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RJ150-30 / Operations and Maintenance Manual
Mobile Aircraft Air Conditioner
Trailer Mounted, Cool Mode Only

______________________________________________________________________________
SECTION 4 - 1

JANUARY 20, 2004

PAGE 2

The List of Vendors in Table 1 below identifies the vendor sources by Commercial
and Government Entity (CAGE) Code (if applicable) or Trilectron Industries, Inc.
vendor code, name, and address.

Table 1. CAGE/Vendor Code and Addresses

CAGE /

Vendor #

Vendor Name and Address

00705

MARATHON ELECTRIC MFG. CO., P.O. Box 8003, Wausau, WI. 34402

04034

IMO INDUSTRIES INC. (GEMS), 1 Cowles Rd., Plainville, CT 06062-1107

0BG11

NATIONAL BATTERY CORP., 152-18 Union turnpike, Flushing, NY 11367

0BWU9

PROCESS DEVELOPMENT & CONTROL, P.O. Box 51, Imperial, PA 15126

0J639

R&R SUPPLY, 613 Triumph Ct. Suite 1, Orlando, FL 32815

0RR12

RUBBER & ACCESSORIES INC., 2120 Edgewood Dr. South, Lakeland, FL 33803

0SMN2

J AND B AVIATION SERVICES, INC., 2860 Cordelia Rd., Suite 170, P.O. Box 27, Fairfield, CA
94533-0727

0TW02

NELSON IND. INC., (UNIVERSAL SILENCER), Hwy 51/138W, Stoughton, WI 53589

0W357

PDI GROUND SUPPORT SYSTEMS, INC., 5905 Grant Ave., Cleveland, OH 44105

12867

TRILECTRON INDUSTRIES, INC., 12297 U.S. Hwy 41 North, Palmetto, FL 34221-2504

15912

THOMAS & BETTS CORP., Electronics Group, 76 Fairbanks, Irvine, CA 92718

16476

DATCON INSTRUMENTS CO., P.O. Box 128, East Petersburgh, PA 17520-0128

23826

FURNAS ELEC. CO., 1004 McKee St., Batavia, IL 60510

25795

GRAINGER, INC., W.W., 6685 Whitfield Ind. Ave., Sarasota, FL 34243

44512

SUPER RADIATOR COILS, 451 Southlake Blvd, P.O. Box 35687, Richmond, VA 23235

4F532

STROMQUIST CO., P.O. Box 180219, Atlanta, GA 30318

4G366

CUMMINS SOUTHEASTERN POWER INC., 5910 E. Hillsborough Ave., Tampa, FL 33610

50831

JOHNSON CONTROLS INC., P.O. Box 423, Milwaukee, WI 53201

5W026

AERO HARDWARE AND SUPPLY CO., 7200 E. Buffalo Ave., Tampa, FL 33619-1130

60532

TRANE CO., P.O. Box 955, Lacrosse, WI 54601

63988

CROWLEY CO., P.O. Box 281, Newbury, OH 44065

67575

PERKINS ENGINES LTD., Peterborough PE1 5NA, England

6V625

NAPA AUTOMOTIVE PARTS CO., 3389 E. Main St., Columbus, OH 43213-2744

77342

POTTER & BRUMFIELD INC., 200 S. Richland Creek Rd., Princeton, IN 47671-0001

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Summary of Contents for TRILECTRON AIR-A-PLANE RJ150-30

Page 1: ...CHNICAL MANUAL OPERATION AND MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN MANUAL RJ150 30 JANUARY 20 2004 MOBILE AIRCRAFT AIR CONDITIONER UNIT MODEL RJ150 30 Trailer Mounted Cool Mode Onl...

Page 2: ...are known to the State of California to cause cancer birth defects and other reproductive harm NOTE In accordance with the Montreal Protocol on Substances That Deplete the Ozone Layer venting refriger...

Page 3: ...Industries Inc Palmetto Florida Please log changes revisions to your manuals as they are inserted indicating the date of the change revision and the date inserted in the manual If any changes revisio...

Page 4: ...nance Manual Mobile Aircraft Air Conditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________ RECORD OF CHANGES JANUARY 20 2004 PAGE 2 This...

Page 5: ...4 1 1 19 Jan 20 2004 1 1 20 Jan 20 2004 1 1 21 Jan 20 2004 1 1 22 Jan 20 2004 Section 1 2 1 2 1 Jan 20 2004 1 2 2 Jan 20 2004 1 2 3 Jan 20 2004 1 2 4 Jan 20 2004 1 2 5 Jan 20 2004 1 2 6 Jan 20 2004 1...

Page 6: ...Page Date 2 5 1 Jan 20 2004 2 5 2 Jan 20 2004 Section 3 1 3 1 1 Jan 20 2004 3 1 2 Jan 20 2004 Section 4 1 4 1 1 Jan 20 2004 4 1 2 Jan 20 2004 4 1 3 Jan 20 2004 4 1 4 Jan 20 2004 Section 4 2 4 2 1 Jan...

Page 7: ...ries Inc Specific equipment nomenclature is normally presented in bold print for emphasis Placarded text is normally presented in BOLD CAPS Electrical components are normally listed by their noun foll...

