vibration coming from the blower motor during the change. Excessive
noise could indicate that the blower wheel is rubbing against the blower scroll.

3.3.3 If there is excessive noise and/or vibration coming from blower motor/wheel assembly during
this test, please refer to the disassembly procedures in section 5 and inspection procedures
in section 7. This will help in identifying whether the blower motor wheel is dirty or damaged
and is need of repair or replacement, the blower scroll is dirty or damaged and is need of
repair or replacement, or the blower motor itself is in need of replacement.
NOTE: Blower motor may/or may not be a field serviceable item depending on the part number of the
Forward Evaporator Module Assembly. Refer to Section [Link].3 for information on the blower motor and the
options available for repair and/or 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.

SUBTASK 21-00-05-70-003

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

[Link] Remove, if required, all panels, doors, shrouds, etc, to gain access to
system/component being leak checked (refer to aircraft maintenance manual).

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[Link] Remove, if required, any enclosures or access doors to expose all tubing, hoses,
fittings, etc. to the compressor condenser module/ evaporator module.

[Link] Verify all plumbing connections are tight.

[Link] 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.

[Link] Remove service port caps from the A/C system. The high and low pressure
service ports are most commonly located on the receiver-dryer and the
compressor suction header respectively but may be remotely located elsewhere in
the system.

[Link] Close all manifold gauge valves and verify hose connections are tight.

[Link] 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 a pull to
remove quick-connect fittings.

[Link] Connect yellow charging hose to a regulated dry nitrogen source

NOTE: An adapter is required to connect yellow charging hose to the nitrogen source.
CAUTION: DO NOT EXCEED 200 PSIG NITROGEN PRESSURE DURING PROCEDURE OR DAMAGE TO
EXPANSION VALVE WILL RESULT.

[Link] Regulate nitrogen source to a pressure of 200 PSIG maximum.

[Link] 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.

[Link] Apply soapy leak check fluid to each fitting connection. If leaks are detected,
attempt to tighten fitting without over tightening. If leak cannot be corrected with
tightening, system must be evacuated(refer to Servicing, Section 13) and then
fitting must be disconnected and new thread sealant and loctite primer applied.

[Link] 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.
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[Link] 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

[Link] Apply a light coating of R-134a refrigerant oil to flare and/or o-ring to prevent metal
galling or o-ring damage.

[Link] 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 THAT COMPRESSOR OIL IS NOT
VENTED WITH THE NITROGEN. DO NOT LET AIR ENTER THE SYSTEM.

[Link] 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.

[Link] Close manifold valve.

[Link] System is now ready for charging (refer to Servicing, Section 13).

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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.
NOTE: Refer to Refrigerant Flow (Figure 1) and Electrical Schematic (Figure 2).

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. Contactor control line fuse 10. Replace
blown

Table 3 Trouble Shooting List

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INDICATION PROBABLE CAUSE POSSIBLE SOLUTION

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

D. Evaporator Noisy 1. Wobbly blower wheel 1. Replace

2. Blower wheel hitting scroll 2. Align
3. Defective blower motor bearing 3. Replace motor
4. Loose mounting bracket 4. Tighten hardware
5. Air inlet clogged 5. Remove debris

E. Compressor Noisy 1. Loose drive belt 1. Tension belt

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

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INDICATION PROBABLE CAUSE POSSIBLE SOLUTION

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

Not Operate
2. Relay failed 2. Replace
3. Pressure switch failed 3. Replace
4. Power contactor failed 4. Replace
5. Drive motor failed 5. Replace
6. Drive motor fuse blown 6. Replace
7. Ground power cart not plugged 7. Connect as required
in
8. Low ambient temperature 8. Normal cutout
9. Low refrigerant charge 9. Charge system
10. Motor temperature switch 10. Replace switch
failed

G. No Evaporator Module Air 1. Circuit breaker off 1. Energize or replace

Flow
2. Mode switch failed 2. Replace
3. Fan speed switch failed 3. Replace
4. Seized motor 4. Replace
5. Blower wheel failed 5. Replace
6. Blocked air ducts 6. Remove debris
7. Aircraft power not on 7. Energize
8. Ground power not on 8. Energize

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

Freezing
2. Expansion valve failed or 2. Remove debris or replace
clogged
3. Expansion valve setting low 3. Reset to obtain 26-30 psig
suction pressure

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

Table 3 Trouble Shooting List

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SCHEMATIC AND WIRING DIAGRAMS

21-00-05-99-801

4.0 R-134a AIR CONDITIONING SYSTEM

SUBTASK 21-00-05-99-001

4.1 R-134a Refrigerant Flow Schematic:

4.1.1 The following schematic shows the system components and the flow of the R-134a
refrigerant.

Figure 1 R-134a refrigerant Flow Schematic

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4.2 R-134a System Electrical Schematic:

4.2.1 The following electrical schematic, shows a general representation of the system
components and how they interrelate to each other. For detailed schematics, refer to the
airframe manual.

Figure 2 Electrical Schematic

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DISASSEMBLY

TASK 21-00-05-00-801

5.0 R-134a AIR CONDITIONING SYSTEM COMPONENT

SUBTASK 21-00-05-99F-010

5.1 General:
WARNING: SERVICE TECHNICIANS ARE ADVISED TO OBSERVE STANDARD SAFETY
PRECAUTIONS, SUCH AS WEARING PERSONAL SAFETY GEAR, TO PREVENT INJURY WHILE
PERFORMING SERVICE TO THE UNIT.
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.

5.1.1 Gain access to the Compressor Condenser Module, Forward Evaporator Module, or Aft
Evaporator Module (refer to the aircraft maintenance manual for removal of access panels
and other hardware that might need to be removed)

5.1.2 Verify that power is removed from aircraft. If it is not practical to remove aircraft power,
technician must pull and collar applicable circuit breakers.

5.1.3 Partial disassembly of system components and other subcomponents is required in order to
facilitate the required inspections in accordance with the inspection schedule (Section 7).
Disassemble the components just enough to perform the required inspection.

5.1.4 If replacement of any component is required, further disassembly may be required. If

component requires complete disassembly, keep all parts of each subassembly in a separate
and clean tray.

