R-134a AIR COND SYSTEM

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
http://www.enviro-ok.com
OPERATING, SERVICING, AND COMPONENT
MAINTENANCE MANUAL
WITH ILLUSTRATED PARTS LIST
HAWKER BEECHCRAFT 400A
R-134a AIR CONDITIONING SYSTEM COMPONENTS:
1) COMPRESSOR CONDENSER MODULE ASSEMBLY, PART # 1134400-1
2) EVAPORATOR MODULE ASSEMBLY, PART # 1134310-5
3) AUTO LOAD SHED MODULE, PART # 1240100

HAWKER BEECHCRAFT PART # 132-384028-1
ATA SPECIFICATION 21-00-12
COPYRIGHT  2007 ORIGINAL ISSUE

21-00-12
AUGUST 16/ 2007
ENVIRO SYSTEM INC. July 15, 2014
Component Maintenance Manual
RECORD OF REVISIONS
REV DESCRIPTION OF CHANGE DATE APPROVAL

ORIGINAL RELEASE 8/16/07 BH
1 Corrected Hawker Beechcraft part # for the Auto Load Shed 10/1/07 BH
Module on title page. Was “134-“. Is “132-“.
2 Added in procedures on removing and installing Power Relay 10/25/07 BH
and inserted new IPL calling out Power Relay.
3 Figure 1….Changed figure to reflect correct measurements. 1/16/08 BH
Was….new length 0.875, min length 0.44 in
Is…..new length 1.00 in, min length 0.45
4 Added references to “thread sealant primer Loctite 7471” 3/12/08 BH
throughout the manual.
5 Updated Storage, Section 14. Updated information concerning 5/5/08 BH
cold weather operations under General and System Off
Season/On Aircraft Functional Testing.
6 IPL Figure10001 add item 45A, 55A, O-rings 5/12/09 BH
7 IPL Figure10001 item 130 change qty from 4 to 1 03/10/10 BH
8 IPL Change all AN960 washer# to equivalent Nas # 07/12/11 BH
Service Bulletins Add SB11-105 .Delete Sec. 3.4 and Figure1
Brush replacement wear details Renumber subsequent
Figures. Add new Figure 3 and new Figure 4.5. Section
8.2.1.2: change verbiages to reflect replacement of brushes and
refer to commutator wear condition examples. Table 2 add
RL100E to consumables as alternative. Change and Label
Table 3.5 and 3.6. Remove IPL item numbers from Sections 2
thru 10. IPL Figure 10001-10 Changed motor P/N was P/N
1134104-1 is P/N 1134104-5.
9 Section 12.4.1 was Motor bearing will be inspected every 800- 08/16/11 BH
1000 operational hours. Is Motor bearing will be inspected
according to Section 7 Inspection Schedule Table 3.5.Sec
12.5.1 was Compressor Bearing will be inspected every 1000-
1500 operational hours IS Compressor bearing will be inspected
according to Section 7 Inspection Schedule Table 3.5
10 Table 3.5 Motor overhaul was incorrectly changed to 500 hours 02/09/12 BH
in previous revision 8, correct to 2500-3000 hours
11 Table 3.5 Clarify Motor Brush Replacement 03/15/12 BH
12 -Figure 10001 Updated table Item 50A page 10003 to include 07/15/2014 BS
1134140-7 replacement receiver dryer for 1134140-1
-Removed references to check manual revision against Enviro
website due to redesigned website
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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
11-105 Add Motor Temp Switch 07/05/11
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LIST OF EFFECTIVE PAGES
CHAPTER / SECTION PAGE DATE CHAPTER / SECTION PAGE DATE

All All 10/25/07
All All 3/12/08
All All 5/5/08
All All 5/12/09
All All 03/10/10
All All 07/12/11
All All 08/16/11
All All 02/09/12
All All 7/15/14
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TABLE OF CONTENTS
RECORD OF REVISIONS ................................................................................................................................... 1

RECORD OF TEMPORARY REVISIONS ........................................................................................................... 2
LIST OF SERVICE BULLETINS ......................................................................................................................... 3
LIST OF EFFECTIVE PAGES ............................................................................................................................. 4
TABLE OF CONTENTS ...................................................................................................................................... 5
LIST OF ILLUSTRATIONS ................................................................................................................................. 7
LIST OF TABLES ................................................................................................................................................ 7
INTRODUCTION.................................................................................................................................................. 8
1.0 MANUAL INTRODUCTION .................................................................................................................... 8
1.1 General introduction (How to Use): .................................................................................................... 8
1.2 Acronyms, Abbreviations, and Symbols:........................................................................................... 9
1.3 Standard Torque Values: ................................................................................................................... 10
1.4 Documents required: .......................................................................................................................... 10
1.5 Consumable Products:....................................................................................................................... 10
DESCRIPTION AND OPERATION ................................................................................................................... 11
2.0 R-134A AIR CONDITIONING SYSTEM DESCRIPTION AND OPERATION ...................................... 11
2.1 General:................................................................................................................................................ 11
2.2 System Description and Operation: .................................................................................................. 12
2.3 System Component Description and Operation:............................................................................. 13
TESTING AND FAULT ISOLATION ............................................................................................................. 1001
3.0 R-134A AIR CONDITIONING SYSTEM COMPONENT – TESTING AND FAULT ISOLATION .... 1001
3.1 General:............................................................................................................................................ 1001
3.2 Compressor Condenser Module Assembly Testing Procedures .............................................. 1001
3.3 Evaporator Module Assembly Testing Procedures .................................................................... 1001
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 SCHEMATIC AND WIRING DIAGRAMS ........................ 2001
4.1 R-134A Refrigerant Flow Schematic: ............................................................................................ 2001
4.2 R-134A System Electrical Schematic: .......................................................................................... 2002
DISASSEMBLY ............................................................................................................................................. 3001
5.0 R-134A AIR CONDITIONING SYSTEM COMPONENT - DISASSEMBLY ..................................... 3001
5.1 General:............................................................................................................................................ 3001
5.2 Compressor Condenser Module Disassembly Procedures ....................................................... 3002
5.3 Evaporator Module Assembly Disassembly Procedures ........................................................... 3006
5.4 Auto Load Shed Device Disassembly Procedures ...................................................................... 3006
CLEANING .................................................................................................................................................... 4001
6.0 R-134A AIR CONDITIONING SYSTEM COMPONENT – CLEANING PROCEDURES ................. 4001
6.1 General:............................................................................................................................................ 4001
6.2 Compressor Condenser Module Cleaning Procedures: ............................................................. 4002
6.3 Evaporator Module Assembly Cleaning Procedures: ................................................................. 4002
CHECK (INSPECTION SCHEDULE) ............................................................................................................ 5001
7.0 R-134A AIR CONDITIOING SYSTEM COMPONENT – INSPECTION SCHEDULE ...................... 5001
7.1 Compressor Condenser Module Assembly Inspection Schedule: ............................................ 5001
7.2 Evaporator Module Assembly Inspection Schedule: .................................................................. 5005
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REPAIRS ....................................................................................................................................................... 6001

8.0 R-134A AIR CONDITIONING SYSTEM COMPONENT – REPAIR PROCEDURES ...................... 6001
8.1 General:............................................................................................................................................ 6001
8.2 Compressor Condenser Module Repair Procedures: ................................................................. 6001
8.3 Evaporator Module Assembly Repair Procedures: ..................................................................... 6003
8.4 Auto Load Shed Device Repair Procedures: ............................................................................... 6005
ASSEMBLY ................................................................................................................................................... 7001
9.0 R-134A AIR CONDITIONING SYSTEM COMPONENT - ASSEMBLY ........................................... 7001
9.1 General:............................................................................................................................................ 7001
9.2 Compressor Condenser Module Assembly Procedures ............................................................ 7002
9.3 Evaporator Module Assembly Procedures .................................................................................. 7007
9.4 Auto Load Shed Device Assembly Procedures ........................................................................... 7008
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 ILLUSTRATED PARTS LISTING.......... 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 Compressor Bearing Inspection: ................................................................................................ 11004
12.6 Motor Brush Seating Procedure: ................................................................................................ 11004
12.7 Compressor Oil Level Check: ...................................................................................................... 11002
SERVICING ................................................................................................................................................. 14001
13.0 R-134A AIR CONDITIONING SYSTEM SERVICING PROCEDURES ......................................... 14001
13.1 General:.......................................................................................................................................... 14001
13.2 Evacuating The System (R-134A): .............................................................................................. 14002
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 System Off Season Functional Tests: ........................................................................................ 15002
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LIST OF ILLUSTRATIONS
Figure 1 R-134A Refrigerant Flow Schematic ........................................................................................... 2001

Figure 2 Electrical Schematic ..................................................................................................................... 2002
Figure 3 1134400-1 Compressor Condenser Schematic ......................................................................... 2002
Figure 4 Brush Removal Details ................................................................................................................. 3005
Figure 4.3: Commutator Excellent Condition Example ........................................................................... 5002
Figure 4.4: Commutator Serviceable Condition Example ...................................................................... 5003
Figure 4.5: Commutator Unserviceable Condition Example .................................................................. 5004
Figure 5 Belt Tensioning Reference........................................................................................................... 7006
Figure 10001 Compressor Condenser Module Assembly 1134400-1 ................................................... 10002
Figure 10001 Compressor Condenser Module Assembly Details ........................................................ 10003
Figure 10002 Evaporator Module Assembly 1134310-5 ......................................................................... 10004
Figure 10002 Evaporator Module Assembly Details .............................................................................. 10005
LIST OF TABLES
Table 1 Standard Torque Values .................................................................................................................... 10

