Enviro PILATUS PC12 Setup guide

Component Maintenance Manual
12037 N Highway 99
Seminole, OK 74868
Phone [phone]
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Copyright © 2017
Original Release
ATA 21-00-23
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 # 1134400-53
(Supersedes 1134400-13, 1134400-56), 1134400-59
2) EVAPORATOR MODULE ASSEMBLY, PART # 1134200-60 (L) /-61 (R) /-63 (C)
(Supersedes 1134200-42, L /-43. C&R)
ATA SPECIFICATION 21-00-23

Component Maintenance Manual
12037 N Highway 99
Seminole, OK 74868
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Fax [phone]
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Copyright © 2017
ATA 21-00-23
Page | 2
Revision 10
June 1, 2017
RECORD OF REVISIONS
REV
DESCRIPTION OF CHANGE
DATE
APPROVAL
ORIGINAL RELEASE
1/4/08
BH
1
Updated Storage, Section 14. Updated information concerning
cold weather operations under General and System Off
Season/On Aircraft Functional Testing.
5/5/08
BH
2
Page 10003, Figure 10001, Fig. Item 40A…was 1134162…is
1134160
7/7/08
BH
3
Delete page 2002 Subtask 21-00-23-99-002
This removes wiring diagram Figure 3, and removes 4.2 “Wiring
Schematic” and 4.2.1 “The following electrical schematic shows
the system components and how they interrelate to each other”.
Renumber subsequent figures 4 and 5 and references to those
figures.
Revises Note above table 3 to remove reference to Figure 3
Wiring Schematic.
9/22/08
BH
4
Correct refrigerant oil specification in SEC. 13.1.2 was BVM100
is RL100H refrigerant 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
SEC. 13.1.2. IPL Change all AN960 washer# to equivalent Nas
#. Add SB11-102.IPL Figure 10001 Add P/N 1134400-53 add
item 10C replacement motor. IPL Item -21A Brush qty. was 4 is
1 (set) Delete Sec. 3.4 and Figure1 Brush replacement wear
details Renumber subsequent Add new Figure 3.3, 3.4, and
3.5. Section 8.2.1.2: change verbiages to reflect replacement
of brushes and add CAUTION referring to commutator wear
condition examples. Change and Label Table 3.5 and 3.6.
Section 12.4.1 was Motor bearing will be inspected every 800-
1000 operational hours. Is Motor bearing will be inspected
according to Section 7 Inspection Schedule Table 3.5.Sec
12.5.1 was Compressor Bearing will be inspected every 1000-
1500 operational hours IS Compressor bearing will be inspected
according to Section 7 Inspection Schedule Table 3.5.
Remove IPL item numbers from Sections 2 thru 10.
08/16/11
BH
Continued Next Page
NOTE: Check Enviro Systems Inc. web site to verify current revision. www.enviro-ok.com

Component Maintenance Manual
12037 N Highway 99
Seminole, OK 74868
Phone [phone]
Fax [phone]
http://www.enviro-ok.com
Copyright © 2017
ATA 21-00-23
Page | 3
Revision 10
June 1, 2017
REV
DESCRIPTION OF CHANGE-Continued
DATE
APPROVAL
7
SEC 9.2.6 replace belt tensioning instructions for use with Gates
Sonic Meter. Replace Fig 4 with detail of meter use. Add new
Table 4 tensioning information. Renumber Table 5 was Table 4
Typical Operating Values SEC 13.3.3 add refrigerant charge to
this section and omit table 5. Table 3.5 change 3rd column title
from Service Hours to Unit Operating Hours IPC indicate part
numbers in detail list for motor and fan of -13 config. ITEM 50C
was 1134192-1 is 1134192-13, ITEM 60A deleted was
1250232-4
11/11/11
BH
8
SEC 1.3 Table 1 Added row 2 .25-28 SET SCREW
EVAPORATOR BLOWER WHEEL 12-15 IN-LBS, changed
torque values for 6-32 SCREW was 7-9 IN-LBS is 8-10 IN-LBS,
changed torque values for 10-32 SCREW/BOLT was 60-75 IN-
LBS is 20-25 IN-LBS, changed ¼-28-UNF torque values was
135-185 IN-LBS is 50-70 IN-LBS, changed 5/16-24UNF was
270-360 IN-LBS is 100-140 IN-LBS, changed 3/8-24UNF torque
values was 270-360 IN-LBS is 160-190 IN-LBS
4/19/12
BS
9
•Section 2.3.1 Added (Superseded by 1134400-53)
•Section 2.3.2 Added (1134400-13/-53)
•Section 11 Figure 10001, 10001-10C, Was: 1134104-5
Is: 1134104-6
•Section 11 Figure 10001, 50C Was: 1134192-13 Is:
1134192-1 (Superseded by 1134192-15)
•SEC. 9.2.4 Added instructions to replace drive motor
with incorporated thermal fuse
1/21/14
BS
10
- Updated drive motor brush removal an installation procedures.
- Remove references of SB11-102
- Added 1134400-56 configuration to title page
- Added note to IPL Figure 10001 for -56 configurations to be
returned for update to -53
- Minor formatting and spelling corrections
- Table 3.6 removed note to remove and replace blower motor
between 4900 – 5100 hours.
- Section 14.4.2 removed reference to General Motors Service
Bulletin 83-12-21
- Added 1134400-59 Configuration
- Removed Section 10.2.4.4.1 through 10.2.2.4.4 describing
procedures for replacing an 1134104-1 motor with an 1134104-
6 motor.
- Removed Section 13.6 Motor brush seating procedure
- Updated Table 2 Consumable Products to include Pilatus part
number where applicable and to specify Enviro part number.
6/1/17
BS