5.1.5 In the event that a component requires disassembly and the removal of refrigerant plumbing
lines or hoses, ensure that the system refrigerant charge has been recovered prior to starting
maintenance (refer to Servicing, Section 13).
NOTE: Do not disassemble the parts unnecessarily.

5.1.6 Refer to Illustrated Parts Listing (IPL) for figure/item numbers (Section 11).

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SUBTASK 21-00-05-00-001

5.2 Compressor Condenser Module disassembly procedures:

5.2.1 Removal of Receiver Dryer

[Link] Verify that system refrigerant charge has been recovered (refer to Servicing,
Section 13)

[Link] Disconnect electrical wiring to binary pressure switch.

[Link] Disconnect refrigerant plumbing connection from receiver dryer inlet port.

[Link] Disconnect discharge refrigerant line from receiver dryer outlet port.
CAUTION: RECEIVER DRYER MUST BE REPLACED ANY TIME THE VCS PLUMBING IS OPENED FOR
MAINTENANCE.

[Link] Loosen receiver dryer attaching clamps and slide receiver dryer out.

5.2.2 Removal of Belt Cover

[Link] Remove belt cover/motor mounting attaching bolts and washers.

[Link] Remove belt cover attaching screws.

[Link] Remove belt cover from assembly.

5.2.3 Removal of Drive Belt and Pulley

CAUTION: DO NOT BEND OR TWIST THE DRIVE BELT EXCESSIVELY DURING REMOVAL OR
DAMAGE MAY RESULT.

[Link] Remove belt cover.

[Link] Loosen compressor attaching bolts.

[Link] Loosen drive pulley set screws.

[Link] Slide drive pulley and belt from motor shaft and compressor pulley.

5.2.4 Removal of Compressor Assembly

[Link] Remove belt cover, drive belt, and drive pulley.

[Link] Disconnect condenser refrigerant line from compressor plumbing port.

[Link] Remove compressor mounting bolts and washers.

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[Link] Lift compressor from mounting bracket.

[Link] Swing compressor towards drive motor to loosen belt.

[Link] Loosen drive motor pulley set screws.

[Link] Slide drive pulley and belt from motor shaft, while at the same time sliding the
drive belt off the compressor pulley.

5.2.5 Removal of Condenser Outlet Shroud

[Link] Remove outlet shroud attaching screws, washers, and nuts from condenser.

[Link] Cut RTV seal between shroud and condenser coil assembly.

[Link] Remove outlet shroud from coil.

5.2.6 Removal of Drive Motor

[Link] Remove belt cover, drive pulley, and belt.

[Link] Remove receiver dryer.

[Link] Disconnect electrical motor leads.

[Link] Remove condenser support bracket attaching screws and washers.

[Link] Remove motor mounting bolts and washers.

CAUTION: TAKE EXTREME CARE WHEN REMOVING DRIVE MOTOR FROM ASSEMBLY OR DAMAGE
TO FAN OR FAN SHROUD COULD OCCUR.

[Link] Remove condenser support bracket and carefully slide motor from assembly.

5.2.7 Removal of Fan Shroud

[Link] Remove drive motor.

[Link] Remove fan shroud attaching screws, nuts, and washers from condenser.

[Link] Cut RTV seal between shroud and condenser coil assembly.

[Link] Remove fan shroud from coil.

5.2.8 Removal of Fan

[Link] Remove drive motor.

[Link] Remove fan assembly attaching nut and washer.

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[Link] Loosen fan assembly set screw.

[Link] Slide fan assembly off motor shaft.

5.2.9 Removal of Power Relay

[Link] Disconnect electrical connections and mark polarity.

[Link] Remove relay mounting hardware and carefully slide relay from assembly.

5.2.10 Removal of Drive Motor Brushes

[Link] Remove brush cover, attaching screws and washers.

[Link] Remove brush shunt wire attaching screw from brush rack terminal.
CAUTION: DO NOT ALLOW BRUSH SPRING TO SNAP AGAINST BRUSH OR BRUSH DAMAGE MAY
RESLULT.

[Link] Lift brush spring and slide brush from brush rack.

Figure 4 Brush Removal Details

SUBTASK 21-00-05-00-002

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5.3 Forward / Aft Evaporator Module disassembly procedures:

5.3.1 Removal of the Blower Motor/Wheel

[Link] Disconnect electrical power from blower motor by removing leads from power
source.

[Link] Remove blower motor attachment screws and lock washers

CAUTION: USE EXTREME CARE TO PREVENT DAMAGE OR BENDING OF BLOWER MOTOR WHEEL.

[Link] Carefully remove blower motor /blower wheel assembly from scroll.

[Link] Loosen blower wheel set screw on blower motor shaft and remove blower wheel.

5.3.2 Removal of Expansion Valve

CAUTION: SYSTEM MUST BE EVACUATED AND REFRIGERANT RECLAIMED PRIOR TO REMOVING
THE EXPANSION VALVE.

[Link] Disconnect expansion valve from coil header tube fitting and place protective cap
onto header tube fitting opening.

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CLEANING

TASK 21-00-05-10-801

6.0 R-134a AIR CONDITIONING SYSTEM COMPONENT

SUBTASK 21-00-05-99F-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.
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.
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.

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SUBTASK 21-00-05-10-001

6.2 Compressor Condenser Module cleaning procedures:

6.2.1 The following components 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 10001and 10002).
 Compressor Condenser Module Assembly
 Condenser Coil
 Condenser Outlet and Fan Shroud

[Link] 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 brushes, commutator should be cleaned with
compressed air blast to remove any carbon dust or contaminants
CAUTION: USE EXTREME CARE TO PREVENT DAMAGE OR BENDING OF COIL FINS

[Link] CONDENSER COIL: 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 compressor condenser 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.

[Link] CONDENSER OUTLET SHROUD/FAN SHROUD ASSEMBLY: Over time, the

outlet shroud and fan shroud may show signs of separating and this can cause the
compressor condenser module assembly to have less than optimal performance.
If there are signs of separation between the shrouds and the condenser assembly,
the shrouds must be removed and reinstalled using new RTV. The outlet shroud
and the fan shroud can be removed and reinstalled (refer to Disassembly section 5
and Assembly section 9). Once the shrouds are removed, clean the separated
areas carefully with isopropyl alcohol to remove any dirt, dust, and other foreign
matter, to include the old RTV sealant. Refer to Repair (section 8) for resealing
procedures.