Table 2 Consumable Products ....................................................................................................................... 10
Table 3 Trouble Shooting List .................................................................................................................... 1005
Table 3.5 Compressor Condenser Module inspection schedule ............................................................ 5001
Table 3.6 Forward and Aft Evaporator Module inspection schedule ..................................................... 5005
Table 4 Gates Sonic Tension Meter Data .................................................................................................. 7006
Table 5 Blower Motor Electrical Connections........................................................................................... 7008
Table 6 Typical Operating Values............................................................................................................. 11001
Table 7 Refrigerant Charge ....................................................................................................................... 14003
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INTRODUCTION
TASK 21-00-12-99F-801
1.0 MANUAL INTRODUCTION
SUBTASK 21-00-12-99F-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 Hawker
Beechcraft 400A Aircraft. This document includes component descriptions, servicing,
maintenance, inspection requirements and an illustrated parts list.
1.1.2 This component maintenance manual has been prepared with guidance from the Air
Transport Association of America (ATA) Specification 2200. The user must not change the
repair methods in this manual without authorization from the aviation authorities and the
manufacturer.
1.1.3 This manual gives the procedures to perform the servicing and maintenance of the
component in a workshop environment as well as on the aircraft. Only approved personnel
with the necessary skills shall perform the maintenance procedures in this manual.
Although Enviro Systems tries to cover all conceivable issues that may arise, there may be
issues that are not covered in this manual. In these cases, please call Enviro Systems
customer service.
1.1.4 This manual uses the Maintenance Task Oriented Support System (MTOSS) to organize
the maintenance information. It is divided into maintenance tasks and subtasks, graphics
and tables. Each task consists of one or more subtasks. Each subtask contains procedural
steps and can contain one or more graphics or tables. The maintenance tasks and other
data have special MTOSS numbers that are used for Electronic Data Processing (EDP).
1.1.5 You must use the instructions in this manual to do all the maintenance procedures related to
the component. Read all the related warnings, cautions and notes before you begin work
on the components. Warnings, cautions and notes shown in this manual provide the
following information:
1.1.5.1 WARNING: Discloses vital information in order to prevent injury or death while
performing the maintenance procedure.
1.1.5.2 CAUTION: Discloses vital information in order to prevent damage to the equipment
during the maintenance procedure.
1.1.5.3 NOTE: Discloses more information that will help perform a step of the procedure or
refers to a different procedure.
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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.
SUBTASK 21-00-12-99F-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 21-00-12-99F-003
1.3 Standard Torque Values:
TYPE FASTENER DESCRIPTION/LOCATION TORQUE
.25-28 SET SCREW ALL LOCATIONS 40-50 IN-LBS
6-32 SCREW ALL LOCATIONS 8-10 IN-LBS
¼-28-UNF ALL LOCATIONS 50-70 IN-LBS
5/16-24UNF ALL LOCATIONS 100-140 IN-LBS
3/8-24UNF ALL LOCATIONS 160-190 IN-LBS
5/8-18 PLUMBING RECEIVER DRYER DISCHARGE PORT 180-220 IN-LBS
CONNECTIONS
7/8-14 PLUMBING COMPRESSOR SUCTION PORT 360-430 IN-LBS
CONNECTIONS
Table 1 Standard Torque Values
SUBTASK 21-00-12-99F-004
1.4 Documents required:
 Illustrated Parts Listings (IPL) (included with this manual)
SUBTASK 21-00-12-99F-005
1.5 Consumable Products:
PART NUMBER DESCRIPTION REMARKS
11602 SEALANT RTV BLACK
7471 THREAD SEALANT PRIMER LOCTITE
569 THREAD SEALANT LOCTITE
RL100H or RL100E REFRIGERANT OIL EMKARATE
Table 2 Consumable Products
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DESCRIPTION AND OPERATION
TASK 21-00-12-99F-802
2.0 R-134A AIR CONDITIONING SYSTEM DESCRIPTION AND OPERATION
SUBTASK 21-00-12-99F-006
2.1 General:
2.1.1 The air conditioning system installed on the Hawker Beechcraft 400A Aircraft is not
considered a primary flight system. However, an air conditioning system does perform the
important function of providing passenger and flight crew comfort during aircraft movement
on the ground and while in flight. Aircraft air conditioning systems not only provide effective
passenger cooling, but must also maintain a high level of reliability to minimize aircraft
downtime due to unscheduled repairs.
2.1.2 In order to ensure component reliability and achieve a long service life for which the system
is designed, periodic inspection and preventive maintenance must be performed. Failure to
complete periodic inspections, service, or maintenance schedules may reduce product life
and potentially void manufacturer’s warranty.
2.1.3 Inspections, servicing, and/or maintenance schedules are presented in the following
sections. This will ensure component and/or system reliability and performance are
maintained when performed at the specified intervals.
WARNING: SERVICE TECHNICIANS ARE ADVISED TO OBSERVE STANDARD SAFETY
PRECAUTIONS, SUCH AS WEARING PERSONAL SAFETY GEAR, TO PREVENT INJURY WHILE
PERFORMING SERVICE TO THE UNIT. LIQUID REFRIGERANT CAN CAUSE FROSTBITE AND/OR
BLINDNESS.
WARNING: PROPER VENTILATION IS REQUIRED. KEEP REFRIGERANTS AND OILS AWAY FROM
OPEN FLAMES. REFRIGERANTS CAN PRODUCE POISONOUS GASSES IN THE PRESENCE OF A
FLAME. WORK IN A WELL VENTILATED AREA AND AVOID BREATHING REFRIGERANT /LUBRICANT
VAPOR MIST IF ACCIDENTAL DISCHARGE OCCURS.
WARNING: AVOID USE OF COMPRESSED AIR. DO NOT INTRODUCE COMPRESSED AIR OR
OXYGEN INTO AN AIR CONDITIONING SYSTEM OR REFRIGERANT CONTAINER. R-134A IN THE
PRESENCE OF AIR OR OXYGEN ABOVE ATMOSPHERIC PRESSURE MAY FORM A COMBUSTIBLE
MIXTURE.
2.1.4 Do not discharge R-134A refrigerant into the atmosphere. Although its ozone depletion
potential is zero, it can have an effect on global warming. In the United States recovery and
recycling are mandated by the Clean Air Act.
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2.1.5 Refrigerant recovery/recycling service equipment must be approved for use with R-134A
refrigerant. Recycling machines must be approved by Underwriters Laboratories (UL) and
meet SAE standard J2210 and SAE standard J2099 for refrigerant purity.
SUBTASK 21-00-12-99F-007
2.2 System Description and Operation:
2.2.1 The cabin cooling system installed in the Hawker Beechcraft 400A Aircraft operates using a
closed vapor cycle concept using refrigerant R-134A as the heat absorption media. The R-
134A air conditioning system cools the aircraft in a similar manner as systems found in an
automobile or home. However, aircraft air conditioning systems contain components which
are designed to be light weight, compact, provide high performance, and provide the ability
to operate at extreme altitudes and ambient temperatures.
2.2.2 The concept of air conditioning a room, cabin or cockpit is straight forward. Examples of a
system are shown in Figures 2 and 3 (refer to Schematic and Wiring Diagrams, Section 4).
Refrigerant is the media which absorbs and rejects the room or cabin heat. By continuous
recirculation of the warm cabin air, heat is absorbed in the evaporator module(s) and is
rejected to the outside through the system condenser. When the system is turned on, the
electric motor drives the R-134A compressor at a constant speed and capacity which
compresses the R-134A refrigerant gas to a high pressure. The hot, high pressure gas then
passes through the condenser coil where it is cooled and condensed into a warm liquid at
constant pressure. The warm liquid is then routed into a receiver-dryer container where the
liquid and any remaining gas are separated and any moisture is absorbed. The warm, dry
liquid is then directed to the evaporator module expansion valve where the high pressure
liquid is expanded to a low pressure. The expansion process creates a super cool gas
which passes through the evaporator coil and absorbs heat from the warm cabin air passing
over the coils. The warm low pressure refrigerant then enters the R-134A compressor
where the process starts all over again. In addition to cooling the cabin air, a refrigerant
type system also removes a large percentage of the moisture in the air as well as removing
dust and pollen particles in the air. Thus, the system conditions the air as well as cooling it.
As a safety feature, the unit is also equipped with a binary pressure switch. This switch
prevents the unit from operating if the discharge pressure becomes excessively high. The
switch also prevents the unit from operating if the internal pressure is very low due to
leakage or low ambient temperatures.
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SUBTASK 21-00-12-99F-008
2.3 System Component Description and Operation:
2.3.1 The R-134A air conditioning system installed on the Hawker Beechcraft 400A Aircraft uses
the Compressor Condenser Module Assembly (PN 1134400-1), Evaporator Module
Assembly (PN 1134310-5, 2 ea.), and an Auto Load Shed Module (PN 1240100).
2.3.2 The COMPRESSOR CONDENSER MODULE ASSEMBLY (PN 1134400-1) has a rated
cooling capacity of 16,500 BTUH when operating with the other components in the Hawker
Beechcraft 400A Aircraft at an ambient temperature of 95°F OAT. Under this condition, the
nominal current draw is 100 AMPS at 28 VDC.
2.3.3 The Compressor Condenser Module Assembly is packaged to meet the aircraft installation
requirements and contains the following major components (refer to Figure 10001):
 Compressor Drive Motor
 Compressor Assembly
 Condenser Coil
 Receiver Dryer Assembly
2.3.3.1 COMPRESSOR DRIVE MOTOR: The compressor drive motor has a double-ended
shaft and operates on 27.5 VDC power with a rated current draw of 115 AMPS
nominal. 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 5000-5250 RPM. The motor
is specially designed to provide a high starting torque to overcome the compressor
startup requirements. The motor is a brush commutated permanent magnet design
and was selected for its efficiency, excellent controllability, long life, and low vibration.
The motor shaft is supported on high speed ball bearings for reliability and friction
reduction.
2.3.3.2 COMPRESSOR ASSEMBLY: The compressor assembly contains an R-134A

compressor and 5.01 inch pitch diameter pulley assembly. The compressor also
features a six piston wobble plate design as well as anti-slugging features that
eliminate the need for a suction trap/accumulator. The compressor displacement is
5.0 cu in. /rev. and has light-weight aluminum housing. The pulley assembly is
designed for a high strength, positive grip 232L100 timing belt and contains a radial
bearing to assure no side loads are transmitted into the compressor input shaft. The
assembly is designed for a max speed of 6000 RPM
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2.3.3.3 CONDENSER COIL ASSEMBLY: The condenser coil assembly is a copper tube and
aluminum fin configuration with 6061-T6 aluminum support brackets. The coil heat
rejection is 24,000 BTUH based on a 95°F ambient day. Condenser cooling airflow
and coil sizes are based on the design cooling capacity and compressor input
horsepower. The coil working pressure is up to 1500 PSIG.
2.3.3.4 RECEIVER DRYER ASSEMBLY: The receiver-dryer assembly consists of a

