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Component Maintenance Manual

12037 N Highway 99
Seminole, OK 74868
Phone (405) 382-0731
Fax (405) 382-0737
http://www.enviro-ok.com

Copyright © 2017

ATA 21-00-23

P a g e

|

10

Revision 10

June 1, 2017

INTRODUCTION

TASK 21-00-23-99F-801

1.0

MANUAL INTRODUCTION

SUBTASK 21-00-23-99F-001

1.1

General introduction (How to Use):

1.1.1

This operating, servicing and component maintenance manual (OSCMM) covers the
requirements for field servicing the R-134A air conditioning system for the Pilatus PC12
Aircraft. This document includes component descriptions, servicing, maintenance,
inspection requirements and an illustrated parts list.

1.1.2

This component maintenance manual has been prepared with guidance from the Air
Transport Association of America (ATA) Specification 2200. The user must not change the
repair methods in this manual without authorization from the aviation authorities and the
manufacturer.

1.1.3

This manual gives the procedures to perform the servicing and maintenance of the
component in a workshop environment as well as on the aircraft. Only approved personnel
with the necessary skills shall perform the maintenance procedures in this manual.
Although Enviro Systems tries to cover all conceivable issues that may arise, there may be
issues that are not covered in this manual. In these cases, please call Enviro Systems
customer service.

1.1.4

This manual uses the Maintenance Task Oriented Support System (MTOSS) to organize
the maintenance information. It is divided into maintenance tasks and subtasks, graphics
and tables. Each task consists of one or more subtasks. Each subtask contains procedural
steps and can contain one or more graphics or tables. The maintenance tasks and other
data have special MTOSS numbers that are used for Electronic Data Processing (EDP).

1.1.5

You must use the instructions in this manual to do all the maintenance procedures related to
the component. Read all the related warnings, cautions and notes before you begin work
on the components. Warnings, cautions and notes shown in this manual provide the
following information:

1.1.5.1

WARNING

: Discloses vital information in order to prevent injury or death while

performing the maintenance procedure.

1.1.5.2

CAUTION

: Discloses vital information in order to prevent damage to the equipment

during the maintenance procedure.

1.1.5.3

NOTE

: Discloses more information that will help perform a step of the procedure or

refers to a different procedure.

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Содержание PILATUS PC12

Страница 1: ...23 January 2008 OPERATING SERVICING AND COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST PILATUS PC12 R 134a AIR CONDITIONING SYSTEM COMPONENTS 1 COMPRESSOR CONDENSER MODULE ASSEMBLY PART 113...

Страница 2: ...frigerant oil 08 17 10 BH 5 IPC Delete item 51 was AS568A 011 O ring 11 04 10 BH 6 Title Page P n 1134400 53 Supersedes 1134400 13 Table 2 add RL100E to consumables as alternative Also add to list in...

Страница 3: ...0 70 IN LBS changed 5 16 24UNF was 270 360 IN LBS is 100 140 IN LBS changed 3 8 24UNF torque values was 270 360 IN LBS is 160 190 IN LBS 4 19 12 BS 9 Section 2 3 1 Added Superseded by 1134400 53 Secti...

Страница 4: ...12037 N Highway 99 Seminole OK 74868 Phone 405 382 0731 Fax 405 382 0737 http www enviro ok com Copyright 2017 ATA 21 00 23 P a g e 4 Revision 10 June 1 2017 RECORD OF TEMPORARY REVISIONS REV DESCRIP...

Страница 5: ...12037 N Highway 99 Seminole OK 74868 Phone 405 382 0731 Fax 405 382 0737 http www enviro ok com Copyright 2017 ATA 21 00 23 P a g e 5 Revision 10 June 1 2017 LIST OF SERVICE BULLETINS SERVICE BULLETI...

Страница 6: ...737 http www enviro ok com Copyright 2017 ATA 21 00 23 P a g e 6 Revision 10 June 1 2017 LIST OF EFFECTIVE PAGES CHAPTER SECTION PAGE DATE CHAPTER SECTION PAGE DATE All All 5 5 08 ALL All 7 7 08 All A...