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SUBTASK 21-00-05-10-002

6.3 Forward and Aft Evaporator Module cleaning procedures:

6.3.1 The following components of both the Forward and Aft Evaporator Module Assemblies will
require periodic cleaning (refer to section 6 for time intervals) (refer to Figure 10003 and
10004):
 Evaporator Coil Air Inlet
 Evaporator Housing Assembly
 Blower Assembly
 Condensate Drain (part of Evaporator Housing Assembly)
 Water Deflector
CAUTION: USE EXTREME CARE TO PREVENT DAMAGE OR BENDING OF COIL FINS

[Link] 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.

[Link] EVAPORATOR HOUSING ASSEMBLY: The components that comprise the

evaporator housing assembly are the shroud and escutcheon. Over time, the
shroud and escutcheon may show signs of separating and this can cause the
evaporator module assembly to have less than optimal performance. If there are
signs of separation between the shroud and escutcheon, clean the separated
areas carefully with isopropyl alcohol to remove any dirt, dust, and other foreign
matter, to include the old RTV sealant. Refer to Repair (section 8) for resealing
procedures.
CAUTION: USE EXTREME CARE TO PREVENT DAMAGE OR BENDING TO THE BLOWER WHEEL
FRAME AND/OR BLADES.

[Link] BLOWER ASSEMBLY: The components that comprise the blower assembly are
the blower motor, blower scroll and blower wheel. Over time, these components
can become dirty causing the assembly to have less than optimal performance. It
is essential that this assembly remains free and clear of all dirt, dust, and foreign
matter. In an effort to ensure that the blower assembly is free and clear,
disassembly may be required (refer to disassembly, section 5). Using a soft utility
brush, vacuum, and/or rags (or other tools that may be required), remove all dirt,
dust, and foreign matter from the blower wheel and from the inside of the blower
scroll. After cleaning procedure is accomplished, refer to Assembly (section 9).

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[Link] 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.

[Link] WATER DEFLECTOR: The water deflector can become clogged with dirt, dust
and foreign matter over time. It is essential that the deflector remain free and clear
of foreign matter or performance will be less than optimal. Use a small brush or
other suitable cleaning tool to ensure that all foreign matter is removed from the
deflector.

[Link] EXPANSION VALVE: The expansion valve should be free from dirt, dust and
foreign matter. Use a brush or rag to clean.

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CHECK (INSPECTION SCHEDULE)

TASK 21-00-05-21-801

7.0 R-134a AIR CONDITIOING SYSTEM COMPONENT – INSPECTION SCHEDULE

SUBTASK 21-00-05-21-001

7.1 Compressor Condenser Module 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 Service Hours

Drive belt/pulley/cover Visually inspect for wear, nicks, cracks or looseness, and proper tracking. 500
Realign & tension and/or replace as required.
Inspect belt cover for cracks or other damage.
Compressor shaft seal Visually inspect for leaks (excessive oil spray) 500

Condenser outlet and fan Visually inspect condenser outlet and fan shroud for signs of cracking, 500
shrouds separation between shroud and condenser coil.
Condenser coil Visually inspect condenser coil for damage or dirt accumulation. 500
Visually inspect, clean and comb coil fins.
Inspect for leakage.
Inspect plumbing for damage weathering and wear
Visually inspect return bends for nicks, dents, cracks, or other damage..
Electrical wiring Visually inspect wiring for insulation damage, replace as required. 500
Drive motor Visually inspect drive motor commutator for wear.(See Illustration 4.5) 500
Internal contamination inspection
Motor bearing inspection (refer to Special Procedures, Section 12) 500

Drive Motor Brushes Replace Brushes Mandatory every

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

Table 3.5 Compressor Condenser Module inspection schedule

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Excellent Condition
Commutator is still bright and shows little sign of wear.
Figure 4.3: Commutator Excellent Condition Example

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Serviceable Condition
Shows some signs of wear and carbon build up
Figure 4.4: Commutator Serviceable Condition Example

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Unserviceable Condition
Shows excessive pitting and chipping on commutator.

Figure 4.5: Commutator Unserviceable Condition Example

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SUBTASK 21-00-05-21-002

7.2 Forward and Aft Evaporator Module inspection schedule:

NOTE: This is the recommended visual inspection schedule for the Forward and Aft Evaporator Module
Assemblies. 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 Motor must be removed
*Blower Scroll and replaced between 4900-5100
hours in service
Expansion Valve Inspect for cleanliness and damage/integrity 12 Months

Table 3.6 Forward and Aft Evaporator Module inspection schedule

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REPAIR

TASK 21-00-05-30-801

8.0 R-134a AIR CONDITIONING SYSTEM COMPONENT

SUBTASK 21-00-05-99F-012

8.1 General:

8.1.1 Refer to Illustrated Parts Listing (IPL) for figure/item numbers (Section 11).
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.
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).

SUBTASK 21-00-05-30-001

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
 Compressor Shaft Seal
 Condenser Outlet/Fan Shrouds
 Condenser Coil
 Electrical Wiring
 Drive Motor Brushes

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[Link] 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).

[Link] 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).
NOTE: The compressor should not be changed because of a small amount of oil found on an adjacent
surface near the shaft seal. The seal is designed to leak some oil for lubrication purposes.

[Link] CONDENSER OUTLET SHROUD/FAN SHROUD: The condenser outlet and fan
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 of shrouds. Then refer to Cleaning
(Section 6). After insuring that the seam between the shrouds and condenser has
been cleaned according to the cleaning procedures (Section 6), apply a new bead
of RTV () and reinstall shrouds (refer to Assembly, Section 9). Allow RTV to cure
for a minimum of 24 hours before operating system. If the shrouds are cracked or
are damaged in any other way, the shrouds should be replaced.

[Link] 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 of the
compressor condenser module assembly. Refer to Cleaning (Section 6) for proper
cleaning procedures. If coil fins are bent, use a fin comb and try straightening the
fins. If fins are excessively damaged or the return bends are excessively
damaged, the entire compressor condenser module assembly must be removed
and sent for repairs.

[Link] 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.