refrigerant container, Schrader valve, high pressure charging port and a binary
pressure switch. The receiver-dryer is constructed of aluminum alloy and contains a
standpipe, wire filter, and desiccant. The receiver dryer assembly is provided with a
corrosion resistant baked enamel finish. The receiver volume is approximately 40
cubic inches and can store up to 1.8 pounds of refrigerant at 240 PSIG. The Schrader
valve located in the container inlet port allows for the binary pressure switch to be
removed without venting the system refrigerant charge.
2.3.4 The EVAPORATOR MODULE ASSEMBLY (PN 1134310-5) has a rated cooling capacity of
8000 BTUH at an ambient air temperature of 90° F (db), and 50% RH (relative humidity).
The assembly provides an air flow of 200 CFM (cubic feet per minute) in order to maintain
these performance specifications.
2.3.5 The Evaporator Module Assembly is packaged to meet the aircraft installation requirements
and contains the following major components (refer to Figure 10002):
 Coil Assembly
 Blower Motor
 Blower Wheel
 Blower Scroll
 Expansion Valve
 Evaporator Housing
2.3.5.1 COIL ASSEMBLY: The evaporator coil assembly contains the evaporator coil,
mounting hardware, and refrigerant plumbing connections. The coil is constructed of
copper tube and aluminum fins with aluminum support brackets. The assembly
receives its air (return air) from the suction created by the blower assembly.
2.3.5.2 BLOWER MOTOR: The blower motor operates on 28 VDC with a current draw of 10
amps and has a design RPM of 5250-6250. The blower motor is a brushless design
with an integrated controller. It was selected for its efficiency, excellent controllability,
long life and low vibration at high speeds. The motor has two speeds, low speed
designed for the heating recirculation requirement and high speed designed for
maximum system cooling.
2.3.5.3 BLOWER WHEEL: The blower wheel is the component that is used in concert with
the blower motor and provides for the movement of air.
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2.3.5.4 BLOWER SCROLL: The blower scroll is constructed of high impact, fire retardant,
self extinguishing, and corrosion resistant, lightweight polycarbonate material. The
blower scroll has successfully passed blower wheel containment testing.
2.3.5.5 EXPANSION VALVE: The expansion valve is an automatic thermostatic type. The
valve provides the proper refrigerant flow while maintaining constant return gas
superheat at all evaporator heat load conditions. Controlling the evaporator
refrigerant flow based on cooling demand prevents coil freeze up. This allows the
system cooling capacity to best meet transient aircraft heat load demands.
2.3.5.6 EVAPORATOR HOUSING: The evaporator housing is constructed of high impact, fire
retardant, self extinguishing, and corrosion resistant, lightweight polycarbonate
material.
2.3.6 The AUTO LOAD SHED MODULE (PN 1240100) is designed to provide automatic load
shedding of high current draw, non-essential components or sub-systems (such as air
conditioning) in the event the aircrafts electrical system is experiencing problems or is
unable to handle the electrical load. The auto load shed module is a solid state device
enclosed in a compact, high impact, light weight, self extinguishing polycarbonate material.
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TESTING AND FAULT ISOLATION
TASK 21-00-12-70-801
3.0 R-134A AIR CONDITIONING SYSTEM COMPONENT – TESTING AND FAULT ISOLATION
SUBTASK 21-00-12-99F-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 21-00-12-70-001
3.2 Compressor Condenser Module Assembly Testing Procedures
(refer to Figure 10001):
3.2.1 Ensure that power is applied to the aircraft and that the air conditioning system is switched
on using the cockpit mounted selector switch. Gain access to the Compressor Condenser
Module (refer to the aircraft maintenance manual for removal of access panels and other
hardware that might need to be removed). Verify that these components are operating and
perform the following:
 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.
SUBTASK 21-00-12-70-002
3.3 Evaporator Module Assembly Testing Procedures
3.3.1 Verify blower motor operation in both low and high speed positions using cockpit mounted
selector switch.
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3.3.2 While blower motor is operating in both positions, listen carefully for the following:
 Verify that there is a distinct and noticeable change in sound of blower motor when changing
from low to high speed positions. This indicates that the cockpit selector switch is functioning
properly and that the blower motor is responding accordingly.
 Verify that there is a smooth transition when changing from low to high speed positions, and
that there is no excessive noise or vibration coming from the blower motor during the change.
Excessive noise could indicate that the blower wheel is rubbing against the blower scroll .
3.3.3 If there is excessive noise and/or vibration coming from blower motor/wheel assembly
during this test, please refer to the disassembly procedures in section 5 and inspection
procedures in section 7. This will help in identifying whether the blower motor wheel is dirty
or damaged and is need of repair or replacement, the blower scroll is dirty or damaged and
is need of repair or replacement, or the blower motor itself is in need of replacement.
3.3.4 Verify that the system is cooling properly. If not, the expansion valve(s) might need
aligning. Refer to Special Procedures, Section 12, for Expansion Valve Alignment
procedures.
SUBTASK 21-00-12-70-003
3.4 System Leak Check Testing Procedure:
3.4.1 A leak check of the refrigerant plumbing system is important to ensure the system maintains
its charge to provide the designed performance and reduce damage to system components.
A periodic check of the system charge is required to determine if any loss of refrigerant has
occurred.
3.4.2 A system leak check is required any time one or more of the following conditions occur:
 New system plumbing installation
 Component replacement in the plumbing system
 Line or hose rupture
3.4.3 Special Tools and/or Equipment Required:

 Gaseous dry nitrogen, regulated source (0-500 psig)
 R-134A refrigerant charging manifold with gauges and hoses
 Leak check fluid (soap solution)
 Assorted hand tools
 Hand and eye protection
 Thread sealant primer, PN 7471 (Loctite)
 Thread sealant, PN 569 (loctite)
 Hose adapter (1/2 in. male acme to ¼ in. female flare)
EFFECTIVITY: ALL
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3.4.3.1 Remove, if required, all panels, doors, shrouds, etc, to gain access to
system/component being leak checked (refer to aircraft maintenance manual).
3.4.3.2 Remove, if required, any enclosures or access doors to expose all tubing, hoses,
fittings, etc. to the system components.
3.4.3.3 Verify all plumbing connections are tight.
3.4.3.4 Verify that power is removed from aircraft. If it is not practical to remove aircraft
power, technician must pull and collar applicable circuit breakers.
CAUTION: HIGH PRESSURE HOSE (RED) IS CONNECTED TO PORT MARKED “D” AND THE LOW
PRESSURE HOSE (BLUE) IS CONNECTED TO THE SERVICE PORT MARKED “S”. INCORRECT
CONNECTION COULD RESULT IN MANIFOLD DAMAGE AND/OR INCORRECT PRESSURE READINGS.
3.4.3.5 Remove service port caps from the A/C system. The high pressure service port is
located on the receiver-dryer and low pressure service port is located on the
compressor suction header.
3.4.3.6 Close all manifold gauge valves and verify hose connections are tight.
3.4.3.7 Connect R-134A refrigerant charging manifold. R-134A service gauges contain quick-
connect fittings to minimize refrigerant loss. To install quick-connect, push on firmly
until locked (a "clicking" sound is heard). Hold the grip ring and pull to remove quick-
connect fittings.
3.4.3.8 Connect yellow charging hose to a regulated dry nitrogen source

NOTE: An adapter is required to connect yellow charging hose to the nitrogen source.
CAUTION: DO NOT EXCEED 200 PSIG NITROGEN PRESSURE DURING PROCEDURE OR DAMAGE TO
EXPANSION VALVE WILL RESULT.
3.4.3.9 Regulate nitrogen source to a pressure of 200 PSIG maximum.
3.4.3.10 Slowly open high pressure (red) manifold valve and allow system pressure to increase
gradually until a pressure of 200 psig is achieved. Allow time for system pressure to
equalize across expansion valve and note final system pressure.
CAUTION: DO NOT USE ANY LEAK DYE IN R-134A SYSTEM OR DAMAGE TO SYSTEM MAY RESULT.
CAUTION: DO NOT OVER TIGHTEN PLUMBING CONNECTIONS. STRIPPED THREADS OR CRACKED
FLARES MAY RESULT.
3.4.3.11 Apply soapy leak check fluid to each fitting connection. If leaks are detected, attempt
to tighten fitting without over tightening. If leak cannot be corrected with tightening,
system must be evacuated (refer to Servicing, Section 13) and then fitting must be
disconnected and new thread sealant applied.
3.4.3.12 Using a wire brush and cleaning solvent, completely remove old thread sealant. Apply
a thin layer of thread sealant primer to fitting threads.
EFFECTIVITY: ALL
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July 15, 2014
CAUTION: WHEN APPLYING THREAD SEALANT, TAKE EXTREME CARE TO KEEP SEALANT OFF
FIRST 2 OR 3 THREADS.
3.4.3.13 Apply Loctite thread sealant on all male fitting threads sparingly.
CAUTION: WHEN APPLYING R-134A OIL TO FLARE AND O-RING, TAKE EXTREME CARE TO KEEP OIL
AWAY FROM FITTING THREADS
3.4.3.14 Apply a light coating of R-134A refrigerant oil to flare and/or o-ring to prevent metal
galling or o-ring damage.
3.4.3.15 Tighten joints as required to stop leaks (refer to Table 1, Section 1.3 for torque
values).
CAUTION: VENT SYSTEM PRESSURE VERY SLOWLY TO ASSURE COMPRESSOR OIL IS NOT
VENTED WITH THE NITROGEN. DO NOT LET AIR ENTER THE SYSTEM.
3.4.3.16 After leak check is finished and system integrity is sound, turn off nitrogen source,
disconnect yellow charging hose from nitrogen source and slowly release nitrogen
pressure to zero.
3.4.3.17 Close manifold valve.
3.4.3.18 System is now ready for charging (refer to Servicing, Section 13).
EFFECTIVITY: ALL
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3.4.3.19
SUBTASK 21-00-12-81-001
3.5 Fault Isolation (Trouble Shooting):
3.5.1 The following list of system/component failures and/or abnormal operation and possible
solutions is only a partial listing of what may occur. The more informed service personnel
are in the operation of the system and its various components, the less time will be required
to diagnose failures. Use this trouble shooting list as well as all information contained in this
manual, to aid in diagnosing system faults. Contact Enviro Systems customer service for
any items not listed in this trouble shooting list.
NOTE: Refer to Refrigerant Flow (Figure 2) and Electrical Schematic (Figure 3), Section 4.
INDICATION PROBABLE CAUSE POSSIBLE SOLUTION

A. No System Power 1. Ground power not connected 1. Plug in ground power cart
2. Aircraft power switch off 2. Energize power switch
B. Power On But System Will 1. Air conditioner breaker off 1. Turn on

Not Operate
2. Air conditioner breaker failed 2. Replace
3. Air conditioner mode switch 3. Replace
failed
4. Relay(s) failed 4. Replace
5. Failed pressure switch 5. Replace
6. Failed drive motor 6. Replace
7. Vented system 7. Pressure check, evacuate and
charge
8. Low ambient temperature 8. Normal cut out function
9. Drive motor fuse blown 9. Replace
10 Drive motor temp sw failed 10 Replace switch
11. Contactor control line fuse 11. Replace
blown
Table 3 Trouble Shooting List
EFFECTIVITY: ALL
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Page 1005
July 15, 2014

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

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

2. Drive belt hitting cover 2. Align belt & adjust bracket
3. Motor fan hitting shroud 3. Adjust as required
4. Defective compressor 4. Replace
5. Defective drive pulley 5. Replace
6. Loose pulley 6. Tighten or replace
7. Loose mounting hardware 7. Tighten as required
8. Loose hose assembly 8. Secure as required
9. Loose fan blade 9. Tighten or replace
F. No low evap. Fan speed 1. Failed switch 1. Replace

(hi speed ok)
2. Failed resistor 2. Replace
3. Failed relay 3. Replace
EFFECTIVITY: ALL
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G. Compressor Assembly Will 1. Circuit Breaker failed or off 1. Energize or replace

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

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

Freezing
2. Expansion valve failed or 2. Remove debris or replace
clogged
3. Expansion valve setting low 3. Reset to obtain 26-30 psig
suction pressure
J Pressure Switch Cycles (High 1. System over charged 1. Reclaim refrigerant as required
Pressure Cutout)
2. Condenser coil inlet air 2. Normal condition
extremely hot
3. Condenser inlet clogged 3. Remove debris
4. Discharge line clogged or 4. Replace or straighten line
kinked
5. Excessively high ambient 5. Normal Condition
temperature
EFFECTIVITY: ALL
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SCHEMATIC AND WIRING DIAGRAMS
21-00-12-99-801
4.0 R-134A AIR CONDITIONING SYSTEM SCHEMATIC AND WIRING DIAGRAMS
SUBTASK 21-00-12-99-001
4.1 R-134A Refrigerant Flow Schematic:
4.1.1 The following schematic shows an air conditioning system and its associated components
as well as the flow of the R-134A refrigerant.
Figure 1 R-134A Refrigerant Flow Schematic
EFFECTIVITY: ALL
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SUBTASK 21-00-12-99-002
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.
Figure 2 Electrical Schematic
Figure 3 1134400-1 Compressor Condenser Schematic

With Thermal Fuse Motor Switch
EFFECTIVITY: ALL
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DISASSEMBLY
TASK 21-00-12-00-801
5.0 R-134A AIR CONDITIONING SYSTEM COMPONENT - DISASSEMBLY
SUBTASK 21-00-12-99F-010
5.1 General:
PERFORMING SERVICE TO THE UNIT.
CAUTION: SERVICE TECHNICIANS MUST PREVENT CONTAMINATION OF INTERNAL SYSTEM
PLUMBING DURING ANY SERVICING AND/OR MAINTENANCE OPERATION. THIS INCLUDES NOT
ALLOWING THE RECEIVER DRYER TO BE EXPOSED TO ATMOSPHERIC CONDITIONS FOR ANY
LENGTH OF TIME. ALL PLUMBING LINES SHOULD REMAIN CAPPED WHENEVER POSSIBLE DURING
THE SERVICING OF THE SYSTEM.
CAUTION: RECEIVER DRYER MUST BE REPLACED ANY TIME THE VCS PLUMBING IS OPENED FOR
MAINTENANCE. REFER TO DISASSEMBLY (SECTION 5) AND ASSEMBLY (SECTION 9).
NOTE: Refer to Testing and Fault Isolation (Section 3) for establishing the condition of the component or
most probable cause of detected malfunction(s) to determine extent of disassembly required. Disassembly
should only be performed to the extent necessary to access any faulty subassembly.
5.1.1 Gain access to the Compressor Condenser Module, Evaporator Module Assembly, or Auto
Load Shed 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).
EFFECTIVITY: ALL
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5.1.7 Tools, fixtures, equipment, or consumable items required:

 Small hand tools and socket set
 Straight edge
 Measuring device
 Micrometer
 Scribe or wire hook
 Volt or OHM meter (digital)
 Shop air, 40 PSIG max
 Respiration mask
SUBTASK 21-00-12-00-001
5.2 Compressor Condenser Module Disassembly Procedures
5.2.1 Removal of Receiver Dryer
5.2.1.1 Verify that system refrigerant charge has been recovered (refer to Servicing, Section
13)
5.2.1.2 Disconnect refrigerant plumbing connection from receiver dryer inlet port.
5.2.1.3 Disconnect discharge refrigerant line from receiver dryer outlet port.
5.2.1.4 Loosen receiver dryer attaching clamps and carefully slide receiver dryer from
mounting rack.
5.2.2 Removal of Belt Cover
5.2.2.1 Remove 4 belt cover attaching fasteners (2 located at bottom, mid cover, 2 located at
top, mid cover).
5.2.2.2 Loosen 2 attaching bolts that secure the motor relay power control connector and fuse
bracket, as well as the motor itself.
5.2.2.3 Carefully slide 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.
5.2.3.1 Remove belt cover per 5.2.2.
EFFECTIVITY: ALL
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5.2.3.2 Slightly loosen the bottom compressor mounting bolts.
5.2.3.3 Loosen upper compressor adjustment bolt and slide upper compressor towards drive
motor.
5.2.3.4 Loosen motor pulley set screws and slide drive pulley and belt from motor shaft, while
at the same time sliding the drive belt off the compressor pulley.
5.2.4 Removal of Compressor Assembly
5.2.4.1 Remove belt cover, drive belt, and drive pulley per 5.2.2 and 5.2.3.
5.2.4.2 Disconnect condenser refrigerant lines from compressor plumbing port and cap off
immediately.
5.2.4.3 Remove compressor mounting bolts and washers.
5.2.4.4 Carefully lift compressor from mounting bracket.
5.2.5 Removal of Drive Motor
5.2.5.1 Remove belt cover, drive pulley, and belt per 5.2.2 and 5.2.3
5.2.5.2 Remove receiver dryer per 5.2.1.
5.2.5.3 Remove 10 screws securing condenser support bracket and carefully remove bracket
from assembly.
5.2.5.4 Disconnect power cables and tag.

CAUTION: DO NOT ALLOW MOTOR TO FALL ON POWER CONTACTOR DURING THIS PROCEDURE
OR DAMAGE MAY RESULT.
5.2.5.5 Remove all cable ties used to secure wiring to motor.

NOTE: It may be necessary for technician to remove upper compressor mounting bolt, loosen the 2 lower
compressor mounting bolts, and slide upper compressor away from drive motor a short distance in order to
access the drive motor mounting bolts, being careful not to damage refrigerant plumbing and connections.
5.2.5.6 Remove motor mounting bolts from motor support bracket.

CAUTION: TAKE EXTREME CARE WHEN REMOVING DRIVE MOTOR FROM ASSEMBLY OR DAMAGE
TO COIL COULD OCCUR.
5.2.5.7 Carefully slide motor sideways from assembly.
EFFECTIVITY: ALL
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5.2.6 Removal of Fan
5.2.6.1 Remove motor shaft retaining nut and washer.
5.2.6.2 Loosen fan hub set screw.
5.2.6.3 Slide fan assembly from motor shaft.
5.2.7 Removal of Fan Shroud
5.2.7.1 Remove drive motor per 5.2.5.
5.2.7.2 Remove four shroud mounting screws, washers, and nuts.
5.2.7.3 Cut RTV between shroud and coil using a putty knife.
5.2.7.4 Carefully remove shroud from assembly.
5.2.8 Removal of Outlet Shroud
5.2.8.1 Remove four shroud mounting screws, washers, and nuts.
5.2.8.2 Cut RTV between shroud and coil using a putty knife.
5.2.8.3 Carefully remove shroud from assembly.
5.2.9 Removal of Power Relay
5.2.9.1 Disconnect electrical connections and mark polarity.
5.2.9.2 Remove relay mounting hardware and carefully slide relay from assembly.
5.2.10 Removal of Drive Motor Brushes
5.2.10.1 Remove receiver dryer per 5.2.1.
5.2.10.2 Remove 10 screws securing condenser support bracket and remove bracket from
assembly.
5.2.10.3 Remove brush cover screen, attaching screws, and washers (refer to Figure 4).
5.2.10.4 Remove brush shunt wire attaching screw from brush rack terminal.
EFFECTIVITY: ALL
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CAUTION: DO NOT ALLOW BRUSH SPRING TO SNAP AGAINST BRUSH OR BRUSH DAMAGE MAY
RESLULT.
5.2.10.5 Lift brush spring and slide brush from brush rack.
Figure 4 Brush Removal Details
EFFECTIVITY: ALL
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SUBTASK 21-00-12-00-002
5.3 Evaporator Module Assembly Disassembly Procedures
5.3.1 Removal of Expansion Valve
5.3.1.1 Disconnect refrigerant plumbing lines and cap off immediately.
5.3.1.2 Remove expansion valve from evaporator fitting and cap off fitting immediately.
5.3.2 Removal of Blower Motor/Wheel
5.3.2.1 Disconnect motor electrical connection.
5.3.2.2 Remove 4 mounting screws and washers.
5.3.2.3
Use a putty knife and carefully cut RTV between motor and scroll, taking care not to
damage scroll.
CAUTION: USE EXTREME CARE TO PREVENT DAMAGE OR BENDING OF BLOWER MOTOR WHEEL.
5.3.2.4 Carefully remove blower motor /blower wheel assembly from scroll
5.3.2.5 Loosen blower wheel set screw on blower motor shaft and remove blower wheel.
SUBTASK 21-00-12-00-003
5.4 Auto Load Shed Device Disassembly Procedures
(refer to Figure 10001 for PN):
5.4.1 Removal of Auto Load shed Device
5.4.1.1 Disconnect electrical connection.
5.4.1.2 Remove 4 attaching screws, washers, and nuts.
EFFECTIVITY: ALL
21-00-09
Page 3006
July 15, 2014
CLEANING
TASK 21-00-12-10-801
6.0 R-134A AIR CONDITIONING SYSTEM COMPONENT – CLEANING PROCEDURES
SUBTASK 21-00-12-99F-011
6.1 General:
6.1.1 This section details the procedures required to perform certain cleaning functions. The
components listed have certain cleaning procedures associated with them, however these
procedures are in no way an all encompassing list of what may be required. Care should be
taken to follow the listed procedures and to use common sense when using any cleaning
tools or solvents.
PRECAUTIONS, SUCH AS WEARING PERSONAL SAFETY GEAR TO PREVENT INJURY WHILE
WARNING: SERVICE TECHNICIANS ARE ADVISED TO OBSERVE STANDARD SAFETY PRECAUTIONS
SUCH AS WEARING SAFETY GLASSES, GLOVES AND PROTECTIVE CLOTHING WHEN USING
CERTAIN CLEANING SOLVENTS AND/OR CHEMICALS. INGESTION OF CERTAIN SOLVENTS AND/OR
CHEMICALS CAN CAUSE SERIOUS INJURY OR EVEN DEATH. WHENEVER CLEANING PROCEDURES
INVOLVE THE USE OF SOLVENTS AND/OR CHEMICALS, IT IS HIGHLY RECOMMENDED THAT THE
TECHNICIAN REVIEW THE APPLICABLE MSDS (MATERIAL DATA SAFETY SHEET) PRIOR TO
BEGINNING THE PROCEDURE TO FAMILIARIZE THEMSELVES WITH THE HAZARDS ASSOCIATED
WITH THAT SOLVENT AND/OR CHEMICAL, AND APPROPRIATE RESPONSE NEEDED SHOULD
INGESTION OCCUR.
CAUTION: ALWAYS USE PROTECTIVE COVERINGS AND/OR PROTECTIVE CAPS ON OPEN OR
EXPOSED HOLES, PLUMBING, ETC. THIS WILL ENSURE THE COMPONENT STAYS FREE FROM
DIRT, DUST, AND ANY OTHER FOREIGN MATTER.
6.1.2 Gain access to the Compressor Condenser Module or Evaporator Module Assembly (refer
to the aircraft maintenance manual for removal of access panels and other hardware that
might need to be removed)
EFFECTIVITY: ALL
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SUBTASK 21-00-12-10-001
6.2 Compressor Condenser Module Cleaning Procedures:
6.2.1 The following components of the Compressor Condenser Module will require periodic
cleaning (refer to the Inspection Schedule in section 7 for time intervals). This is in no way
an all encompassing list. If at any time during the inspection process a component is found
to be dirty, use a soft cloth to remove all contaminants from external surfaces (refer to
Figure 10001).
 Compressor Condenser Module Assembly
 Condenser Coil
6.2.1.1 COMPRESSOR CONDENSER MODULE ASSEMBLY: Over time, the Compressor

Condenser Module assembly will become dirty and require general cleaning. It is
essential that the assembly remain clean to ensure proper operation and optimal
performance. Use soft cloth, a soft utility brush and/or vacuum, or other suitable
cleaning tools, and remove any dirt, dust, or other foreign matter. Prior to the
installation of the motor brushes, commutator should be cleaned with compressed air
blast to remove any carbon dust or contaminants
6.2.1.2 CONDENSER COIL: Over time, the Condenser Coil will become dirty and require
general cleaning. It is essential that the assembly remain clean to ensure proper
operation and optimal performance. The coil fins will, over time, become clogged with
dirt, dust and other foreign matter. It is essential that the coil fins remain clear for
proper operation of the condenser coil. Using a soft utility brush and/or vacuum,
remove any accumulated, lint, dirt, dust and other foreign matter. A small stiff brush
such as a tooth brush can be used to break loose any caked on dirt.
SUBTASK 21-00-12-10-002
6.3 Evaporator Module Assembly Cleaning Procedures:
6.3.1 The following components of the Evaporator Module Assembly will require periodic cleaning
(refer to the Inspection Schedule in section 7 for time intervals) (refer to Figure 10002):
 Evaporator Coil Air Inlet
 Evaporator Housing Assembly
 Blower Assembly
 Condensate Drain (part of Evaporator Housing Assembly)
 Expansion Valve
CAUTION: USE EXTREME CARE TO PREVENT DAMAGE OR BENDING OF COIL FINS
EFFECTIVITY: ALL
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6.3.1.1 EVAPORATOR COIL AIR INLET: The coil fins will, over time, become clogged with
dirt, dust and other foreign matter. It is essential that the coil fins remain clear for
proper operation of the evaporator module assembly. Using a soft utility brush and/or
vacuum, remove any accumulated, lint, dirt, dust and other foreign matter. A small
stiff brush such as a tooth brush can be used to break loose any caked on dirt.
6.3.1.2 EVAPORATOR HOUSING ASSEMBLY: The components that comprise the