Page 8: ...n for unit and component overhaul repair and field adjustments Sections may be included as required for major systems subsystems Chapter 4 Illustrated Parts List Section 4 1 Vendor List Provides list...

Page 9: ...nts 5 TRILECTRON warrants any closed refrigerant system to be leak free at the time of shipment from the factory TRILECTRON extends no warranty with respect to the loss of refrigerant gases or oils 6...

Page 10: ...______________________________________________________________________________ INTRODUCTION JANUARY 20 2004 PAGE 4 Warranty Inquiries Customer Services Department In the USA Telephone 1 877 874 5622 F...

Page 11: ...ION 1 GENERAL 1 2 MAJOR COMPONENTS 5 A General Description 5 B Chassis 5 C Tow Bar and Running Gear 5 D Engine Generator Set Genset Assembly 5 E Fuel Fill Station Assembly 7 F Low Fuel Detection Shutd...

Page 12: ...ditioned Air PCA Duct 6 D Engine Start Procedure 6 E Air Conditioner Operations 6 F Normal Genset Shutdown 7 3 EMERGENCY PROCEDURES 8 A Genset Shutdown 8 SECTION 3 SPECIFICATIONS 1 GENERAL 1 2 VEHICLE...

Page 13: ...Access 9 C Compressors 14 D Refrigerant 16 E Checking Refrigerant Charge 16 F Charging Refrigerant 17 G Refrigerant Leak Testing 18 H Refrigerant Leak Repair 19 I Refrigerant System Evacuation 19 J Pr...

Page 14: ...TROL SWITCH 8 A Hot Gas Bypass Valve 8 B Thermostatic Expansion Valve 8 SECTION 5 CLEANING AND PAINTING 1 CLEANING 1 2 PAINTING 1 CHAPTER 3 OVERHAUL MAJOR REPAIR 1 GENERAL 1 CHAPTER 4 ILLUSTRATED PART...

Page 15: ...Figure 4 Fuel Fill Station 6 Figure 5 Low Fuel Circuit Junction Box 8 Figure 6 Refrigeration System Schematic 11 Figure 7 Electrical Controls Box 12 Figure 8 Operator Control Station 15 Figure 9 Refri...

Page 16: ...ower Assembly Mounts 8 Figure 6 Condenser Fan 9 Figure 7 Radiator Drain Access 10 Figure 8 Radiator Hoses Connections 11 Figure 9 Radiator Condenser Side Support Gussets 12 SECTION 4 ADJUSTMENT AND TE...

Page 17: ...el engine generator set which powers a nominal 15 ton 180 000 British Thermal Units per hour BTU Hr refrigeration system Refer to Section 1 3 for unit specifications This manual provides the basic uni...

Page 18: ...__________ SECTION 1 1 JANUARY 20 2004 PAGE 2 Left Side View Right Side View Figure 1 RJ150 30 Mobile Aircraft Air Conditioner Unit Typical Sheet 1 of 3 Blower Inlet Air Filter Condenser Radiator Fan...

Page 19: ...____________________________________________________ JANUARY 20 2004 SECTION 1 1 PAGE 3 Forward View Aft View Figure 1 RJ150 30 Mobile Aircraft Air Conditioner Typical Sheet 2 of 3 Operator Control St...

Page 20: ...____________________________________ SECTION 1 1 JANUARY 20 2004 PAGE 4 Figure 1 RJ150 30 Mobile Aircraft Air Conditioner Unit Sheet 3 of 3 Generator Typical Dual Compressor Set Radiator Condenser Coi...

Page 21: ...air access Pre conditioned air PCA hose storage tray is mounted on the rear of the unit See Figure 1 C Tow Bar and Running Gear The unit includes forward trunnion mounted dual wheel set a fixed rear a...

Page 22: ...ECTION 1 1 JANUARY 20 2004 PAGE 6 Figure 2 Genset Major Components Typical Refer to Genset Supplemental Technical Manuals Diesel Engine Typical Generator EMERGENCY STOP Switch Red Some Units Digital G...

Page 23: ...Protecto Seal cap and removable strainer inside the filler neck Refer to Section 2 1 Servicing for periodic maintenance to clean the strainer and for fuel servicing An electrically operated fuel gauge...

Page 24: ...Fuel Level Switch FLS the control relay CR5 energizes a warning beacon DS2 BLUE mounted on the unit top canopy Upon detecting Shut Down Level low fuel condition the Fuel Level Switch FLS energizes co...

Page 25: ...components require the genset as a power source Unit PCA functions are selected at the Operator Control Station See Figure 9 2 Air Conditioner Refrigeration Assembly Dual 7 5 ton Compressors The air...

Page 26: ...tenance Manual Mobile Aircraft Air Conditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________ SECTION 1 1 JANUARY 20 2004 PAGE 10 This pa...

Page 27: ...tioner Trailer Mounted Cool Mode Only _________________________________________________________________________________________________________________________________________________________ JANUARY...

Page 28: ...Conditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________________________________________________________________________________ SECTIO...

Page 29: ...ip indication providing 480VAC 3 phase to condenser fan motor contactor MC3 Normal trip setting 10 A 3A Condenser Fan Motor Contactor MC3 Provides 3 phase power to condenser fan motor M3 This 24VAC co...