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[Link] DRIVE MOTOR BRUSHES: Drive motor brushes can, over time, become worn or
damaged. It is essential that the drive motor brushes remain in excellent condition
for proper operation of the compressor condenser module assembly. They must
be replaced according to the inspection schedule in Section 7. Refer to
Disassembly (Section 5) and Assembly (Section 9).
CAUTION: THE COMMUTATOR MUST BE INSPECTED FOR EXCESSIVE OR UNEVEN WEAR. THE
COMMUTATOR SHOULD HAVE A BURNISHED APPEARANCE WITH LIGHT FILMING. IF THE
COMMUTATOR IS BLACK, BURNED, PITTED, GROOVED OR EXCESSIVELY WORN, THE MOTOR
SHOULD BE REPLACED OR REBUILT. IF THE DEPTH OF THE MICA UNDERCUT REMAINING ON THE
COMMUTATOR IS LESS THAN .020 INCH THE MOTOR SHOULD ALSO BE REPLACED. (See Illustration
4.3 THRU 4.5 in Section 7 for examples)

SUBTASK 21-00-05-30-002

8.3 Forward and Aft Evaporator Module repair procedures:

8.3.1 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 10002 and
10003):
 Evaporator Coil Air Inlet
 Evaporator Housing Assembly
 Blower Assembly
 Condensate Drain (part of Evaporator Housing Assembly)
 Water Deflector

[Link] EVAPORATOR COIL AIR INLET: The coil fins will, over time, become damaged
or bent. It is essential that the coil fins are in excellent condition for proper
operation of the evaporator module assembly. If the coil fins are damaged or bent,
try to straighten fins using a fin comb. If coil fins are excessively damaged, coil
replacement will be required.

[Link] EVAPORATOR HOUSING ASSEMBLY: The components that comprise the

evaporator housing assembly are the shroud and escutcheon. Over time, the
shroud and escutcheon may show signs of separating and this can cause the
evaporator module assembly to have less than optimal performance. After
insuring that the seam between the shroud and escutcheon has been cleaned
according to the cleaning procedures (Section 6), apply a new bead of RTV and
smooth. Allow RTV to cure for a minimum of 24 hours before operating system. If
housing assembly is damaged in any way other than seam separation, the entire
Forward Evaporator Module Assembly must be removed and sent for repair.
CAUTION: USE EXTREME CARE TO PREVENT DAMAGE OR BENDING TO THE BLOWER WHEEL
FRAME AND/OR BLADES.

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[Link] BLOWER ASSEMBLY: The components that comprise the blower assembly are
the blower motor (10), 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.

[Link].1 If blower motor wheel is damaged, such as having bent or cracked blades,
removal and replacement is required. Refer to Disassembly (Section 5) for
removal procedures. Refer to Assembly (Section 9) for installation
procedures. After completing the removal and installation of the new blower
wheel, perform functional check (Section 3).

[Link].2 If blower motor scroll is damaged in any way, the entire Forward Evaporator
Module Assembly must be removed and sent for repair.

[Link].3 If blower motor is damaged or is not operating to specifications, removal and

replacement is required. If the Forward Evaporator Module Assembly is P/N
1134820-13, then the blower motor can be removed and replaced in the field.
Refer to Disassembly (Section 5) for removal. Refer to Assembly (Section 9)
for installation. After completing the removal and installation of the new
blower motor, perform functional check (Section 3). If the Forward Evaporator
Module Assembly is other than P/N 1134820-13, the entire assembly must be
removed and sent for repair.

[Link] CONDENSATE DRAIN: The condensate drain (part of the housing assembly)
can, over time, become damaged. It is essential that the drain remains in
excellent condition for proper operation of the evaporator module assembly. If the
condensate drain is damaged, the entire Forward Evaporator Module Assembly
must be removed and sent for repair.

[Link] WATER DEFLECTOR: The water deflector can, over time, become damaged. It
is essential that the deflector remains in excellent condition for proper operation of
the evaporator module assembly. If the water deflector is damaged, the entire
Forward Evaporator Module Assembly must be removed and sent for repair.

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ASSEMBLY

TASK 21-00-05-40-801

9.0 R-134a AIR CONDITIONING SYSTEM COMPONENT

SUBTASK 21-00-05-99F-013

9.1 General:

9.1.1 Refer to Illustrated Parts Listing (IPL) during assembly procedures for figure/item numbers
(Section 11).
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.
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).

9.1.2 Gain access to the Compressor Condenser Module, Forward Evaporator Module, or Aft
Evaporator Module (refer to the aircraft maintenance manual for removal of access panels
and other hardware that might need to be removed)

9.1.3 Verify that power is removed from aircraft. If it is not practical to remove aircraft power,
technician must pull and collar applicable circuit breakers.

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.

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SUBTASK 21-00-05-40-001

9.2 Compressor Condenser Module assembly procedures

9.2.1 Assembly of Drive Motor Brushes (refer to IPL for details Figure 10001and 10002):)
CAUTION: DO NOT ALLOW BRUSH SPRING TO SNAP AGAINST THE BRUSH OR BRUSH DAMAGE
MAY RESULT.

[Link] Lift brush spring and slide brush into brush rack. Verify that brush direction is
against commutator.
CAUTION: APPLY THREAD SEALANT SPARINGLY TO MALE FITTING THREADS STAYING CLEAR OF
FIRST 2-3 THREADS.

[Link] Attach brush shunt wire terminal to brush rack using attaching screw. Apply a
drop of thread sealant to screw.

[Link] Route brush shunt leads to allow for brush wear and to prevent shorting.

[Link] Install brush cover screen and secure with attaching screws and washers (refer to
table 1, section 1.3 for torque specifications). Safety wire screws in place.

9.2.2 Assembly of Receiver Dryer

[Link] Position receiver dryer on motor support bracket and attach with mounting clamps.

[Link] Connect pressure switch electrical wiring (if applicable).

9.2.3 Assembly of Fan

[Link] Slide fan assembly onto motor shaft.

CAUTION: APPLY THREAD SEALANT SPARINGLY TO MALE FITTING THREADS STAYING CLEAR OF
FIRST 2-3 THREADS..

[Link] Apply a drop of thread sealant to the set screw thread. Tighten fan assembly set
screw (refer to table 1, Section 1.3 for torque specifications), insuring that the
screw is located on flat part of motor shaft.