evaporator housing assembly are the shroud and escutcheon . Over time, the shroud
and escutcheon may show signs of separating and this can cause the evaporator
module assembly to have less than optimal performance. If there are signs of
separation between the shroud and escutcheon, clean the separated areas carefully
with isopropyl alcohol to remove any dirt, dust, and other foreign matter, to include the
old RTV sealant. Refer to Repair (section 8) for resealing procedures.
CAUTION: USE EXTREME CARE TO PREVENT DAMAGE OR BENDING TO THE BLOWER WHEEL
FRAME AND/OR BLADES.
6.3.1.3 BLOWER ASSEMBLY: The components that comprise the blower assembly are the
blower motor, blower scroll and blower wheel. Over time, these components can
become dirty 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). Over time, the blower scroll
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, clean the
separated areas carefully with isopropyl alcohol to remove any dirt, dust, and other
foreign matter, to include the old RTV sealant. Refer to Repair (section 8) for
resealing procedures.
6.3.1.4 CONDENSATE DRAIN: The condensate drain can become clogged with dirt, dust
and foreign matter over time. It is essential that the drain remain free and clear of
foreign matter or performance will be less than optimal. Use a small brush or other
suitable cleaning tool to ensure that all foreign matter is removed from the drain.
6.3.1.5 EXPANSION VALVE: The expansion valve should be free from dirt, dust and foreign
matter. Use a brush or rag to clean.
EFFECTIVITY: ALL
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CHECK (INSPECTION SCHEDULE)
TASK 21-00-12-21-801
7.0 R-134A AIR CONDITIOING SYSTEM COMPONENT – INSPECTION SCHEDULE
SUBTASK 21-00-12-21-001
7.1 Compressor Condenser Module Assembly Inspection Schedule:
NOTE: This is the recommended visual inspection schedule for the Compressor Condenser Module
Assembly. Adherence to this schedule will ensure that all components of the assembly are in accordance
with the manufacturer’s specifications and is necessary to detect structural failure, deterioration or damage,
and to determine the need for corrective action.
7.1.1 If any component listed in this schedule requires cleaning, refer to Cleaning Procedure
(Section 6).
7.1.2 If any component listed in this schedule requires repair and/or replacement, refer to Repair
(Section 8).
Component Type Inspection Unit
Operating
Hours
Drive belt/pulley/cover 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
Bearing inspection
Condenser fan / outlet Visually inspect condenser fan shroud for signs of cracking, separation between 500
shroud 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 Motor bearing inspection 500
Motor overhaul and Bearing Replacement 2500-3000
Drive Motor and Visually inspect drive motor commutator for wear. (See Illustration 4.5) 500
Commutator Internal contamination inspection
Motor insulation resistance check
Inspect brushes for cracks, chipped edges, frayed leads, loose rivets or shunt
connections.
Inspect brush holders for looseness, damage from arcing, heat distortion or cracks.
Motor Brushes Replacement Mandatory

every 500
hours
Receiver dryer Inspect for leakage. Inspect refrigerant charge level. 500
assembly Inspect plumbing for damage, weathering, and wear.
Verify mounting hardware is secure.
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
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 21-00-12-21-002
7.2 Evaporator Module Assembly Inspection Schedule:
NOTE: This is the recommended visual inspection schedule for the Evaporator Module Assembly.
Adherence to this schedule will ensure that all components of the assembly are in accordance with the
manufacturer’s specifications and is necessary to detect structural failure, deterioration or damage, and to
determine the need for corrective action.
7.2.1 If any component listed in this schedule requires cleaning, refer to Cleaning Procedure
(Section 6).
7.2.2 If any component listed in this schedule requires repair and/or replacement, refer to Repair
(Section 8).
Component Type Inspection Required Times
Evaporator Coil Assembly Inspect refrigerant plumbing for leakage 12 Months
Inspect coil fins for cleanliness and damage
Inspect cold air ducting for leaking cracks or damage
Evaporator housing Assembly Inspect seam between shroud assembly and 12 Months
Shroud Assembly escutcheon for signs of separation and condensate
Escutcheon leakage.
Water Deflector Inspect for cleanliness and damage/integrity.
Inspect condensate drain, making sure hole is clear
and secure.
Blower Assembly Inspect for cleanliness and damage/integrity 12 Months
Blower Motor Verify that blower wheel is clean and operates vibration
Blower Wheel free. Blower 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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REPAIRS
TASK 21-00-12-30-801
8.0 R-134A AIR CONDITIONING SYSTEM COMPONENT – REPAIR PROCEDURES
SUBTASK 21-00-12-99F-012
8.1 General:
8.1.1 Refer to Illustrated Parts Listing (IPL) for figure/item numbers (Section 11).
SUBTASK 21-00-12-30-001
8.2 Compressor Condenser Module Repair Procedures:
8.2.1 The following components may require periodic repair and/or replacement (refer to the
Inspection Schedule in Section 7 for mandatory time intervals) (refer to Figure 10001):
 Drive Belt /Cover/Pulley
 Drive Motor/Brushes
 Compressor Assembly
 Compressor Shaft Seal
 Electrical Wiring
 Receiver Dryer
 Fan / Outlet Shroud
 Condenser Coil
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8.2.1.1 DRIVE BELT/COVER/PULLEYS: The drive belt and the associated pulleys will, over
time, become worn or damaged, or may simply be out of alignment. It is essential that
the drive belt and the pulleys are in excellent condition for proper operation of the
Compressor Condenser Module assembly. If the drive belt edges are showing signs
of wearing or if cracking is noticed, it should be replaced. If the motor drive pulley is
showing signs of wearing, both on the pulley teeth and pulley flanges, it should be
replaced. If belt cover is cracked or damaged in any way, it should be replaced. If
assembly is out of alignment, system will need to be aligned and tensioned. Refer to
Disassembly (Section 5) and Assembly (Section 9). Contact Enviro Systems
customer service to order new components.
8.2.1.2 DRIVE MOTOR BRUSHES: Drive motor brushes can, over time, become worn or
damaged. It is essential that the drive motor brushes remain in excellent condition for
proper operation of the compressor condenser module assembly. They must be
replaced according to the inspection schedule in Section 7. If the commutator shows
signs of pitting, burnt spots, or grooving, (See Illustration 4.5 in Section 7 for
examples) the drive motor should be removed and replaced with an overhaul. Refer
to Disassembly (Section 5) and Assembly (Section 9).
8.2.1.3 COMPRESSOR ASSEMBLY: The compressor and pulley can, over time, become
dirty and shows signs of wear and/or damage. It is essential that the compressor and
its pulley remain in excellent condition for proper operation of the Compressor
Condenser Module assembly. Check the pulley condition as per 8.2.1.1. If there is
damage to the pulley, it should be replaced. Check the compressor shaft seal as per
8.2.1.4. If a leak is detected and it is excessive, the compressor should be replaced.
If there is visible damage to the compressor housing, the compressor should be
removed and replaced. Refer to Disassembly (Section 5) and Assembly (Section 9).
Contact Enviro Systems customer service.
8.2.1.4 COMPRESSOR SHAFT SEAL: Over time, the compressor shaft seal may show signs
of excessive oil spray and this can cause the Compressor Condenser Module
assembly to have less than optimal performance. If excessive oil spray is observed,
the compressor should be replaced. Refer to Disassembly (Section 5) and Assembly
(Section 9). Contact Enviro Systems customer service to order new compressor.
NOTE: If the compressor has not been operated for 30-60 days or more, the dynamic shaft seal may indicate
a small leak due to the absence of oil on the dynamic seal surface. Operation of the system should eliminate
this type of leak. If not, proceed with removal and replacement procedures.
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8.2.1.5 ELECTRICAL WIRING: The electrical wiring can, over time, become worn and
damaged. If the wiring insulation is showing signs of abrasion or damage of any other
kind, replace wiring as required
8.2.1.6 RECEIVER DRYER ASSEMBLY: The receiver dryer assembly can, over time,
become damaged. The component can also become contaminated due to damaged,
opened, cracked, or ruptured lines or hoses. If the receiver dryer shows signs of
damage, the receiver dryer should be removed and replaced. If the receiver dryer has
been contaminated, it must be removed and replaced (refer to Disassembly, Section 5
and Assembly, Section 9). Contact Enviro Systems customer service to order a new
receiver dryer
8.2.1.7 FAN / OUTLET SHROUD: The fan / outlet shrouds can, over time, show signs of
cracking and separation between the shrouds and the condenser. This can cause the
compressor condenser module assembly to have less than optimal performance. If
the shrouds are separating, refer to Disassembly (Section 5) for removal. Then refer
to Cleaning (Section 6). After insuring that the seam between the shrouds and
condenser have been cleaned according to the cleaning procedures (Section 6), apply
a new bead of RTV and reinstall shrouds (refer to Assembly, Section 9). Allow RTV to
cure for a minimum of 24 hours before operating system. If the shrouds are cracked
or are damaged in any other way, they should be replaced. Contact ENVIRO
Systems customer service to order new components.
8.2.1.8 CONDENSER COIL: The condenser coil fins can, over time, become clogged with
dirt, dust, and other foreign matter. The component can also become damaged. The
coil return bends can, over time, become damaged. Dents, nicks, cracks, and other
damage can cause less than optimal performance. It is essential that the condenser
coil remain clear and undamaged for proper operation. Refer to Cleaning (Section 6)
for proper cleaning procedures. If coil fins are bent, use a fin comb and try
straightening the fins. If fins are excessively damaged or the return bends are
excessively damaged, the entire compressor condenser module assembly must be
removed (refer to Disassembly, Section 5) and sent to Enviro Systems for repair.
SUBTASK 21-00-12-30-002
8.3 Evaporator Module Assembly Repair Procedures:
8.3.1 The following components may require periodic repair and/or replacement (refer to the
Inspection Schedule in Section 7 for mandatory time intervals) (refer to Figure 10002):
 Evaporator Coil
 Evaporator Housing Assembly
 Blower Assembly
 Condensate Drain (part of Evaporator Housing Assembly)
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8.3.1.1 EVAPORATOR COIL: The evaporator coil fins can, over time, become clogged with
dirt, dust, and other foreign matter. The component can also become damaged. The
coil return bends can, over time, become damaged. Dents, nicks, cracks, and other
damage can cause less than optimal performance. It is essential that the evaporator
coil remain clear and undamaged for proper operation. Refer to Cleaning (Section 6)
for proper cleaning procedures. If coil fins are bent, use a fin comb and try
straightening the fins. If fins are excessively damaged or the return bends are
excessively damaged, the entire evaporator coil assembly must be removed (refer to
Disassembly, Section 5) and sent to Enviro Systems for repair. Contact Enviro
Systems customer service.
8.3.1.2
EVAPORATOR HOUSING ASSEMBLY: The components that comprise the
evaporator housing assembly are the shroud and escutcheon . Over time, the shroud
and escutcheon may show signs of separating and this can cause the evaporator coil
assembly to have less than optimal performance. After insuring that the seam
between the shroud and escutcheon has been cleaned according to the cleaning
procedures (Section 6), apply a new bead of RTV and smooth. Allow RTV to cure for
a minimum of 24 hours before operating system. If housing assembly is damaged in
any way other than seam separation, the entire assembly must be removed and sent
to Enviro Systems for repair. Contact Enviro Systems customer service.
CAUTION: USE EXTREME CARE TO PREVENT DAMAGE OR BENDING TO THE BLOWER WHEEL
FRAME AND/OR BLADES.
8.3.1.3 BLOWER ASSEMBLY: The components that comprise the blower assembly are the
blower motor , blower scroll and blower wheel . Over time, these components can
become dirty or damaged causing the assembly to have less than optimal
performance. Occasionally damage will occur to unit that requires repair and/or
replacement of one or more of the assembly components.
8.3.1.3.1 If blower motor wheel is damaged, such as having bent or cracked blades,
removal and replacement is required. Refer to Disassembly (Section 5) for
removal procedures. Refer to Assembly (Section 9) for installation procedures.
After completing the removal and installation of the new blower wheel, perform
functional check (Section 3). Contact Enviro Systems customer service to
order new blower wheel.
8.3.1.3.2 If blower motor scroll is damaged in any way, the entire Forward Evaporator
Module Assembly must be removed and sent to Enviro Systems for repair.
8.3.1.3.3 If blower motor is damaged or is not operating to specifications, removal and