Page 30: ...onfigured for use provides generator output surveillance for voltage and phase loss Integral contact s close when acceptable voltage and phase rotation are established 14 Fuse FU3 Over load protection...

Page 31: ...erator Control Station Table 2 Operator Control Station Controls and Indicators Figure 8 Item No Description Function 1 OFF GEN ON FAN ON selector switch SW1 When set to GEN ON energizes start signal...

Page 32: ...ted by the compressor set and is controlled by the expansion valve The ambient air temperature setpoint is factory set to 50 F 10 C The ambient air temperature sensor RTD2 continuously signals the Coo...

Page 33: ...__________________________________________________ JANUARY 20 2004 SECTION 1 1 PAGE 17 Figure 9 Refrigeration System Major Components Sheet 1 of 2 High Pressure Switch Red Reset Button Low Pressure Sw...

Page 34: ..._______ SECTION 1 1 JANUARY 20 2004 PAGE 18 Figure 9 Refrigeration System Major Components Sheet 2 of 2 Air Flow Pressure Port Air Flow Switch Damper Valve Assembly Sight Glass High Pressure Fill Test...

Page 35: ...ature of the refrigerant leaving the evaporator The expansion valve is located adjacent to the evaporator coil See Figure 9 6 Evaporator Coil The refrigerant liquid in the low pressure refrigerant cir...

Page 36: ...h HPS1 by pressing the reset push button on the switch Refer to Section 2 2 Troubleshooting See Figure 9 2 Refrigerant Low Pressure Switch LPS1 The Low Pressure Switch LPS1 will shutdown the compresso...

Page 37: ...s factory set to 70 open 100 fully open This setting may be adjusted as required by local environmental conditions by setting the cooling damper control potentiometer P1 to the desired setting See Fig...

Page 38: ...relay output and light emitting diode LED ON indicator Temperature setpoint may be manually set from 30 to 130 F 34 to 54 4 C and controls the minimum ambient air temperature at which the air conditio...

Page 39: ...ARDOUS NOISE MAY RESULT IN PERMANENT HEARING LOSS EAR PROTECTION DEVICES MUST BE USED WHEN WORKING WITHIN CLOSE PROXIMITY OF THIS EQUIPMENT WHILE ENGINE GENERATOR IS OPERATING 2 NORMAL OPERATING PROCE...

Page 40: ...2 Canopy Enclosure Visually inspect for obvious defects or damage Ensure all access doors panels are secured Ensure condenser radiator grille and blower inlet filter are clear of any obstructions or...

Page 41: ...rol Panel a On front of Genset Control Panel ensure genset TEST OFF AUTO toggle switch is set to AUTO Units with analog control panel b Verify EMERGENCY STOP red mushroom switch optional on some units...

Page 42: ...le Ensure engine air filter intake is unobstructed Refer to Section 2 1 Servicing and to Supplemental Technical Manuals as required 8 Fluid Levels WARNING NEVER SMOKE OR ALLOW AN OPEN FLAME WITHIN THE...

Page 43: ...and observe fuel gauge d Release FUEL LEVEL switch e Service with approved fuel as required Refer to Section 2 1 Servicing Figure 3 Fuel Level Gauge Typical B Position the Unit for Aircraft Servicing...

Page 44: ...DEQUATE SUPPLY OF AIR FLOW TO THE AIRCRAFT 1 Remove PCA duct and service coupling from stowage location 2 Attach the service coupling to the aircraft receiver 3 Ensure all couplings clamps and connect...

Page 45: ...nly On Operator Control Station set OFF GEN ON FAN ON selector switch to GEN ON Blower will stop but engine will continue to operate 6 To stop all genset functions On Operator Control Station set OFF...

Page 46: ...mushroom push button If equipped See Figure 4 Genset engine will immediately stop and bypass normal cool down period 2 On Genset Control Panel set TEST OFF AUTO switch to OFF if equipped See Figure 4...

Page 47: ...ight 76 5 inches 194 cm Weight 4 800 lbs 2 180 kg Operating Temperature 40 F to 125 F 40 C to 52 C Relative humidity 0 100 2 VEHICLE CHASSIS FRAME Painted steel channel sub frame Painted aluminum uppe...

Page 48: ...del serial number and configuration options for major subassemblies Table 1 Unit Configuration Matrix Serial Options Engine Generator Electrical Schematics 2 201047 R134a Refrigerant Kilimanjaro Trail...

Page 49: ...Inspect fuel fill port cap for proper seal and security CAUTION DO NOT ANCHOR THE UNIT BY PASSING BANDS OR CABLES OVER THE SUPERSTRUCTURE SEVERE DAMAGE TO THE UPPER FRAME AND CANOPY PANELS MAY OCCUR U...

Page 50: ...damage 4 Open access doors canopy panels and inspect the unit interior Check fuel system for leakage Check electrical wiring for exposed wiring Check the entire unit for loose connections parts bolts...

Page 51: ...________________________________________________________________ JANUARY 20 2004 SECTION 1 4 PAGE 3 Figure 1 Normalize Control Panels Set to OFF Set to VENT Operator Control Station Analog Genset Cont...