[Link] Install fan assembly attaching nut and washers (refer to table 1, section 1.3 for
torque specifications).

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9.2.4 Assembly of Fan Shroud

[Link] After insuring that the shroud/coil mating surface has been cleaned in accordance
with section 6, apply a 1/8 inch bead of RTV to fan 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 SUFFICIENT BLADE TIP
CLEARANCE BETWEEN THE FAN AND THE SHROUD.

[Link] Attach fan shroud to coil with mounting screws, washers and nuts (refer to table 1,
Section 1.3 for torque specifications).

9.2.5 Assembly of Drive Motor

CAUTION: TAKE EXTREME CARE WHEN INSTALLING DRIVE MOTOR ONTO ASSEMBLY OR DAMAGE
TO FAN OR FAN SHROUD COULD OCCUR.

[Link] Position drive motor in motor support bracket and attach with mounting bolts and
washers (refer to table 1, section 1.3 for torque specifications).

[Link] Verify compressor and condenser support brackets are installed and oriented as
shown in IPL.

[Link] Reconnect motor electrical leads. Observe correct motor lead polarity when
making connections.

[Link] Attach condenser support bracket to motor support bracket with attaching screws
and washers (refer to table 1, section 1.3 for torque specifications). Safety wire
screws in place.

[Link] Verify that electrical wires are secure and pinched.

9.2.6 Assembly of Condenser Outlet Shroud

[Link] After insuring that shroud/coil mating surface has been cleaned in accordance with
section 6, apply a 1/8 inch bead of RTV to both the shroud and coil mating surface.

[Link] Attach shroud to coil with mounting screws, washers and nuts (refer to table 1,
Section 1.3 for torque specifications).

9.2.7 Assembly of Compressor

[Link] Position compressor on mounting bracket ears and attach with bolt and washers.
Finger tighten bolts only, as installation of drive belt and pulley will require slight
adjustment of the compressor.

[Link] Using a wire brush and cleaning solvent, completely remove old thread sealant.
Apply a thin layer of thread sealant primer to fitting threads.

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[Link] Apply 1-2 drops of thread sealant on compressor discharge port threads.
CAUTION: TAKE EXTREME CARE NOT TO GET REFRIGERANT OIL ON FITTING THREADS

[Link] Apply a thin film of refrigerant oil to compressor discharge port flare surface.

[Link] Connect condenser fitting to compressor discharge port and tighten (refer to table
1, section 1.3 for torque specifications).

[Link] Using a wire brush and cleaning solvent, completely remove old thread sealant.
Apply a thin layer of thread sealant primer to fitting threads.

[Link] Apply 1-2 drops of thread sealant on receiver dryer inlet port threads.

[Link] Apply thin film of refrigerant oil to O-ring and install on condenser fitting.

[Link] Connect condenser fitting to receiver dryer and tighten (refer to table 1, section 1.3
for torque specifications).

9.2.8 Assembly of Drive Belt and Pulley

[Link] Place drive belt over motor drive pulley and slide belt onto compressor pulley while
sliding motor pulley onto motor shaft.

[Link] Position motor pulley to align belt with compressor pulley. Tighten belt by rotating
compressor in mounting bracket.

[Link] Belt should be tensioned (refer to Figure 5) and tested utilizing Gates Sonic
Tension Meter to ranges shown (refer to Figure 6). Securely tighten attachment
hardware when proper tension is achieved. Follow the procedure outlined below.

[Link].1 Verify all the compressor mounting hardware is slightly tight and belt is
properly aligned.
CAUTION: DO NOT OVER TENSION BELT. IMPROPER BELT TRACKING AND BELT / MOTOR DAMAGE
MAY RESULT.

[Link].2 Adjust the rod end adjustment bolt to increase belt tension and tighten upper
compressor mounting bolt

[Link].3 Gates Sonic Tension meter method: (Preferred method)

 Input the following information into the Meter:
 Weight: 3.2 g/m/mm
 Width: 25 mm
 Span: 147 mm

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Component Maintenance Manual

[Link].4 In A Quiet/Non Windy Environment – Cord Sensor

[Link].5 Push the measure button on the meter, hold the cord sensor approximately 1
cm (0.4 in) above the belt at the midway point between the pulleys.
 Lightly strum the belt with finger to induce a vibration.
 Record the results in Hz or Newton’s
 Repeat 3 times (or more if necessary) to verify consistent readings

[Link].6 In A Noise Filled Environment – Inductive Sensor

CAUTION: REMOVE THE TAPE AND MAGNET FROM BELT BEFORE PROCEEDING.

[Link].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

[Link] Rotate compressor by hand through several revolutions and verify belt tracking.
Readjust as required.

[Link] Secure drive pulley by tightening drive pulley set screws (refer to table 1, section
1.3 for torque specifications).

[Link] Tighten and secure compressor mounting bolts and washers (refer to table 1,
section 1.3 for torque specifications).

9.2.9 Assembly of Belt Cover

[Link] Position belt cover on assembly and attach with motor mounting bolts and washers
and belt cover attaching screws (refer to table 1, section 1.3 for torque
specifications).

9.2.10 Assembly of Power Relay

[Link] Carefully slide power relay into position and attach using mounting hardware.

[Link] Connect electrical connections and install boots for protection.

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Component Maintenance Manual

Figure 5 Belt Tensioning Reference

Tensioning Information: (Sonic Tension Meter 507C, [Link])

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

SUBTASK 21-00-05-40-002

9.3 Forward / Aft Evaporator Module assembly procedures:

CAUTION: USE EXTREME CARE TO PREVENT DAMAGE OR BENDING OF BLOWER MOTOR WHEEL.

9.3.1 Assembly of Blower Motor/ Wheel

[Link] Position blower wheel on blower motor shaft. Ensure that there is a gap of 0.25”
between motor and back of blower wheel.

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Component Maintenance Manual

CAUTION: APPLY THREAD SEALANT SPARINGLY TO MALE FITTING THREADS STAYING CLEAR OF
FIRST 2-3 THREADS.

[Link] Apply a drop of thread sealant to the set screw threads. Tighten set screw (refer
to table 1, Section 1 for torque specifications), insuring that the screw is located on
flat part of motor shaft.

[Link] Sparingly apply a thin bead of RTV to blower motor mounting plate.