Страница 7: ...Testing Procedures 18 3 3 Evaporator Module Assembly Testing Procedures 18 3 4 System Leak Check Testing Procedure 19 3 5 Fault Isolation Trouble Shooting 21 SCHEMATIC AND WIRING DIAGRAMS 25 4 0 R 134...

Страница 8: ...PARTS LISTING 68 11 1 Introduction 68 SPECIAL PROCEDURES 78 12 0 SPECIAL PRODECURES 78 12 1 Expansion Valve Alignment 78 12 2 Balancing Multiple Evaporators 80 12 3 Motor Insulation Resistance Check...

Страница 9: ...dule Assembly 1134400 53 Details 70 Figure 10001 Compressor Condenser Module Assembly 1134400 53 Details 71 Figure 10002 Evaporator Module Assembly 1134200 42 L 43 C R 74 Figure 10002 Evaporator Modul...

Страница 10: ...ntenance 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 Envir...

Страница 11: ...for all figure and item numbers SUBTASK 21 00 23 99F 002 1 2 Acronyms Abbreviations and Symbols CMM Component Maintenance Manual ATA Air Transport Association MTOSS Maintenance Task Oriented Support...

Страница 12: ...8 24UNF AN6 10A AN6 14A ALL LOCATIONS 160 190 IN LBS 5 8 18 PLUMBING CONNECTIONS RECEIVER DRYER INLET DISCHARGE PORT 132 156 IN LBS 7 8 14 PLUMBING CONNECTIONS COMPRESSOR SUCTION PORT 252 324 IN LBS...

Страница 13: ...edules 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...

Страница 14: ...at 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 a...

Страница 15: ...sor Assembly 40A Condenser Coil 120A Receiver Dryer Assembly 50C Binary Pressure Switch 60A 2 3 3 1 COMPRESSOR DRIVE MOTOR The compressor drive motor has a double ended shaft and operates on 27 5 VDC...

Страница 16: ...charge 2 3 3 5 BINARY PRESSURE SWITCH The binary pressure switch performs two major functions The first function prevents the R 134A compressor from operating if the system charge is lost or the ambie...

Страница 17: ...t of air It is made of lightweight aluminum that provides superior strength and durability 2 3 5 4 BLOWER SCROLL The blower scroll is constructed of high impact fire retardant self extinguishing and c...

Страница 18: ...d 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 t...

Страница 19: ...3 3 4 Verify that the system is cooling properly If not the expansion valve s might need aligning Refer to Special Procedures Section 12 for Expansion Valve Alignment procedures NOTE If a failure has...

Страница 20: ...C system Service ports are located on the compressor 3 4 3 6 Close all manifold gauge valves and verify hose connections are tight 3 4 3 7 Connect R 134A refrigerant charging manifold R 134A service g...

Страница 21: ...rigerant 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 PRESS...

Страница 22: ...power cart 2 Aircraft power switch off 2 Energize power switch B Power On But System Will Not Operate 1 Air conditioner breaker off 1 Turn on 2 Air conditioner breaker failed 2 Replace 3 Air condition...

Страница 23: ...t clogged 12 Remove Debris 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 No...

Страница 24: ...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 Ener...

Страница 25: ...n 10 June 1 2017 SCHEMATIC AND WIRING DIAGRAMS 21 00 23 99 801 4 0 R 134A AIR CONDITIONING SYSTEM SCHEMATIC AND WIRING DIAGRAMS SUBTASK 21 00 23 99 001 4 1 R 134A Refrigerant Flow Schematic 4 1 1 The...

Страница 26: ...ion 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 suba...

Страница 27: ...as been recovered refer to Servicing Section 13 5 2 1 2 Disconnect electrical wiring to binary pressure switch 5 2 1 3 Disconnect refrigerant plumbing connection from receiver dryer inlet port 5 2 1 4...

Страница 28: ...mpressor from mounting bracket 5 2 5 Removal of Condenser Coil 120A 5 2 5 1 Remove receiver dryer per 5 2 1 5 2 5 2 Remove two nuts and washers retaining receiver dryer bracket to condenser coil and r...