Page 52: ...ntenance Manual Mobile Aircraft Air Conditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________ SECTION 1 4 JANUARY 20 2004 PAGE 4 This pa...

Page 53: ...if the unit is to be placed out of service for three 3 months or less The unit should be prepared for storage as soon as possible after being removed from service 1 Check coolant mixture is adequate...

Page 54: ...lly controlled during cold weather months Moisture absorbing chemicals devices should be placed inside the unit in climates where there is excessive humidity Refer to appropriate Supplemental Technica...

Page 55: ...Engine Generator Set RJ150 CUN 01 Cummins Newage Engine Generator Set RJ150 DZM 01 Deutz Marathon Engine Generator Set RJ150 PKM 01 Perkins Marathon Engine Generator Set WARNING WHENEVER SERVICE OR MA...

Page 56: ...NANCE warning tags on all controls configured in steps 1 through 5 above B Return to Service Perform the following when all unit maintenance servicing is completed 1 Inspect interior of unit and remov...

Page 57: ...Cool Mode Only ______________________________________________________________________________ JANUARY 20 2004 SECTION 2 1 PAGE 3 Figure 1 Operator Controls Sheet 2 of 2 Genset Control Panel Typical G...

Page 58: ...dule Inspection Item Daily 125 HR 250 HR 375 HR 500 HR 625 HR 750 HR Unit Canopy 1 Inspect for signs of physical damage X 2 Inspect doors and hinges for damage Lubricate hinges latches X X X X X X 3 I...

Page 59: ...eaning agent mixed 2 parts cleaner and 1 part water X X X X X X 8 Inspect adapter gasket for signs of wear X X X X X X 9 Inspect compressor oil level in sight glass located on the compressor housing O...

Page 60: ...ntenance Manual Mobile Aircraft Air Conditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________ SECTION 2 1 JANUARY 20 2004 PAGE 6 This pa...

Page 61: ...itioner Trailer Mounted Cool Mode Only _________________________________________________________________________________________________________________________________________________________ JANUARY...

Page 62: ...ile Aircraft Air Conditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________ SECTION 2 1 JANUARY 20 2004 PAGE 8 DO NOT REPRODUCE THIS PAGE...

Page 63: ...tools wrench sets socket sets screwdrivers etc the following special tools may be required Compressor oil pump Refrigerant leak detector Vacuum pump Refer to Tables 3 and 4 Refrigeration ratchet Manif...

Page 64: ...3 Refrigeration System Component Locations Sheet 1 of 4 Evaporator Coil Service Access Door Discharge Air Duct Blower Assembly Sight Glass Hot Gas Bypass Regulator Filter Drier Fuel Fill Cap Rear Moun...

Page 65: ..._ JANUARY 20 2004 SECTION 2 1 PAGE 11 Figure 3 Refrigeration System Component Locations Sheet 2 of 4 Fuel Fill Cap Green Rear mounted on some units Filter Drier Refrigerant Sight Glass Hot Gas Bypass...

Page 66: ...2 1 JANUARY 20 2004 PAGE 12 Figure 3 Refrigeration System Component Locations Sheet 3 of 4 Filter Drier Refrigerant High Pressure Line Shut off Valve Refrigerant Low Pressure Return Line Shown withou...

Page 67: ..._____________________________________ JANUARY 20 2004 SECTION 2 1 PAGE 13 Figure 3 Refrigeration System Component Locations Sheet 4 of 4 Dual Compressor Set Location Some Units CAUTION Hot Surfaces Mo...

Page 68: ...s are shipped with the correct amount and type of oil installed It is not normally necessary to add oil to the compressor before using the equipment for the first time In the event compressor oil is t...

Page 69: ...the filter drier See Figure 3 When suction pressure falls to 25 psig the unit will shut down c Loosely connect the charging tube of the oil pump to the oil charging and drain valve See Figure 4 d Ins...

Page 70: ...ation Matrix to determine the type of refrigeration used in a specific unit If charging unit ensure the proper refrigerant specified for the unit is used E Checking Refrigerant Charge With the unit op...

Page 71: ...t Charge for Model RJ150 Refer to Section 1 3 Units with R 22 or R 407C Refrigerant 30 lbs 13 6 kg Units with R 134a Refrigerant 32 lbs 14 5 kg If the system has lost its charge completely it should b...

Page 72: ...pounds 1 4 kg of refrigerant at a time Stop the charging process and operate the unit in COOL mode Refer to Section 1 2 Observe the refrigerant charge in the sight glass as stated above Repeat the pro...

Page 73: ...cations Refer to Servicing The Filter Drier procedure paragraph 3 L in this Section 4 Repair leak Use standard refrigeration system repair procedures to remove and repair replace the leaking damaged c...

Page 74: ...on the high and low pressure sides of the system respectively 3 With the valves on the manifold gauges closed front seated open the service valves and adjust to a point approximately midway between t...

Page 75: ...lete loss of cooling As the expansion valve warms due to the lack of refrigerant the ice melts and passes through the expansion valve The moisture will then cycle through the system until it again ret...