replacement is required. Refer to Disassembly (Section 5) for removal. Refer
to Assembly (Section 9) for installation. After completing the removal and
installation of the new blower motor, perform functional check (Section 3).
Contact ENVIRO Systems customer service to order a new motor or to return
entire assembly.
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8.3.1.4 CONDENSATE DRAIN: The condensate drain (part of the housing assembly) can,
over time, become damaged. It is essential that the drain remains in excellent
condition for proper operation of the evaporator coil assembly. If the condensate drain
is damaged, the entire assembly must be removed and sent to Enviro Systems for
repair. Contact Enviro Systems customer service.
SUBTASK 21-00-12-30-003
8.4 Auto Load Shed Device Repair Procedures:
8.4.1 The Auto Load Shed Device cannot be repaired in the field. If there is damage to the unit or
unit does not function properly, it will need to be removed and replaced. Refer to
Disassembly (Section 5) and Assembly (Section 9). Contact Enviro Systems Customer
Service to order new components.
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ASSEMBLY
TASK 21-00-12-40-801
9.0 R-134A AIR CONDITIONING SYSTEM COMPONENT - ASSEMBLY
SUBTASK 21-00-12-99F-013
9.1 General:
9.1.1 Refer to Illustrated Parts Listing (IPL) during assembly procedures for figure/item numbers
(Section 11).
9.1.2 Gain access to the Compressor Condenser Module, Evaporator Module Assembly, and
Auto Load Shed Device (refer to the aircraft maintenance manual for removal of access
panels and other hardware that might need to be removed)
9.1.4 After assembly of any component requiring installation of refrigerant plumbing or hoses,
charge refrigerant system (refer to Servicing, Section 13).
NOTE: A functional test should be performed any time one or more components are removed and replaced.
Prior to starting functional test, ensure that all components of the assembly are installed. Refer to Test and
Fault Isolation Section 3.
9.1.5 Tools, fixtures, equipment, or consumable items required

 Tape
 Gates Sonic Tension Meter
 Straight edge
 Measuring device
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 Micrometer
 Inspection mirror
 Thermometer, 0-150°F
 Flash light or service lamp
 Leak check fluid (soapy)
 Thread sealant primer
 Thread sealant
 Dry nitrogen, regulated
SUBTASK 21-00-12-40-001
9.2 Compressor Condenser Module Assembly Procedures
9.2.1 Assembly of Drive Motor Brushes

(refer to Figure 4 for details)
CAUTION: ENSURE THAT MOTOR COMMUTATOR IS CLEAR OF ANY CONTAMINATION AND THAT
ALL CARBON DUST IS REMOVED.
CAUTION: DO NOT ALLOW BRUSH SPRING TO SNAP AGAINST THE BRUSH OR BRUSH DAMAGE
MAY RESULT.
9.2.1.1 Ensure that brushes have been tested (refer to Testing and Fault Isolation, Sect. 3).
9.2.1.2 Lift brush spring and slide brush into brush rack. Verify that brush direction is against
commutator.
9.2.1.3 Seat new brushes according to Special Procedures, Section 12. All new brushes
must be seated to ensure proper motor operation and/or performance.
CAUTION: APPLY THREAD SEALANT SPARINGLY TO MALE FITTING THREADS STAYING CLEAR OF
FIRST 2-3 THREADS.
9.2.1.4 Attach brush shunt wire terminal to brush rack using attaching screw. Apply a drop of
thread sealant to screw.
9.2.1.5 Route brush shunt leads to allow for brush wear and to prevent shorting.
9.2.1.6 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.
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9.2.1.7 Run system for a minimum of 15 minutes to seat brushes and check motor operation.
9.2.2 Assembly of Fan / Outlet Shrouds
9.2.2.1 After insuring that the shroud/coil mating surfaces have been cleaned in accordance
with section 6, apply a 1/8 inch bead of RTV to fan/outlet shroud/coil mating surface.
CAUTION: DO NOT TIGHTEN FAN SHROUD MOUNTING SCREWS UNTIL MOTOR AND FAN HAVE
BEEN INSTALLED. TIGHTEN ONLY AFTER INSURING THAT THERE IS SUFFICIENT BLADE TIP
CLEARANCE BETWEEN THE BLADE AND THE SHROUD.
9.2.2.2 Attach fan / outlet shroud to coil with mounting screws, washers and nuts (refer to
table 1, Section 1.3 for torque specifications).
9.2.3 Assembly of Fan
9.2.3.1 Slide fan assembly onto motor shaft.

CAUTION: APPLY THREAD SEALANT SPARINGLY TO THREADS STAYING CLEAR OF FIRST 2-3
THREADS.
9.2.3.2 Apply a drop of thread sealant to the set screw thread. Tighten fan assembly set
screw (refer to table 1, Section 1.3 for torque specifications), insuring that the screw is
located on flat part of motor shaft.
9.2.3.3 Tighten motor shaft retaining nut and washer.
9.2.4 Assembly of Drive Motor

CAUTION: TAKE EXTREME CARE WHEN INSTALLING DRIVE MOTOR ONTO ASSEMBLY OR DAMAGE
TO COIL OR FAN SHROUD COULD OCCUR.
9.2.4.1 Carefully slide drive motor into position taking extreme care not to damage coil or fan
shroud.
NOTE: It may be necessary for technician to remove upper compressor mounting bolt, loosen the 2 lower
compressor mounting bolts, and slide upper compressor away from drive motor a short distance in order to
access the drive motor mounting bolts, being careful not to damage refrigerant plumbing and connections.
9.2.4.2 Install 6 mounting bolts. Install remaining 2 bolts only after motor relay power control
connector and fuse bracket is in place (refer to table 1, Section 1.3 for torque
specifications).
9.2.4.3 Connect electrical harness, secure with cable ties and route to prevent chaffing.
9.2.4.4 Install drive motor belt and pulley per 9.2.6.
9.2.4.5 Install 10 screws securing condenser support bracket (refer to Table 1, Section 1.3 for
torque specifications).
9.2.4.6 Install receiver dryer per 9.2.8.
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9.2.4.7 Install drive motor belt cover per 9.2.7.
9.2.5 Assembly of Compressor
9.2.5.1 Position compressor in mounting bracket and install 3 mounting bolts. Finger tighten
bolts only.
9.2.5.2 Rotate upper compressor towards drive motor Tighten mounting hardware only after
tensioning and alignment have been accomplished (refer to installation of drive belt
and pulley, 9.2.6).
9.2.5.4 Apply 1-2 drops of thread sealant on compressor discharge port threads.
CAUTION: TAKE EXTREME CARE NOT TO GET REFRIGERANT OIL ON FITTING THREADS
9.2.5.5 Apply a thin film of refrigerant oil to compressor discharge port flare surface.
9.2.5.6 Connect condenser fitting to compressor discharge port and tighten (refer to table 1,
section 1.3 for torque specifications).
9.2.6 Assembly of Drive Belt and Pulley
9.2.6.1 Verify key is installed and motor is free to rotate. Place drive belt (232L100) over
motor drive pulley and slide belt onto compressor pulley while sliding motor pulley
onto motor shaft.
9.2.6.2 Belt should be tensioned (refer to Figure 5) and tested utilizing Gates Sonic Tension
Meter to ranges shown (refer to Table 4). Securely tighten tensioner’s attachment
hardware to include installing turn buckle locking device when proper tension is
achieved. Follow the procedure outlined below.
CAUTION: DO NOT OVER TENSION BELT. IMPROPER BELT TRACKING AND BELT / MOTOR DAMAGE
MAY RESULT.
9.2.6.2.1 Gates Sonic Tension meter method: (Required Method)

 Input the following information into the Meter:
 Weight: 3.2 g/m/mm
 Width: 25 mm
 Span: 147 mm
9.2.6.2.2 In A Quiet/Non Windy Environment – Cord Sensor
9.2.6.2.3 Push the measure button on the meter, hold the cord sensor approximately 1
cm (0.4 in) above the belt at the midway point between the pulleys.
 Lightly strum the belt with finger to induce a vibration.
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 Record the results in Hz or Newton’s

 Repeat 3 times (or more if necessary) to verify consistent readings
9.2.6.2.4 In A Noise Filled Environment – Inductive Sensor

CAUTION: REMOVE THE TAPE AND MAGNET FROM BELT BEFORE PROCEEDING.
9.2.6.2.5 Tape the Small Magnet in the mid-span of the belt; push the measure button
on the meter. Hold the inductive sensor approximately 1 cm (0.4 in) above
the magnet
9.2.6.2.6 Lightly strum the belt with finger to induce a vibration.

 Record the results in Hz or Newton’s (N)
 Repeat 3 times (or more if necessary) to verify consistent readings
9.2.6.3 Rotate compressor by hand through several revolutions and verify belt tracking.
Readjust as required.
9.2.6.4 Secure drive pulley by tightening drive pulley set screws (refer to table 1, section 1.3
for torque specifications).
9.2.6.5 Tighten and secure compressor mounting bolts, washers, and lock nuts (refer to table
1, section 1.3 for torque specifications).
9.2.7 Assembly of Belt Cover
9.2.7.1 Position belt cover on assembly and attach 2 fasteners at lower cover, attach 2
fasteners at upper mid cover just inside belt cover opening. Install 2 mounting bolts
on side of assembly used to secure hour meter bracket and drive motor (refer to
table 1, section 1.3 for torque specifications).
9.2.8 Assembly of Receiver Dryer
9.2.8.1 Position receiver dryer on top of condenser support bracket and attach with mounting
clamps.
a thin layer of thread sealant primer to fitting threads. Apply 1-2 drops of thread
sealant on receiver dryer inlet port threads.
9.2.8.3 Apply thin film of refrigerant oil to all O-rings and install on condenser fitting and
suction fitting.
9.2.8.4 Connect condenser fitting to receiver dryer and tighten (refer to table 1, section 1.3 for
torque specifications).
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Figure 5 Belt Tensioning Reference
Tensioning Information: (Sonic Tension Meter 507C, www.gates.com)
New Belt Used Belt

Min Max Min Max
Belt Frequency: (Hz) 125 141 106 121
Table 4 Gates Sonic Tension Meter Data
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9.2.9 Assembly of Power Relay
9.2.9.1 Carefully slide power relay into position and attach using mounting hardware.
9.2.9.2 Connect electrical connections and install boots for protection.
SUBTASK 21-00-12-40-003
9.3 Evaporator Module Assembly Procedures
9.3.1 Assembly of Expansion Valve