[Link] Carefully install blower motor/wheel into blower motor scroll and attach with blower
motor attachment screws and flat washers. Refer to table 1, Section 1 for torque
specifications.

[Link] Connect blower motor to electrical power and perform a functional test (Section 3).
Wire hookup is as follows:

Black Ground
Orange +28 VDC, Hi Speed
Red +28 VDC, Low Speed
Table 5 Blower Motor Electrical Connections

9.3.2 Assembly of Expansion Valve

[Link] Using a wire brush and cleaning solvent, completely remove old thread sealant.
Apply a thin layer of thread sealant primer to fitting threads.
CAUTION: APPLY THREAD SEALANT SPARINGLY TO MALE FITTING THREADS STAYING CLEAR OF
FIRST 2-3 THREADS.

[Link] 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.

[Link] Apply thin film of refrigerant oil to expansion valve flare surface and a very small
amount to the O-rings to prevent damage.

[Link] Connect expansion valve to coil header fitting. Refer to table 1, Section 1 for
torque specifications.

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Component Maintenance Manual

SPECIAL TOOLS, FIXTURES, AND EQUIPMENT

TASK 21-00-05-99F-803

10.0 SPECIAL TOOLS/EQUIPMENT

SUBTASK 21-00-05-99F-014

10.1 General:

10.1.1 This section describes the necessary tools and test equipment required to perform
maintenance, functional testing, troubleshooting, and repair procedures. Equivalent test
equipment may be substituted only if it meets the listed equipment specifications.
 Regulated Shop Air 40 PSIG
 Fin comb SK1250101-13
 Miscellaneous hand tools and socket set
 Shop vacuum with soft utility brush
 Gates Sonic Tension Meter
 Vacuum pump, air or electric 0-30 [Link].
 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.
 Hose adapter 1/2 in. male ACME to 1/4 in. female flare
 Leak check fluid soap solution
 External or aircraft power source 200 amps.
 Inspection mirror
 Thermometer 0-150°F
 Flashlight or service lamp
 Kent-More Flush Adapter J42939

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Component Maintenance Manual

ILLUSTRATED PARTS LIST

TASK 21-00-05-98-801

11.0 R-134a AIR CONDITIONING SYSTEM COMPONENT

SUBTASK 21-00-05-99F-015

11.1 Introduction:

11.1.1 This Illustrated Parts Listing (IPL) is intended for use during testing and isolation,
disassembly, cleaning, check (inspection), repair, assembly, and issuing the replaceable
equipment components as well as in identification of new and reclaimed parts for the
Compressor Condenser Module Assembly (P/N 1134400-17 or 1134000-31), Forward
Evaporator Module Assembly (PN 1134820-13), and Aft Evaporator Module Assembly (PN
1134820-14).

11.1.2 This IPL includes illustrations of the Compressor Condenser Module Assembly, Forward
Evaporator Module Assembly, and Aft Evaporator Module Assembly to be used during the
procedures outlined previously.

11.1.3 This IPL includes figure and item numbers to call out specific components. Each component
will be assigned an item number. Items listed but not shown are identified by a dash
preceding the item number. The figure refers to the exploded view of the equipment.

11.1.4 This IPL includes part numbers for each component called out in the illustration that is a field
replaceable component.

11.1.5 This IPL includes nomenclature for each component that helps with identification.

11.1.6 This IPL includes units per assembly for each component called out in the illustration that is a
field replaceable component.

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Figure 10001
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Component Maintenance Manual

Figure 10001 Compressor Condenser Module Assembly 1134400-17

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Figure 10001
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Component Maintenance Manual

FIG. ITEM PART NUMBER NOMENCLATURE UNITS ASSY.

10001-10 1134104-1 DRIVE MOTOR ASSEMBLY N/P
REPLACEMENT MOTOR ASSEMBLY (SEE SB
1134104-5 1
11-101)
10A 1250128 POWER RELAY 1
11A ¼-28X1H BOLT 1
12A 21FK-428 LOCK NUT 2
13A AN960-416 FLAT WASHER 2
14A AN345-416 PLAIN NUT 1
15A MS35333-40 LOCK WASHER 1
16A ¼-28X1/2H BOLT 1
17A MS25171-3 LARGE BOOT 1
18A MS25171-1 SMALL BOOT 2
19A 1250253 DIODE ASSEMBLY 1
-11 5/16-24x3/4 H BOLT 8
-12 MS35333-41 FLAT WASHER 8
20 1250146-7 MOTOR PULLEY 1
30 1134170 CONDENSER FAN 1`
-31 AN960-616 FLAT WASHER 1
-32 21FK-624 LOCK NUT 1
40 1134160 COMPRESSOR ASSEMBLY 1
-41 M10-1.2525MM HEX BOLT 3
-42 10MM LOCK WASHER 3
50 1134182-3 RECEIVER DRYER 1
60 1250232-4 BINARY PRESSURE SWITCH 1
70 QS100M36H RECEIVER DRYER CLAMP 1
80 1134199-1 BELT COVER 1
-81 MS35265-28 SCREW 4
-82 AN960-6 FLAT WASHER 4
90 232L100 DRIVE BELT 1
100 1134125-1 SUCTION MANIFOLD ASSEMBLY 1
-101 AS568A-015 O-RING 1
110 1134109-3 FAN SHROUD 1
-111 AN960-10L FLAT WASHER 8
-112 409-1032Z LOCK NUT 8
-113 10-32X3/8 IHW SCREW 8
120 CONDENSER COIL N/P
Figure 10001 Compressor Condenser Module Assembly Details
- ITEMS NOT ILLUSTRATED
N/P ITEMS NOT PROCURABLE
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Figure 10001
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Component Maintenance Manual

130 1134132-1 CONDENSER BRACKET 1

-131 MS35265-28 SCREW 10
-132 AN960-6 FLAT WASHER 10
140 1134111-3 OUTLET SHROUD 1
-150 1251171 MOTOR BRUSH/SHUNT (contains 4 brush pairs) 1
Figure 10001 Cont. Compressor Condenser Module Assembly Details

- ITEMS NOT ILLUSTRATED

N/P ITEMS NOT PROCURABLE

EFFECTIVITY: ALL
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Figure 10001
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Component Maintenance Manual