Page 76: ...n of the system The ideal vacuum pump should evacuate the system to at least 500 microns and must also be capable of holding that vacuum throughout the dehydration process It must pull that vacuum on...

Page 77: ...6 205 5 00 535 000 12 279 194 9 81 425 526 10 162 176 16 02 355 092 6 866 158 20 80 233 680 4 519 140 24 12 149 352 2 888 122 26 36 92 456 1 788 104 27 83 55 118 1 066 86 28 75 31 750 614 80 29 00 25...

Page 78: ...edure paragraph 3 I in this Section The filter drier is not repairable If the system is opened for service or has become contaminated the filter drier must be replaced with a new part 1 Sweat the old...

Page 79: ...AR Periodically inspect the running gear tires for damage wear and proper inflation Follow tire manufacturer s recommend inflation guidelines on tire sidewall Inspect the tow bar arm hinges and brake...

Page 80: ...tenance Manual Mobile Aircraft Air Conditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________ SECTION 2 1 JANUARY 20 2004 PAGE 26 This pa...

Page 81: ...verified identify all components in the circuit whose failure could cause the symptoms observed during the operational checkout The technician should start by checking those items with the highest pro...

Page 82: ...n operational checkout of the unit After the trouble has been verified identify all components in the circuit whose failure could cause the symptoms observed during the operational checkout The techni...

Page 83: ...ng charging and testing equipment such as manifold gauge set Refer to Section 2 1 Servicing See manufacturers manuals for additional tool requirements C Component Failure Stop the engine immediately s...

Page 84: ...e monitor PM1 operation Verify 24 VAC output to controller ETC2 3 Improper cool controller settings or inoperative controller ETC2 a Verify ETC2 settings Set Point 50 F 10 C Differential 1 F 6 C If in...

Page 85: ...capillary tube Replace valve and or power head assembly 3 Clogged filter drier housing feels cool to the touch Replace filter drier Poor or insufficient cooling ambient air above 50 F 10 C 4 Air side...

Page 86: ...e and or power head assembly Suction pressure too low Continued 6 Air side of evaporator coil is dirty Clean coil 1 Improper hot gas regulator valve setting Adjust hot gas regulator valve Refer to Sec...

Page 87: ...ircraft Air Conditioner Trailer Mounted Cool Mode Only ________________________________________________________________________________________________________________________ JANUARY 20 2004 SECTION...

Page 88: ...Conditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________________________________________________________________________________ SECTIO...

Page 89: ...ioner Trailer Mounted Cool Mode Only ________________________________________________________________________________________________________________________ JANUARY 20 2004 SECTION 2 2 PAGE 9 Figure...

Page 90: ...onditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________________________________________________________________________________ SECTION...

Page 91: ...ioner Trailer Mounted Cool Mode Only ________________________________________________________________________________________________________________________ JANUARY 20 2004 SECTION 2 2 PAGE 11 Figure...

Page 92: ...onditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________________________________________________________________________________ SECTION...

Page 93: ...ioner Trailer Mounted Cool Mode Only ________________________________________________________________________________________________________________________ JANUARY 20 2004 SECTION 2 2 PAGE 13 Figure...

Page 94: ...onditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________________________________________________________________________________ SECTION...

Page 95: ...ioner Trailer Mounted Cool Mode Only ________________________________________________________________________________________________________________________ JANUARY 20 2004 SECTION 2 2 PAGE 15 Figure...

Page 96: ...onditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________________________________________________________________________________ SECTION...

Page 97: ...ioner Trailer Mounted Cool Mode Only ________________________________________________________________________________________________________________________ JANUARY 20 2004 SECTION 2 2 PAGE 17 Figure...

Page 98: ...onditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________________________________________________________________________________ SECTION...

Page 99: ...ioner Trailer Mounted Cool Mode Only ________________________________________________________________________________________________________________________ JANUARY 20 2004 SECTION 2 2 PAGE 19 Figure...

Page 100: ...onditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________________________________________________________________________________ SECTION...

Page 101: ...al and installation procedures appropriate for the unit being serviced RJ150 CUM 01 Cummins Marathon Engine Generator Set RJ150 CUN 01 Cummins Newage Engine Generator Set RJ150 DZM 01 Deutz Marathon E...

Page 102: ...30 Mobile Aircraft Air Conditioner Unit Typical Sheet 1 of 5 Blower Inlet Air Filter Condenser Radiator Fan Grille Electrical Controls Box Access Door Fuel Tank Unit Operator Control Station PCA Hose...

Page 103: ..._______________________________________________ JANUARY 20 2004 SECTION 2 3 PAGE 3 Forward View Aft View Figure 1 RJ150 30 Mobile Aircraft Air Conditioner Typical Sheet 2 of 5 Operator Control Station...

Page 104: ...enser Fan Motor Electrical Controls Box Tow Bar Running Gear Damper Control Valve Engine Generator Set Typical Evaporator Coil PCA Hose Stowage Tray Discharge Air Duct Inlet Air Filter Genset Batterie...

Page 105: ..._______________ JANUARY 20 2004 SECTION 2 3 PAGE 5 Figure 1 RJ150 30 Mobile Aircraft Air Conditioner Unit Dual Compressor Configuration Some Units Sheet 4 of 5 Generator Typical Dual Compressor Set So...