FIRST 2-3 THREADS.
9.3.1.2 Set new valve adjustment screw to same position as failed valve.
9.3.1.3 Apply 1-2 drops of thread sealant to threads of expansion valve and to evaporator
header nut threads.
CAUTION: TAKE EXTREME CARE NOT TO GET REFRIGERANT OIL ON FITTING THREADS.
9.3.1.4 Apply thin film of refrigerant oil to expansion valve flare surface and a very small
amount to the O-rings to prevent damage.
9.3.1.5 Connect expansion valve to coil header fitting. Refer to table 1, Section 1 for torque
specifications.
9.3.1.6 Leak check per Testing and Fault Isolation, Section 3.5 and then evacuate and charge
system per Servicing, Section 13.
9.3.2 Assembly of Blower Motor/ Wheel
9.3.2.1 Position blower wheel on blower motor shaft. Ensure that there is a gap of 0.20”
between motor back plate and blower wheel.
FIRST 2-3 THREADS.
9.3.2.2 Apply a drop of thread sealant to the set screw threads. Tighten set screw (refer to
table 1, Section 1 for torque specifications), insuring that the screw is located on flat
part of motor shaft.
9.3.2.3 Sparingly apply a thin bead of RTV to blower motor mounting plate.
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9.3.2.4 Carefully install blower motor/wheel into blower motor scroll and attach with 4 blower
motor attachment screws. Refer to table 1, Section 1 for torque specifications.
9.3.2.5 Ensure that blower wheel does not hit or rub against blower scroll by rotating wheel by
hand, and verifying sufficient clearance.
9.3.2.6 Connect motor wiring as follows:

Black Ground
Orange +28 VDC, Hi Speed
Red +28 VDC, Low Speed
Table 5 Blower Motor Electrical Connections
9.3.2.7 Run all wires through the wire clamp and secure with mounting screw and washer.
SUBTASK 21-00-12-40-005
9.4 Auto Load Shed Device Assembly Procedures
(refer to Figure 10001 for PN):
9.4.1 Assembly of Auto Load Shed Device
9.4.1.1 Install 4 attaching screws. Refer to Table 1, Section 1.3 for torque specifications.
9.4.1.2 Connect electrical wiring.
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SPECIAL TOOLS, FIXTURES, AND EQUIPMENT
TASK 21-00-12-99F-803
10.0 SPECIAL TOOLS/EQUIPMENT
SUBTASK 21-00-12-99F-014
10.1 General:
10.1.1 This section describes the necessary tools and test equipment required to perform
maintenance, functional testing, troubleshooting, and repair procedures. Equivalent test
equipment may be substituted only if it meets the listed equipment specifications.
 Regulated Shop Air 40 PSIG
 Fin comb SK1250101-13
 Miscellaneous hand tools and socket set
 Shop vacuum with soft utility brush
 Gates Sonic Tension Meter 507C (www.gates.com)
 Vacuum pump, air or electric 0-30 in.hg.
 Gaseous dry Nitrogen, regulated source 0-500 PSIG
 Reclaim/Recycle Cart (R-134A) (Robinair model # 342000) (preferred) or R-134A refrigerant
charging manifold with gauges and hoses.
 Hose adapter 1/2 in. male ACME to 1/4 in. female flare
 Leak check fluid soap solution
 External or aircraft power source 200 amp.
 Thermometer 0-150°F
 Flashlight or service lamp
 Kent-More Flush Adapter J42939
 Small “rare earth” magnet
 Tape
 Straight Edge
 Measuring Device
 Micrometer
 Scribe or Wire Hook
 Volt-OHM Meter
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ILLUSTRATED PARTS LIST
TASK 21-00-12-98-801
11.0 R-134A AIR CONDITIONING SYSTEM COMPONENT ILLUSTRATED PARTS LISTING
SUBTASK 21-00-12-99F-015
11.1 Introduction:
11.1.1 This Illustrated Parts Listing (IPL) is intended for use during testing and isolation,
disassembly, cleaning, check (inspection), repair, assembly, and issuing the replaceable
equipment components as well as in identification of new and reclaimed parts.
11.1.2 This IPL includes illustrations of the Compressor Condenser Module and Evaporator
Module Assembly to be used during the procedures outlined previously.
11.1.3 This IPL includes figure and item numbers to call out specific components. Each
component will be assigned an item number. Items listed but not shown are identified by a
dash preceding the item number. The figure refers to the exploded view of the equipment.
11.1.4 This IPL includes a part number for each component called out in the illustration that is a
field replaceable component.
11.1.5 This IPL includes nomenclature for each component that helps with identification.
11.1.6 This IPL includes units per assembly for each component called out in the illustration that is
a field replaceable component.
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Figure 10001 Compressor Condenser Module Assembly 1134400-1
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Figure 10001
Page 10002
July 15, 2014
FIG. ITEM PART NUMBER NOMENCLATURE UNITS ASSY.

10001-10 1134104-5 DC MOTOR 1
10A 1250128 POWER RELAY 1
11A ¼-28X1H BOLT 1
12A 21FK-428 LOCK NUT 2
13A NAS1149F0463P FLAT WASHER (AN960-416) 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 MS35333-41 LOCK WASHER 8
-12 5/16-24X3/4 H HEX BOLT 8
20B 1250146-7 DRIVE PULLEY 1
-30 1134170 MOTOR FAN 1
-31 NAS1149F0463P FLAT WASHER (AN960-616) 1
-32 21FK-624 LOCK NUT 1
40A 1134160 COMPRESSOR ASSEMBLY 1
-41 M10X1.25X25MM HEX BOLT 3
-42 10MM FLAT WASHER 3
45A AS568-013HNBR-70 O-RING 1
50A 1134140-1 RECEIVER DRYER 1
50A 1134140-7 RECEIVER DRYER (SUPERSEDES 1134140-1) 1
-51 QS100M36S RECEIVER DRYER CLAMP 2
55A AS568-011HNBR-70 O-RING 1
70A CONDENSER COIL NP
80B 1134199 BELT COVER 1
-81 MS35265-26 SCREW 4
-82 NAS1149F0463P FLAT WASHER (AN960-6) 4
90B 232L100 DRIVE BELT 1
100A 1134109 FAN SHROUD 1
-101 NAS1149F0463P FLAT WASHER (AN960-10L) 8
-102 MS20364-1032A LOCK NUT 8
-103 10-32UNFX3/8 SCREW 8
120A 1134110 OUTLET SHROUD 1
MOTOR BRUSH/ SHUNT (CONTAINS 4 BRUSH
-130 1251171 1
PAIRS)
-140 1240100 AUTO LOAD SHED DEVICE 1
Figure 10001 Compressor Condenser Module Assembly Details
- ITEMS NOT ILLUSTRATED N/P ITEMS NOT PROCURABLE
EFFECTIVITY: ALL
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Figure 10001
Page 10003
July 15, 2014
Figure 10002 Evaporator Module Assembly 1134310-5
EFFECTIVITY: ALL
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Figure 10002
Page 10004
July 15, 2014
FIG. ITEM PART NUMBER NOMENCLATURE UNITS ASSY.

10002-10A 1133210-20 BRUSHLESS DC MOTOR 1
20A 1250219-5 BLOWER WHEEL 1
30A BLOWER SCROLL N/P
40B SHROUD ASSEMBLY N/P
50B ESCUTCHEON N/P
60B 1134218 EXPANSION VALVE 1
110A 8-32x5/8IHS SCREW 3
120A NAS1149F0463P FLAT WASHER (AN960-8) 4
130A CLN3/16 CLAMP 1
140B BLOWER MOUNTING BRACKET 1
150A 8-32X3/4IHW SCREW 1
Figure 10002 Evaporator Module Assembly Details
- ITEMS NOT ILLUSTRATED

N/P ITEMS NOT PROCURABLE
EFFECTIVITY: ALL
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Figure 10002
Page 10005
July 15, 2014
SPECIAL PROCEDURES
TASK 21-00-12-82-801
12.0 SPECIAL PRODECURES
SUBTASK 21-00-12-82-001
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 6.

 Micrometer
 Volt-OHM meter (digital)
 Respiration mask
 External aircraft power source
 Thermometer, 0-150° F
 Flashlight or service lamp
 R-134A service manifold and gauge set
12.1.3 Verify that system leak check and refrigerant charging has been performed and system is
operating at typical values as outlined in table 6.
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
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12.1.4 Gain access to the Evaporator Coil Assembly (refer to the aircraft maintenance manual for
removal of access panels and other hardware that might need to be removed)
12.1.5 Remove all shrouds, covers or enclosures which prevent access to the evaporator
expansion valve adjustment knob.
12.1.6 Remove expansion valve protective cap.
12.1.7 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.
12.1.8 Verify the blower speed switch is in the high position.
12.1.9 Verify R-134A manifold gauges and hoses are connected to the compressor service valves
and system is operating normally.
12.1.10 Close cabin and cargo doors and allow system to operate for 5 minutes.
12.1.11 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.
12.1.12 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.
12.1.13 If suction pressure is lower than typical values outlined Table 6, the expansion valve must
be turned CW in accordance with the same procedure discussed in previous paragraph.
12.1.14 Allow system to operate for 5-10 minutes after expansion valve adjustment to verify setting.
SUBTASK 21-00-12-82-002
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.
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July 15, 2014
12.2.5 Allow system to stabilize, recheck the evaporator outlet temperatures and repeat adjustment
procedure if required. Evaporator outlet temperatures should be within 1-3° of each other.
NOTE: Proper evaporator balancing should not result in a change of the compressor suction pressure. Verify
system pressures are typical values as shown in table 5.
12.2.6 If the evaporator’s outlet temperature is equal and the suction pressure is typical, then
servicing is complete. Shut system off and replace all shrouds, enclosures, ducting, as
required and remove charging/measurement equipment. If not, repeat adjustment
procedure until temperatures are equal and suction pressure is typical.
SUBTASK 21-00-12-82-003
12.3 Motor Insulation Resistance Check:
12.3.1 After the inspection of the commutator, a quick check of the motor insulation resistance
should be performed. This check may be done with or without the brushes installed, but the
power leads must be removed from the motor during this procedure.
12.3.2 Gain access to the Compressor Condenser Module (refer to the aircraft maintenance
manual for removal of access panels and other hardware that might need to be removed)
12.3.4 With OHM meter positive lead connected to the motor positive terminal and the other lead
connected to motor case (grnd), measure and record resistance. Resistance value must be
equal to or greater than 10,000 OHM’s. If less, the motor should be replaced.
SUBTASK 21-00-12-20-001
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.
12.4.4 Remove brush cover (on some systems, removal of power leads is required prior to brush
cover removal, tag positive terminal).
12.4.5 Remove brushes from guides and remove belt from motor pulley (refer to Disassembly,
Section 5).
12.4.6 Rotate motor shaft by hand to ensure freedom of movement. Visually inspect bearing for
sign of overheating or loss of lubrication using an inspection mirror.
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CAUTION: CAREFULLY LAY BRUSH SHUNT LEADS IN A POSITION WHICH WILL PREVENT ANY
POSSIBLE SHORTING PROBLEMS. LEADS MUST EASILY FOLLOW BRUSH AND SPRING MOVEMENT
AS WEAR OCCURS. IMPROPER LEAD PLACEMENT MAY RESULT IN MOTOR DAMAGE.
12.4.7 If bearings rotate smoothly and are good, reinstall belt and brushes (refer to Assembly,
Section 9). Check belt alignment and tensioning (refer to Assembly, Section 9).
SUBTASK 21-00-12-20-002
12.5 Compressor Bearing Inspection:
12.5.1 Compressor bearing will be inspected according to Section 7 Inspection Schedule Table 3.5
to ensure that premature seizure does not occur.
manual for removal of access panels and other hardware that might need to be removed).
12.5.4 Rotate compressor pulley by hand to ensure freedom of movement and to ensure that the
pulley is not showing signs of loosening. Visually inspect bearing for sign of overheating or
loss of lubrication using an inspection mirror.
12.5.5 If bearings rotate smoothly and are in otherwise good condition, perform belt alignment and
tensioning (refer to Assembly, Section 9).
SUBTASK 21-00-12-82-004
12.6 Motor Brush Seating Procedure:
12.6.1 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.
12.6.2 Remove grit paper and blow out all the carbon dust and other contamination from
commutator and brush area.
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July 15, 2014
12.6.3
SUBTASK 21-00-12-20-003
12.7 Compressor Oil Level Check:
NOTE: Checking compressor oil quantity is only required if an excessive amount of oil is observed due to
leaking or the system has been vented quickly thereby causing a loss of oil. An oil check can only be made
with the system vented.
12.7.1 When replacing the compressor, use the following procedure to add required oil to system.
12.7.2 Drain and measure oil from new compressor (3 oz).
12.7.3 Drain and measure oil from failed compressor. Record quantity in ounces.
CAUTION: DO NOT OVERFILL COMPRESSOR WITH OIL OR SYSTEM PERFORMANCE WILL BE
AFFECTED.
12.7.4 Add new oil to the new compressor in the amount measured from the failed compressor.
Contact Enviro Systems for proper oil.
EFFECTIVITY: ALL
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July 15, 2014
SERVICING
TASK 21-00-12-60-801
13.0 R-134A AIR CONDITIONING SYSTEM SERVICING PROCEDURES
SUBTASK 21-00-12-99F-016
13.1 General:
13.1.1 Reclaiming the system (R-134A) refrigerant charge is required on systems before system
removal, after an accidental line break, component failure or when the system has
excessive leaks. Due to the chemical nature of the refrigerant, every precaution must be
taken to protect the service person from accidental exposure to the refrigerant. Follow all
service precautions previously outlined.
WARNING: DUE TO THE EVER INCREASING NUMBER OF ALTERNATE REFRIGERANTS BEING
INTRODUCED ON THE MARKET, EXTREME CARE MUST BE TAKEN TO PREVENT THEIR USE IN THIS
SYSTEM. ONLY R-134A REFREFRIGERANT IS APPROVED FOR USE IN THIS AIR CONDITIONING
SYSTEM. ANY OTHER REFRIGERANT COULD CREATE A HAZARD TO BOTH THE AIRCRAFT AND
SERVICE PERSONNEL.