Страница 29: ...2 Remove motor shaft retaining nut and washer 5 2 7 3 Loosen fan hub set screw s 5 2 7 4 Slide fan assembly motor shaft 5 2 8 Removal of Fan Shroud 5 2 8 1 Remove condenser coil per 5 2 5 5 2 8 2 Rem...

Страница 30: ...w enviro ok com Copyright 2017 ATA 21 00 23 P a g e 30 Revision 10 June 1 2017 5 2 11 2 Remove attaching screws washers and nuts 5 2 11 3 Carefully slide hour meter from receiver dryer bracket 5 2 12...

Страница 31: ...N Highway 99 Seminole OK 74868 Phone 405 382 0731 Fax 405 382 0737 http www enviro ok com Copyright 2017 ATA 21 00 23 P a g e 31 Revision 10 June 1 2017 5 2 12 2 Remove the Brush Cover 5 2 12 3 Discon...

Страница 32: ...June 1 2017 5 2 12 4 With a 90 pick lift brush spring and remove the worn brushes from the brush guides 5 2 12 5 Upon removal ensure that no FOD remains in the brush guide that may prevent smooth brus...

Страница 33: ...nt screws spacers washers and clamp 5 3 2 4 Remove attachment nuts and washers securing drip tray to escutcheon 5 3 2 5 Carefully slide drip away from evaporator CAUTION USE EXTREME CARE TO PREVENT DA...

Страница 34: ...ARD 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 SERI...

Страница 35: ...her 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...

Страница 36: ...t and other foreign matter It is essential that the air filter remain clear for proper operation of the evaporator module assembly Carefully remove air filter from evaporator assembly and use a soft u...

Страница 37: ...600 Compressor Shaft seal Inspect for leaks excessive oil spray Bearing inspection 600 Condenser fan outlet shrouds Inspect condenser shrouds for signs of cracking separation between shrouds and conde...

Страница 38: ...s are unknown the brush depth measurement from 7 1 3 3 cannot exceed 0 10 inches 7 1 3 3 To calculate remaining brush life use following method Calculations should be based on the shortest brush lengt...

Страница 39: ...r following figures for excessive or uneven wear The commutator should have a burnished appearance with light filming If the commutator is black burned pitted grooved or excessively worn the motor sho...

Страница 40: ...868 Phone 405 382 0731 Fax 405 382 0737 http www enviro ok com Copyright 2017 ATA 21 00 23 P a g e 40 Revision 10 June 1 2017 7 1 4 2 Commutator in serviceable condition shows some signs of wear and c...

Страница 41: ...ne 405 382 0731 Fax 405 382 0737 http www enviro ok com Copyright 2017 ATA 21 00 23 P a g e 41 Revision 10 June 1 2017 7 1 4 3 Commutator in unserviceable condition shows excessive pitting and chippin...

Страница 42: ...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...

Страница 43: ...RNAL 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 S...

Страница 44: ...and Assembly Section 9 The commutator on the armature must be in serviceable condition to maintain proper operation See Section 7 for inspection criteria 8 2 1 3 Compressor Assembly The compressor and...

Страница 45: ...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...

Страница 46: ...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...

Страница 47: ...61 R 63 C and is not compatible with older evaporator 1134200 42 43 Therefore if aircraft has evaporator 1134200 42 43 that has failed left or right side both the left and right side evaporators must...

Страница 48: ...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 MAIN...

Страница 49: ...300 PSIG SUBTASK 21 00 23 40 001 9 2 Compressor Condenser Module Assembly Procedures refer to Figure 10001 9 2 1 Assembly of Drive Motor Brushes refer to IPL for details CAUTION IT IS EXTREMELY IMPOR...

Страница 50: ...http www enviro ok com Copyright 2017 ATA 21 00 23 P a g e 50 Revision 10 June 1 2017 9 2 1 1 Ensure the brush guide interior is free of debris and the surfaces are smooth to allow for proper brush t...