Page 106: ...ir Filters The inlet air filters 2 are located behind a retaining grille on the left side of the unit See Figure 2 1 Remove inlet air filter retaining grille by removing retaining screws Lift grille a...

Page 107: ...lower removal and installation will require appropriate hoist devices and roof canopy panel removal 1 Remove roof canopy panel s as required to gain access to blower assembly 2 Electrically disconnect...

Page 108: ...ge loosen retaining clamps 2 from transition collar connecting the blower outlet flange to the evaporator coil See Figure 4 Figure 4 Blower Outlet Transition 6 Remove blower assemble mounting bolts 4...

Page 109: ...ed on a pedestal interior to the condenser coil assembly See Figure 1 Remove top canopy panel above the condenser fan for access 1 Electrically disconnect the condenser fan Tag all connections Refer t...

Page 110: ...t to verify proper operation Refer to Section 1 2 Operating Procedures 4 RADIATOR CONDENSER COIL ASSEMBLY The radiator condenser coil assembly is mounted on the mid right side of the unit Removing thi...

Page 111: ...mpletely evacuate the refrigerant system Refer to Section 2 1 Servicing Sweat apart the refrigerant lines leading to from the condenser coil Remove retaining bolts from radiator condenser assembly sid...

Page 112: ...de Support Gussets Lift radiator condenser core assembly up and away from unit using appropriate lift devices To install radiator reverse the removal process Once installation is complete fill the ent...

Page 113: ...ave been factory set and tested for proper use Field adjustments are not normally required or recommended However local operating conditions and or maintenance repair replace procedures may require th...

Page 114: ..._______________ SECTION 2 4 JANUARY 20 2004 PAGE 2 Left Side View Right Side View Figure 1 Component Locations Sheet 1 of 3 Blower Inlet Air Filter Condenser Radiator Fan Grille Electrical Controls Bo...

Page 115: ...__________________________________________________________________________ JANUARY 20 2004 SECTION 2 4 PAGE 3 Forward View Aft View Figure 1 Component Locations Sheet 2 of 3 Operator Control Station D...

Page 116: ..._________________________________________________ SECTION 2 4 JANUARY 20 2004 PAGE 4 Figure 1 Component Locations Sheet 3 of 3 Generator Typical Dual Compressor Set Radiator Condenser Coil Assembly Bl...

Page 117: ...intenance Manual Mobile Aircraft Air Conditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________ JANUARY 20 2004 SECTION 2 4 PAGE 5 Figure...

Page 118: ...ip indication providing 480VAC 3 phase to condenser fan motor contactor MC3 Normal trip setting 10 A 3A Condenser Fan Motor Contactor MC3 Provides 3 phase power to condenser fan motor M3 This 24VAC co...

Page 119: ...utput surveillance for voltage and phase loss Integral contact s close when acceptable voltage and phase rotation are established 14 Fuse FU3 Over load protection for phase monitor PM1 Rating 10 A 15...

Page 120: ...require adjustment to the proper settings A Hot Gas Bypass Valve See Figure 3 The hot gas bypass valve allows the system to maintain suction pressure at a minimum pressure during light load cool weat...

Page 121: ...he thermostatic expansion valve acts as a pressure reducing valve and is used to meter the high pressure liquid refrigerant into the low pressure evaporator coil Refrigerant flow through this valve is...

Page 122: ...tenance Manual Mobile Aircraft Air Conditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________ SECTION 2 4 JANUARY 20 2004 PAGE 10 This pa...

Page 123: ...ing with clean water A bristle brush never wire or spray gun may be used Unpainted surfaces are cleaned using clean water and brush approved solvents or steam cleaning equipment Degreasers may be used...

Page 124: ...ntenance Manual Mobile Aircraft Air Conditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________ SECTION 2 5 JANUARY 20 2004 PAGE 2 This pa...

Page 125: ...nce with the maintenance overhaul recommendations of the manufacturer or their authorized agents Refer to appropriate Supplemental Technical Manuals as required RJ150 CUM 01 Cummins Marathon Engine Ge...

Page 126: ...ntenance Manual Mobile Aircraft Air Conditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________ SECTION 3 1 JANUARY 20 2004 PAGE 2 This pa...

Page 127: ...a list of all vendors manufacturers used in the assembly of this unit and contains information on ordering spare parts Section 4 2 contains a cross reference of individual part numbers and illustratio...

Page 128: ...x 27 Fairfield CA 94533 0727 0TW02 NELSON IND INC UNIVERSAL SILENCER Hwy 51 138W Stoughton WI 53589 0W357 PDI GROUND SUPPORT SYSTEMS INC 5905 Grant Ave Cleveland OH 44105 12867 TRILECTRON INDUSTRIES I...

Page 129: ...CO 111 Maryland St El Segundo CA 90245 4116 8R544 NEW YORK BLOWER CO P O Box 47518 St Petersburg FL 33743 8X198 DWYER INSTRUMENT 1505 Cobb Industrial Dr Marietta GA 30066 94222 SOUTHCO FASTENERS 210...