Figure 10002 Compressor Condenser Module Assembly 1134400-31

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Figure 10002
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Component Maintenance Manual

UNITS
FIG. ITEM PART NUMBER NOMENCLATURE
ASSY.
10002-10 1134104-1 DRIVE MOTOR ASSEMBLY N/P
REPLACEMENT MOTOR ASSEMBLY
1134104-5 1
(SEE SB 11-101)
10A 1250128 POWER RELAY 1
11A ¼-28X1H BOLT 1
12A 21FK-428 LOCK NUT 2
13A AN960-416 FLAT WASHER 2
14A AN345-416 PLAIN NUT 1
15A MS35333-40 LOCK WASHER 1
16A ¼-28X1/2H BOLT 1
17A MS25171-3 LARGE BOOT 1
18A MS25171-1 SMALL BOOT 2
19A 1250253 DIODE ASSEMBLY 1
-11 MS35756-6 *WOODRUFF KEY (# 3 1/8X1/2) 1
-12 5/16-24X3/4H *BOLT 8
-13 MS35333-41 *FLAT WASHER 8
20 1250146-7 MOTOR PULLEY 1
-21 ¼-28X5/16B *SET SCREW 2
30 1134170 CONDENSER FAN 1
-31 21FK-624 *LOCK NUT 1
-32 AN960-616 *FLAT WASHER 1
40 1134160 COMPRESSOR ASSEMBLY (R134a) 1
-41 M10x1.2525MM *HEX BOLT 3
-42 10MM *LOCK WASHER 3
50 1134182-5 RECEIVER DRYER 1
60 1250232-12 BINARY PRESSURE SWITCH 1
70 QS100M36H RECEIVER DRYER CLAMP 2
80 1134199-1 BELT COVER 1
-81 MS35265-28 *SCREW 4
-82 AN960-6 *FLAT WASHER 4
-83 5/16-24x3/4H *HEX BOLT 2
-84 AN960-516 *FLAT WASHER 2
90 232L100 DRIVE BELT 1
100 1134125-1 MANIFOLD ASSEMBLY (SUCTION) 1
-101 AS568A-015 *O-RING 1
Figure 10002 Compressor Condenser Module Assembly Details
- ITEMS NOT ILLUSTRATED
N/P ITEMS NOT PROCURABLE

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Component Maintenance Manual

110 1134109-3 FAN SHROUD 1

120 1134111-3 OUTLET SHROUD 1
-121 AN960-10L *FLAT WASHER 8
-122 409-1032Z *LOCK NUT 8
-123 10-32X3/8IHW SCREW 8
130 1134132-1 CONDENSER BRACKET 1
-131 MS35265-28 *FIL HD. SCREW 10
-132 AN960-6 FLAT WASHER 10
MOTOR BRUSH/SHUNT (contains 4
-140 1251171 1
brush pairs)
Figure 10002 Cont. Compressor Condenser Module Assembly Details

- ITEMS NOT ILLUSTRATED

N/P ITEMS NOT PROCURABLE

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Figure 10002
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Component Maintenance Manual

Figure 10003 Forward Evaporator Module Assembly 1134820-13

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Figure 10003
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Component Maintenance Manual

10003-10 1133210-23 BRUSHLESS DC MOTOR ASSEMBLY 1

20 1250219-6 BLOWER WHEEL CW 1
30 BLOWER SCROLL ASSEMBLY N/P
40 1134218 EXPANSION VALVE 1
50 EVAPORATOR SHROUD ASSEMBLY N/P
-60 WATER DEFLECTOR N/P
70 ESCUTCHEON N/P
-80 EVAPORATOR COIL ASSEMBLY N/P
90 NAMEPLATE N/P
100 8-32 HEX SCREW (replacement P/N 8-32X5/8HS) 8
110 AN960-8 FLAT WASHER 8

Figure 10003 Forward Evaporator Module Assembly Details

- ITEMS NOT ILLUSTRATED

N/P ITEMS NOT PROCURABLE

EFFECTIVITY: ALL
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Figure 10003
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Component Maintenance Manual

Figure 10004 Aft Evaporator Module Assembly 1134820-14

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Component Maintenance Manual

UNITS
FIG. ITEM PART NUMBER NOMENCLATURE
ASSY.

10004-10 1133210-7 BRUSHLESS DC MOTOR ASSEMBLY 1

20 1250219-6 BLOWER WHEEL CW 1
30 BLOWER SCROLL ASSEMBLY N/P
40 1134218 EXPANSION VALVE 1
50 EVAPORATOR SHROUD ASSEMBLY N/P
-60 WATER DEFLECTOR N/P
70 ESCUTCHEON N/P
80 EVAPORATOR COIL ASSEMBLY N/P
-90 NAMEPLATE N/P
100 8-32 HEX SCREW (replacement P/N 8-32X5/8HS) 8
110 AN960-8 FLAT WASHER 8
120 CLN3-16 CLAMP (CLN3/16) 1

Figure 10004 Aft Evaporator Module Assembly Details

- ITEMS NOT ILLUSTRATED

N/P ITEMS NOT PROCURABLE

EFFECTIVITY: ALL
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Component Maintenance Manual

SPECIAL PROCEDURES

TASK 21-00-05-82-801

12.0 SPECIAL PRODECURES

SUBTASK 21-00-05-82-001

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.

12.1.2 Verify that system leak check and refrigerant charging has been performed and system is
operating at typical values as outlined in table 2.

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 6 Typical Operating Values

12.1.3 Gain access to the Evaporators (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 6.

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.

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Component Maintenance Manual

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 3, 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 3 the expansion valve must be
turned CW in accordance with the same procedure discussed in previous paragraph. 11.2.10.

12.1.13 Allow system to operate for 5-10 minutes after expansion valve adjustment to verify setting.

SUBTASK 21-00-05-82-002

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 2.

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 21-00-05-82-003

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Component Maintenance Manual

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, Forward Evaporator Module, or Aft
Evaporator Module (refer to the aircraft maintenance manual for removal of access panels
and other hardware that might need to be removed)

12.3.3 Verify that power is removed from aircraft. If it is not practical to remove aircraft power,
technician must pull and collar applicable circuit breakers.

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.