Страница 51: ...rushes cut a 1 5 X 7 5 strip of 200 grit garnet sandpaper Cut 2 pieces of 3M 40PR Utility Tape or equivalent non residue leaving put one piece on each side rough and smooth of one end of the sandpaper...

Страница 52: ...llow brush installation Insert brushes into slots ensuring that the curvature of the brush matches the armature Brushes should slide in brush guides freely without restriction After insertion of the b...

Страница 53: ...sion 10 June 1 2017 9 2 1 7 Rotate the motor through 5 revolutions in the CCW direction as viewed from the brush end 9 2 1 8 Raise the brushes approximately half way and allow the spring to hold the b...

Страница 54: ...on 10 June 1 2017 9 2 1 10 Lower the brushes back into position on the commutator 9 2 1 11 Attach field winding leads and brush shunt wires to the terminals as shown Place the brush shunt terminal on...

Страница 55: ...hour without the belt installed no load After 1 hour the brushes must be checked for proper seating as illustrated below If the brushes are not fully seated after 1 hour of operation the motor must b...

Страница 56: ...enviro ok com Copyright 2017 ATA 21 00 23 P a g e 56 Revision 10 June 1 2017 Note The Brush Shunt Wires shall locate in the slot of the brush guide as shown above this will ensure the brush travel wi...

Страница 57: ...Seminole OK 74868 Phone 405 382 0731 Fax 405 382 0737 http www enviro ok com Copyright 2017 ATA 21 00 23 P a g e 57 Revision 10 June 1 2017 9 2 1 16 Reinstall the brush cover and screws Use safety ca...

Страница 58: ...ectrical harness 9 2 1 6 Install fan per 9 2 2 9 2 1 7 Install compressor assembly per 9 2 3 9 2 1 8 Install drive motor belt and pulley per 9 2 4 9 2 1 9 Install belt cover per 9 2 5 9 2 1 10 Install...

Страница 59: ...faces 9 2 3 6 Connect condenser fitting to compressor discharge port and tighten per Table 1 9 2 4 Assembly of Drive Belt and Pulley 9 2 4 1 Place drive belt over motor drive pulley and slide belt ont...

Страница 60: ...urate readings connect inductive sensor CAUTION REMOVE THE TAPE AND MAGNET FROM BELT BEFORE PROCEEDING 9 2 4 3 7 Tape the Small Magnet in the mid span of the belt push the measure button on the meter...

Страница 61: ...cover attach 2 fasteners at upper mid cover just inside belt cover opening Install 2 mounting bolts on side of assembly used to secure drive motor refer to table 1 section 1 3 for torque specificatio...

Страница 62: ...er Table 1 and apply safety wire or cable 9 2 8 4 Using a wire brush and cleaning solvent completely remove old thread sealant from compressor connection threads Apply a thin layer of thread sealant p...

Страница 63: ...Assembly of Power Relay 9 2 10 1 Carefully slide power relay into position and attach using mounting hardware 9 2 10 2 Connect electrical connections and install boots for protection 9 2 11 Assembly...

Страница 64: ...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 pe...

Страница 65: ...017 9 3 3 4 Slide motor blower wheel into scroll and attach with upper motor screws and washers 9 3 3 5 Attach drip tray to motor with lower motor attachment screws and washers ensuring that spacers a...

Страница 66: ...op Air 40 PSIG Fin comb SK1250101 13 Miscellaneous hand tools and socket set Shop vacuum with soft utility brush Vacuum pump air or electric 0 30 in hg Gaseous dry Nitrogen regulated source 0 500 PSIG...

Страница 67: ...e OK 74868 Phone 405 382 0731 Fax 405 382 0737 http www enviro ok com Copyright 2017 ATA 21 00 23 P a g e 67 Revision 10 June 1 2017 Straight Edge Measuring Device Micrometer Scribe or Wire Hook Volt...

Страница 68: ...ts as well as in identification of new and reclaimed parts This IPL includes Illustrations of the Compressor Condenser Module and Evaporator Module Assembly to be used during the procedures outlined p...