Page 130: ...ntenance Manual Mobile Aircraft Air Conditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________ SECTION 4 1 JANUARY 20 2004 PAGE 4 This pa...

Page 131: ...1275G 12T 8 7 16512 3 3 16931 9 2 16933 9 3 1823 40 4 9 18246 5 9 184TTDR7054 5N309 5 3 19721 1 4 20932 3 1 20944 2 1 21696 5 4 21697 5 5 21698 5 2 21907A 5 11A 21907B 5 11B 23094 2 2 23212 1 5 23363...

Page 132: ...3133 10 38 63188 3 2A 63188 4 8A 7650305 8 3 798 5901 7 5 8 5 8ID X 4 L 4 8 850CCA DTA 7 9 1 8530 10 24 9070FP1 10 18 9070TF300D2 10 39 98A535 10 50 A257B 10 49 A310004 1 4 ODS 4 11 A310004 1 4 ODS 6...

Page 133: ...8 GPF1L02AA 10 12 GPF1L25AA 10 13 GPS1BSAK 10 3 GPS1BSAL 10 1 GPS1BSAN 10 2 GU5032 1 28 GU5032 5 8 HTL83 2 12 JB 728 1 15A JZ 0812 30 1 15 KA4C 10 19 L74 75 13 4 17 MB5030 5 3 ME0012 8 6 P100DA 1 5 1...

Page 134: ...ntenance Manual Mobile Aircraft Air Conditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________ SECTION 4 2 JANUARY 20 2004 PAGE 4 This pa...

Page 135: ...s Where appropriate parts or configurations are listed as OPTIONAL If in doubt refer to the unit identification placard and the Unit Configuration Matrix as required in Section 1 3 Specifications The...

Page 136: ...cs Refer to Section 4 1 for vendor code cross references F Quantity Qty This is the quantity per assembly for the individual part listed Some parts are referenced REF to another figure for details 3 T...

Page 137: ...oner Trailer Mounted Cool Mode Only ______________________________________________________________________________ JANUARY 20 2004 SECTION 4 3 PAGE 3 Left Side View Right Side View Figure 1 RJ150 30 C...

Page 138: ...Conditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________ SECTION 4 3 JANUARY 20 2004 PAGE 4 Forward View Aft View Figure 1 RJ150 30 Co...

Page 139: ...ol Mode Only ______________________________________________________________________________ JANUARY 20 2004 SECTION 4 3 PAGE 5 Top View Canopy Removed Single Compressor Configuration Figure 1 RJ150 30...

Page 140: ...railer Mounted Cool Mode Only ______________________________________________________________________________ SECTION 4 3 JANUARY 20 2004 PAGE 6 Top View Canopy Removed Dual Compressor Configuration Fi...

Page 141: ...OR 12867 See Figure 2 REF 1 12 EN5061 ELECTRICAL CONTROLS BOX ASSY RJ150 30 COOL ONLY 12867 See Figure 10 1 1 13 23365 PANEL FRONT ACCESS 12867 See Figure 2 REF 1 14 23364 PANEL DISCHARGE AIR 12867 Se...

Page 142: ...ON 4 3 JANUARY 20 2004 PAGE 8 Figure 1 RJ150 30 Complete Assembly FIG ITEM NO TRILECTRON PART NO VENDOR PART NO AIRLINE PART NO DESCRIPTION VENDOR CODE QTY 1 29A AA5877 COMPRESSOR 7 5 TON SCROLL Units...

Page 143: ...nditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________ JANUARY 20 2004 SECTION 4 3 PAGE 9 Figure 2 Canopy Frame Assembly Typical Sheet...

Page 144: ...oner Trailer Mounted Cool Mode Only ______________________________________________________________________________ SECTION 4 3 JANUARY 20 2004 PAGE 10 Left Side View Right Side View Figure 2 Canopy Fr...

Page 145: ...SEMBLY 12867 1 2 3 23368 MOD PANEL ROOF FORWARD MODIFIED W OPENINGS FOR EXHAUST NOT SHOWN 12867 1 2 4 23367 PANEL MID ROOF 12867 1 2 5 23368 PANEL ROOF REAR 12867 1 2 6 23366 DOOR COMPRESSOR ACCESS 12...

Page 146: ...e Manual Mobile Aircraft Air Conditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________ SECTION 4 3 JANUARY 20 2004 PAGE 12 Figure 3 Air...

Page 147: ...PART NO DESCRIPTION VENDOR CODE QTY 3 AIR INTAKE BLOWER ASSEMBLY See Figure 1 REF 3 1 20932 BLOWER 7 5 HP MOTOR 460 3 60 3600 RPM W STAND 8R544 1 3 2 EB5761 8 5 8ID X 4 L SLEEVING REINFORCED HOSE 8 5...

Page 148: ...itioner Trailer Mounted Cool Mode Only ______________________________________________________________________________ SECTION 4 3 JANUARY 20 2004 PAGE 14 Figure 4 Discharge Air Evaporator Assembly She...

Page 149: ...aft Air Conditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________ JANUARY 20 2004 SECTION 4 3 PAGE 15 Figure 4 Discharge Air Evaporator...