SUBTASK 21-00-05-20-001

12.4 Motor Bearing Inspection:

12.4.1 Motor bearing will be inspected according to Section 7 Inspection Schedule Table 3.5 to
ensure that premature seizure does not occur.

12.4.2 Gain access to the Compressor Condenser Module, Forward Evaporator Module, or Aft
Evaporator Module (refer to the aircraft maintenance manual for removal of access panels
and other hardware that might need to be removed)

12.4.3 Verify that power is removed from aircraft. If it is not practical to remove aircraft power,
technician must pull and collar applicable circuit breakers.

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 6).

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).

21-00-05-82-004

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12.5 Motor Brush Seating Procedure:

12.5.1 Cut 4” long by 1.5 “ wide strip of 400-500 grit paper and place, with rough side out, on motor
commutator. Secure one end of the paper to the commutator with masking tape in a manner
such that the taped end will lead in the direction of shaft rotation (CCW looking at fan end).
The other end will remain loose and overlap the taped end. Raise each brush momentarily
while rotating the shaft until the taped end passes under each brush. After the grit paper is
properly located tight against the commutator and encompasses all brush surface area,
carefully rotate the armature by hand in the normal direction of rotation until a full seat is
obtained on each new brush. Three to four rotations is generally adequate.
CAUTION: EXCESSIVE SEATING IS NOT ADVISED OR BRUSH LIFE MAY BE REDUCED.

12.5.2 Remove grit paper and blow out all the carbon dust and other contamination from commutator
and brush area.

SUBTASK 21-00-05-20-002

12.6 Compressor Oil Level Check:

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 (3 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.

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Component Maintenance Manual

SERVICING

TASK 21-00-05-60-801

13.0 R-134a AIR CONDITIONING SYSTEM SERVICING PROCEDURES

SUBTASK 21-00-05-99F-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: SERVICE TECHNICIANS ARE ADVISED TO OBSERVE STANDARD SAFETY
PRECAUTIONS, SUCH AS WEARING PERSONAL SAFETY GEAR, TO PREVENT INJURY WHILE
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.
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.

SUBTASK 21-00-05-60-001

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.

13.2.1 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)

13.2.2 Verify that power is removed from aircraft. If it is not practical to remove aircraft power,
technician must pull and collar applicable circuit breakers.

13.2.3 If required perform leak check procedure.

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13.2.4 Connect certified reclaim charging and recycle cart manifolds to system service ports.

13.2.5 Open both valves and reclaim and recycle the systems refrigerant charge (refer to the reclaim
equipment manufacturer’s instruction manual for recovery unit handling and operation).Once
the refrigerant is reclaimed and recycled apply vacuum on the system for approximately 30
minutes. System vacuum should attain 25-27 in. hg. in 10 to 15 minutes. Allow pump to hold
a vacuum (29 to 30 in. hg.) for 15 minutes
CAUTION: ANY CHANGE IN VACUUM PRESSURE OR FAILURE TO ACHIEVE A SYSTEM PRESSURE
OF 29 INCHES HG VACUUM INDICATES THE PRESENCE OF A PLUMBING LEAK. REPEAT LEAK
CHECK PROCEDURE AND LOCATE AND FIX ALL LEAKS.
CAUTION: EXCESSIVE WATER AND/OR AIR IN THE SYSTEM WILL CAUSE PRESSURE TO RISE AND
EXPANSION VALVE TO FREEZE UP.

13.2.6 System in now ready for refrigerant charging.

SUBTASK 21-00-05-60-002

13.3 Charging the system (R-134a):

WARNING: SYSTEM DAMAGE CAN OCCUR FROM OVERCHARGING OR UNDERCHARGING THE
SYSTEM TO THE SPECIFIED AMOUNT OF REFRIGERANT.

13.3.1 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)

13.3.2 Verify that power is removed from aircraft. If it is not practical to remove aircraft power,
technician must pull and collar applicable circuit breakers.

13.3.3 Charging the system with refrigerant is required on a new system installation or when “topped
off”, the proper method is to recover the existing charge and charge with the appropriate
mass of refrigerant. Refer to the reclaim/recycle equipment manufacturer’s instruction
manual for recovery unit handling and operation. Refrigerant charges for the system are as
follows in Table 4.

Aircraft Model Refrigerant Charge (lbs.)

Cessna 525 3.0 + - 0.1

Table 7 Refrigerant Charge

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SUBTASK 21-00-05-60-003

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 WELLVENTILATED
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. General Motors
service bulletin 83-12-21 should be referenced for flushing R-134a systems.
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.

13.4.3 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)

13.4.4 Verify that power is removed from aircraft. If it is not practical to remove aircraft power,
technician must pull and collar applicable circuit breakers.

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.

13.4.7 Remove the receiver dryer and install a jumper hose between the open ports.

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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 13.3)

13.4.17 Verify system performance (refer to Test and Fault Isolation, Section 3.1)

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STORAGE

TASK 21-00-05-55-801

14.0 COMPRESSOR CONDENSER MODULE ASSEMBLY STORAGE PROCEDURES

SUBTASK 21-00-05-99F-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 21-00-05-55-001

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.
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 The following procedures should be performed at 12 months from MFG date on unit and
every 6 months thereafter for a maximum of 36 months.

SUBTASK 21-00-05-55-001

14.3 Internal Pressures:

14.3.1 For internal pressures within a range of 5-15 PSIG, rotate compressor by hand through a
minimum of 10 revolutions.

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14.3.2 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.

14.3.3 If the system does not have any detectable pressure, the compressor oil must be checked for
contamination.

[Link] 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.

[Link] 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.

[Link] Measure an equal amount of new oil and add to compressor. Install oil plug and
tighten.

[Link] Check system pressure per section 14.2.2. System is now ready for storage.

21-00-04-55-003

14.4 System Off Season Functional Tests:

NOTE: If ambient temperature is below 50° F (10°C), the pressure switch is designed to keep the system
from operating and causing possible damage if operated for extended periods of time. In this case, it is
recommended that the aircraft be heated above this threshold to enable the system to operate.
CAUTION: OPERATION OF THE SYSTEM AT LOW AMBIENT TEMPERATURES FOR MORE THAN 15
MINUTES CAN RESULT IN MAJOR DAMAGE OF THE R-134A COMPRESSOR.

14.4.1 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.

14.4.2 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.

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