 Vacuum pump, air or electric (0-30 in.h.g.)
 Refrigerant, R-134A
 R-134A charging manifold with gauges and hoses
 Thermometer, 0-150° F
 Adjustable inspection mirror
 Service light or flash light
 Shop towels
 RL100S Emkarate Ester refrigerant oil
 External or aircraft power source, 200 AMPS.
 Reclaim/ Recycle Cart (R-134A)
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 Hose adapter (1/2 in, male acme to ¼ female flare)
SUBTASK 21-00-12-60-001
13.2 Evacuating The System (R-134A):
NOTE: The system must be evacuated for a minimum of 45 minutes to remove air and moisture which can
cause the system to have less than optimal performance.
13.2.3 If required perform leak check procedure.
13.2.4 Connect certified reclaim charging and recycle cart manifolds to system service ports.
13.2.5 Open both valves and reclaim and recycle the systems refrigerant charge (refer to the
reclaim equipment manufacturer’s instruction manual for recovery unit handling and
operation).Once the refrigerant is reclaimed and recycled apply vacuum on the system for
approximately 30 minutes. System vacuum should attain 25-27 in. hg. in 10 to 15 minutes.
Allow pump to hold a vacuum (29 to 30 in. hg.) for 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 21-00-12-60-002
13.3 Charging The System (R-134A):
WARNING: SYSTEM DAMAGE CAN OCCUR FROM OVERCHARGING OR UNDERCHARGING THE

SYSTEM TO THE SPECIFIED AMOUNT OF REFRIGERANT.
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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 7.
Aircraft Model Refrigerant Charge (lbs.)

Hawker Beechcraft 400A 3.3-3.5 lbs
Table 7 Refrigerant Charge
SUBTASK 21-00-12-60-003
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.
EFFECTIVITY: ALL
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July 15, 2014
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.
13.4.8 Apply power to recovery unit and run for a minimum of 15 minutes.
13.4.9 Check for leaks during flushing process. If leaks are detected, stop machine and repair
leaks before continuing.
13.4.10 Confirm that recovery unit shuts down at the end of the selected recovery time.
13.4.11 Turn power off at the recovery unit and remove from the aircraft.
CAUTION: ALWAYS USE PROTECTIVE COVERINGS AND/OR PROTECTIVE CAPS ON OPEN OR
EXPOSED HOSES, PLUMBING, ETC. THIS WILL ENSURE THAT THE COMPONENT STAYS FREE DIRT,
DUST, OR ANY OTHER FOREIGN MATTER.
13.4.12 Reconnect the lines to the compressor (refer to Assembly, Section 9)
13.4.13 Remove fittings and hoses and re-install the expansion valve (refer to Assembly, Section 9)
13.4.14 Remove jumper hoses from receiver dryer ports and install a new receiver dryer (refer to
Assembly, Section 9)
13.4.15 Perform a system leak check (refer to Test and Fault Isolation, Section 3, System Leak
Check, Section 3.3)
13.4.16 Perform system refrigerant charge (refer to Servicing, Section 13)
13.4.17 Verify system performance (refer to Test and Fault Isolation, Section 3.1)
EFFECTIVITY: ALL
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July 15, 2014
12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
STORAGE
TASK 21-00-12-55-801
14.0 COMPRESSOR CONDENSER MODULE ASSEMBLY STORAGE PROCEDURES
SUBTASK 21-00-12-99F-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 21-00-12-55-001
14.2 System Long Term Shelf Storage:
14.2.1 If unit will be stored for periods in excess of 12 months, the following preventive
maintenance should be followed for the compressor. These procedures should be
performed at 12 months from MFG date on unit and every 6 months thereafter for a
maximum of 36 months.
NOTE: When installing unit with MFG date in excess of 12 months prior to installation date, verify record of
preventive maintenance. If no maintenance record exists, contact Enviro Systems Inc. prior to installation.
14.2.2 For internal pressures within a range of 5-15 PSIG, rotate compressor by hand through a
minimum of 10 revolutions.
14.2.3 For internal pressures below 5 PSIG, system should be pressurized to 15 PSIG using
regulated dry Nitrogen. After pressurizing the system, rotate the compressor by hand
through a minimum of 10 revolutions.
14.2.4 If the system does not have any detectable pressure, the compressor oil must be checked
for contamination using the following procedures:
14.2.4.1 Remove compressor oil plug and insert a clean tie strap into oil fill hole. Remove the
strap to inspect the oil. Oil should have a clear to amber color. If oil shows specs of
black or other contamination, compressor oil should be drained and replaced.
EFFECTIVITY: ALL
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12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
14.2.4.2 Drain old oil into measuring cup to verify amount of oil being replaced.
CAUTION: ONLY AN ENVIRO APPROVED TYPE OF OIL MAY BE USED IN THIS TYPE OF
COMPRESSOR.
CAUTION: DO NOT OVERFILL COMPRESSOR WITH OIL OR SYSTEM PERFORMANCE WILL BE
AFFECTED.
14.2.4.3 Measure an equal amount of new oil and add to compressor. Install oil plug and
tighten.
14.2.4.4 Check system pressure per section 14.2. System is now ready for storage.
21-00-12-55-003
14.3 System Off Season Functional Tests:
NOTE: If ambient temperature is below 50° F (10°C), the pressure switch is designed to keep the system
from operating and causing possible damage if operated for extended periods of time. In this case, it is
recommended that the aircraft be heated above this threshold to enable the system to operate.
CAUTION: OPERATION OF THE SYSTEM AT LOW AMBIENT TEMPERATURES FOR MORE THAN 15
MINUTES CAN RESULT IN MAJOR DAMAGE OF THE R-134A COMPRESSOR.
14.3.1 During cold winter months, the system should be operated for 10-15 minutes every two
weeks to maintain a thin oil film on the compressor output shaft dynamic seal to prevent
shaft leakage.
14.3.2 Prior to turning on the air conditioning system (energizing the compressor drive), run
blowers on high speed for a minimum of 5 minutes. This will aid in warming the refrigerant
and bringing it up to an acceptable temperature enabling operation of the system.
EFFECTIVITY: ALL
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R-134a AIR COND SYSTEM

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R-134a AIR COND SYSTEM

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12037 N Highway 99

OPERATING, SERVICING, AND COMPONENT

WITH ILLUSTRATED PARTS LIST

HAWKER BEECHCRAFT 400A

R-134a AIR CONDITIONING SYSTEM COMPONENTS:

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

2) EVAPORATOR MODULE ASSEMBLY, PART # 1134310-5

3) AUTO LOAD SHED MODULE, PART # 1240100

ATA SPECIFICATION 21-00-12

COPYRIGHT  2007 ORIGINAL ISSUE

REV DESCRIPTION OF CHANGE DATE APPROVAL

RECORD OF TEMPORARY REVISIONS

REV DESCRIPTION OF CHANGE DATE APPROVAL

LIST OF SERVICE BULLETINS

SERVICE DESCRIPTION DATE

LIST OF EFFECTIVE PAGES

CHAPTER / SECTION PAGE DATE CHAPTER / SECTION PAGE DATE

RECORD OF REVISIONS ................................................................................................................................... 1

REPAIRS ....................................................................................................................................................... 6001

Figure 1 R-134A Refrigerant Flow Schematic ........................................................................................... 2001

Table 1 Standard Torque Values .................................................................................................................... 10

Table 2 Consumable Products

DESCRIPTION AND OPERATION

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

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

TESTING AND FAULT ISOLATION

3.4.3 Special Tools and/or Equipment Required:

3.4.3.3 Verify all plumbing connections are tight.

3.4.3.8 Connect yellow charging hose to a regulated dry nitrogen source

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

3.4.3.17 Close manifold valve.

INDICATION PROBABLE CAUSE POSSIBLE SOLUTION

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

Table 3 Trouble Shooting List

INDICATION PROBABLE CAUSE POSSIBLE SOLUTION

D. Evaporator Noisy 1. Blower wheel out of round 1. Replace

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

F. No low evap. Fan speed 1. Failed switch 1. Replace

Table 3 Trouble Shooting List

INDICATION PROBABLE CAUSE POSSIBLE SOLUTION

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

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

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

Table 3 Trouble Shooting List

SCHEMATIC AND WIRING DIAGRAMS

Figure 1 R-134A Refrigerant Flow Schematic

Figure 2 Electrical Schematic

Figure 3 1134400-1 Compressor Condenser Schematic

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

5.1.7 Tools, fixtures, equipment, or consumable items required:

5.2.1 Removal of Receiver Dryer

5.2.2 Removal of Belt Cover

5.2.2.3 Carefully slide belt cover from assembly.

5.2.3 Removal of Drive Belt and Pulley

5.2.3.1 Remove belt cover per 5.2.2.

5.2.3.2 Slightly loosen the bottom compressor mounting bolts.

5.2.4 Removal of Compressor Assembly

5.2.4.3 Remove compressor mounting bolts and washers.

5.2.4.4 Carefully lift compressor from mounting bracket.

5.2.5 Removal of Drive Motor

5.2.5.2 Remove receiver dryer per 5.2.1.

5.2.5.4 Disconnect power cables and tag.

5.2.5.5 Remove all cable ties used to secure wiring to motor.

5.2.5.6 Remove motor mounting bolts from motor support bracket.