Page 150: ...r Trailer Mounted Cool Mode Only ______________________________________________________________________________ SECTION 4 3 JANUARY 20 2004 PAGE 16 Figure 4 Discharge Air Evaporator Assembly Sheet 3 o...

Page 151: ...0V BELIMO 1 4 6 AA5525 081 072 800 DAMPER 8 BUTTERFLY BELIMO MOUNT 1 4 7 24294 DAMPER PLATE ASSY 12867 1 4 8 EB5761 8 5 8ID X 4 L SLEEVING REINFORCED HOSE 8 5 8ID x 4 L 0RR12 1 4 8A CY5110 63188 CLAMP...

Page 152: ...Trailer Mounted Cool Mode Only ______________________________________________________________________________ SECTION 4 3 JANUARY 20 2004 PAGE 18 Figure 5 Dual Compressors Condenser Radiator Assembli...

Page 153: ...7054 5N309 MOTOR FAN 5HP 1750RPM 230 460V 00705 1 5 4 21696 PLATE ORIFICE CONDENSER FAN 12867 1 5 5 21697 PEDESTAL CONDENSER FAN 12867 1 5 6 24155 BRACKET FAN PEDESTAL 12867 1 5 7 AA5879 CONDENSER RAD...

Page 154: ...anual Mobile Aircraft Air Conditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________ SECTION 4 3 JANUARY 20 2004 PAGE 20 Figure 6 Single...

Page 155: ...E COMPRESSOR ASSEMBLY 12867 See Figure 1 REF 6 1 AA5575 5700 1014 31 00 COMPRESSOR 15TON SCROLL ROTALOCK VALVES 60532 1 6 2 SP5055 P100DA 1 SWITCH HIGH PRESSURE 410 PSI 50831 1 6 3 TQ5157 A310004 1 4...

Page 156: ...nd Maintenance Manual Mobile Aircraft Air Conditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________ SECTION 4 3 JANUARY 20 2004 PAGE 22...

Page 157: ...TA5904 F1 RUNNING GEAR 0W357 See Figure 1 REF 7 1 F2 2006 FRONT AXLE ASSY 0W357 1 7 2 6 2146 REAR AXLE ASSY 0W357 1 7 3 24 3500 DRAWBAR ASSY 0W357 1 7 4 5 8005 PIVOT SUPPORT 0W357 1 7 5 798 5901 HANDB...

Page 158: ...Maintenance Manual Mobile Aircraft Air Conditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________ SECTION 4 3 JANUARY 20 2004 PAGE 24 Fig...

Page 159: ...8 2 05340B FUEL TANK COMPOSIT W CLEANOUT 12867 1 8 3 7650305 FLANGE INSERT 5 5 BC 2 8 4 B333A FLANGE INSERT 2 125 BC 1 8 5 SP0003 T12AA01 SWITCH PUSH BUTTON RED 7J764 1 8 5A SP5049 54LAP28 CONTACT BL...

Page 160: ...e 9 Battery Set Assembly Typical Figure 9 Battery Set FIG ITEM NO TRILECTRON PART NO VENDOR PART NO AIRLINE PART NO DESCRIPTION VENDOR CODE QTY 9 BATTERY SET 12867 See Figure 1 REF 9 1 BA5005 850CCA D...

Page 161: ...nce Manual Mobile Aircraft Air Conditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________ JANUARY 20 2004 SECTION 4 3 PAGE 27 ULTRASAFE F...

Page 162: ...10 8 GPB1FA BUS BAR TERMINAL PWR INPUT 1 10 9 NOT USED 10 10 NOT USED 10 11 TGK12 GROUND BAR GND 1 10 12 GPF1L02AA GPS TO CL00 AND CL01 LINK MS MC1 3 2 10 13 GPF1L25AA GPS TO CL25 LINK MS MC2 4 2 10 1...

Page 163: ...FORMER 300VA 240 280 PRI 24V SEC W FUSE HOLDER T1 1 10 40 3FD 8 125 DIN RAIL DIN 35 8 125 2 10 41 3FD 4 125 DIN RAIL DIN 35 4 125 1 10 42 3FD 13 25 DIN RAIL DIN 35 13 25 1 10 43 T1 1530W COVER DUCT WH...

Page 164: ...tenance Manual Mobile Aircraft Air Conditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________ SECTION 4 3 JANUARY 20 2004 PAGE 30 This pa...

Page 165: ...of major components used in this unit Refer to Supplemental Technical Manuals as required for additional information RJ150 CUM 01 Cummins Marathon Engine Generator Set RJ150 CUN 01 Cummins Newage Eng...

Page 166: ...ntenance Manual Mobile Aircraft Air Conditioner Trailer Mounted Cool Mode Only ______________________________________________________________________________ SECTION 5 1 JANUARY 20 2004 PAGE 2 This pa...

Page 167: ...TRILECTRON INDUSTRIES INC RJ150 30 MOBILE AIRCRAFT AIR CONDITIONER UNIT TRAILER MOUNT COOL MODE ONLY RJ150 30 MOBILE AIRCRAFT AIR CONDITIONER UNIT TRAILER MOUNT COOL MODE ONLY MANUAL RJ150 30 1 20 04...

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