Страница 69: ...4868 Phone 405 382 0731 Fax 405 382 0737 http www enviro ok com Copyright 2017 ATA 21 00 23 P a g e 69 Revision 10 June 1 2017 Figure 10001 Compressor Condenser Module Assembly 1134400 53 Supersedes 1...

Страница 70: ...333 41 FLAT WASHER 2 21 1251171 MOTOR BRUSH SET CONTAINS 4 BRUSH PAIRS 1 10B 1250128 POWER RELAY 1 11B 28X1 2H BOLT 1 12B 28X1H BOLT 1 13B 21FK 428 NUT 2 14B MS35333 40 FLAT WASHER 1 15B AN345 416 NUT...

Страница 71: ...100A 1134510 OUTLET SHROUD 1 101 10 32X3 8IHW BOLT 4 102 NAS1149F0332P FLAT WASHER AN960 10L 4 103 409 1032Z LOCK NUT 4 110A 1134509 FAN SHROUD 1 111 10 32X1 2H BOLT RECEIVER DRYER BRACKET SIDE 3 112...

Страница 72: ...nce Manual 12037 N Highway 99 Seminole OK 74868 Phone 405 382 0731 Fax 405 382 0737 http www enviro ok com Copyright 2017 ATA 21 00 23 P a g e 72 Revision 10 June 1 2017 1134400 59 Compressor Condense...

Страница 73: ...MBER NOMENCLATURE UNITS ASSY 1 1134104 9 28VDC Motor Assembly 1 Item Not Shown 1251171 11 Motor Brush Set Contains 4 Brush Pairs 1 2 1260970 Fan Assembly 1 3 1134502 2 Condenser Support Bracket 1 4 11...

Страница 74: ...ay 99 Seminole OK 74868 Phone 405 382 0731 Fax 405 382 0737 http www enviro ok com Copyright 2017 ATA 21 00 23 P a g e 74 Revision 10 June 1 2017 Figure 10002 Evaporator Module Assembly 1134200 42 L 4...

Страница 75: ...June 1 2017 FIG ITEM PART NUMBER NOMENCLATURE UNITS ASSY 10002 10 1134218 EXPANSION VALVE 42 1 1134218 1 EXPANSION VALVE 43 1 20 1250540 11 AIR FILTER 1 21 190940 VELCRO HOOK 2 6 FT 1 22 190911 VELCRO...

Страница 76: ...l 12037 N Highway 99 Seminole OK 74868 Phone 405 382 0731 Fax 405 382 0737 http www enviro ok com Copyright 2017 ATA 21 00 23 P a g e 76 Revision 10 June 1 2017 Figure 10003 Evaporator Module Assembly...

Страница 77: ...EEL 61 63 1 30C BLOWER SCROLL N P 40A SHROUD N P 50A ESCUTCHEON N P 60A 1134218 EXPANSION VALVE 60 1 1134218 1 EXPANSION VALVE 61 63 1 70D 1250540 11 AIR FILTER 1 71 190940 VELCRO HOOK 2 6 FT 1 72 190...

Страница 78: ...es 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 typic...

Страница 79: ...contamination or restrictions which could alter air flow If components are dirty refer to Cleaning Section 7 12 1 7 Verify the blower speed switch is in the high position 12 1 8 Verify R 134A manifol...

Страница 80: ...er 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...

Страница 81: ...rror 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 M...

Страница 82: ...em has been vented quickly thereby causing a loss of oil An oil check can only be made with the system vented 12 6 1 When replacing the compressor use the following procedure to add required oil to sy...

Страница 83: ...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 EXPOS...

Страница 84: ...r 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 min...

Страница 85: ...RANT 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...

Страница 86: ...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...

Страница 87: ...15 MINUTES COULD RESULT IN MAJOR DAMAGE OF THE R 134A COMPRESSOR SUBTASK 21 00 23 55 001 14 2 System Long Term Shelf Storage 14 2 1 If unit will be stored for periods in excess of 12 months the follow...

Страница 88: ...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 m...

Страница 89: ...kaging ensure that the component is packaged in the following manner 14 4 1 5 Ensure duct or refrigerant openings are capped to further protect the component from contamination 14 4 1 6 Slide the evap...

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