Component Maintenance Manual
12037 N Highway 99
Seminole, OK 74868
Phone [phone]
Fax [phone]
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Copyright © 2017
ATA 21-00-23
Page | 4
Revision 10
June 1, 2017
RECORD OF TEMPORARY REVISIONS
REV
DESCRIPTION OF CHANGE
DATE
APPROVAL

Component Maintenance Manual
12037 N Highway 99
Seminole, OK 74868
Phone [phone]
Fax [phone]
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Copyright © 2017
ATA 21-00-23
Page | 5
Revision 10
June 1, 2017
LIST OF SERVICE BULLETINS
SERVICE
BULLETIN #
DESCRIPTION
DATE
RELEASED

Component Maintenance Manual
12037 N Highway 99
Seminole, OK 74868
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Page | 6
Revision 10
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LIST OF EFFECTIVE PAGES
CHAPTER / SECTION
PAGE
DATE
CHAPTER / SECTION
PAGE
DATE
All
All
5/5/08
ALL
All
7/7/08
All
All
9/22/08
All
All
08/17/10
All
All
11/04/10
All
All
08/15/11
All
All
11/11/11
All
All
XX/XX/2017

Component Maintenance Manual
12037 N Highway 99
Seminole, OK 74868
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Copyright © 2017
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Revision 10
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TABLE OF CONTENTS
RECORD OF TEMPORARY REVISIONS...........................................................................................................4
LIST OF SERVICE BULLETINS .........................................................................................................................5
LIST OF EFFECTIVE PAGES.............................................................................................................................6
TABLE OF CONTENTS ......................................................................................................................................7
LIST OF ILLUSTRATIONS .................................................................................................................................9
LIST OF TABLES................................................................................................................................................9
INTRODUCTION................................................................................................................................................10
1.0 MANUAL INTRODUCTION..................................................................................................................10
1.1 General introduction (How to Use):..................................................................................................10
1.2 Acronyms, Abbreviations, and Symbols:.........................................................................................11
1.3 Standard Torque Values: ...................................................................................................................12
1.4 Documents required:..........................................................................................................................12
1.5 Consumable Products:.......................................................................................................................12
DESCRIPTION AND OPERATION...................................................................................................................13
2.0R-134A AIR CONDITIONING SYSTEM DESCRIPTION AND OPERATION......................................13
2.1 General:................................................................................................................................................13
2.2 System Description and Operation:..................................................................................................14
2.3 System Component Description and Operation:.............................................................................15
TESTING AND FAULT ISOLATION.................................................................................................................18
3.0 R-134A AIR CONDITIONING SYSTEM COMPONENT – TESTING AND FAULT ISOLATION........18
3.1 General:................................................................................................................................................18
3.2 Compressor Condenser Module Assembly Testing Procedures ..................................................18
3.3 Evaporator Module Assembly Testing Procedures ........................................................................18
3.4 System Leak Check Testing Procedure: ..........................................................................................19
3.5 Fault Isolation (Trouble Shooting):...................................................................................................21
SCHEMATIC AND WIRING DIAGRAMS..........................................................................................................25
4.0 R-134A AIR CONDITIONING SYSTEM SCHEMATIC AND WIRING DIAGRAMS ............................25
4.1 R-134A Refrigerant Flow Schematic:................................................................................................25
DISASSEMBLY.................................................................................................................................................26
5.0 R-134A AIR CONDITIONING SYSTEM COMPONENT - DISASSEMBLY.........................................26
5.1 General:................................................................................................................................................26
5.2 Compressor Condenser Module Disassembly Procedures ...........................................................27
5.3 Evaporator Module Assembly Disassembly Procedures ...............................................................33
CLEANING ........................................................................................................................................................34
6.0 R-134A AIR CONDITIONING SYSTEM COMPONENT – CLEANING PROCEDURES.....................34
6.1 General:................................................................................................................................................34
6.2 Compressor Condenser Module Cleaning Procedures:.................................................................35
6.3 Evaporator Module Assembly Cleaning Procedures:.....................................................................36
CHECK (INSPECTION SCHEDULE)................................................................................................................37
7.0 R-134A AIR CONDITIOING SYSTEM COMPONENT – INSPECTION SCHEDULE..........................37
7.1 Compressor Condenser Module Assembly Inspection Schedule:................................................37
7.2 Evaporator Module Assembly Inspection Schedule:......................................................................42
REPAIRS ...........................................................................................................................................................43
8.0 R-134A AIR CONDITIONING SYSTEM COMPONENT – REPAIR PROCEDURES..........................43
8.1 General:................................................................................................................................................43
8.2 Compressor Condenser Module Repair Procedures:.....................................................................43
8.3 Evaporator Module Assembly Repair Procedures:.........................................................................46

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

Component Maintenance Manual
12037 N Highway 99
Seminole, OK 74868
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Copyright © 2017
ATA 21-00-23
Page | 9
Revision 10
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LIST OF ILLUSTRATIONS
Figure 1 R-134A Refrigerant Flow Schematic...............................................................................................25
Figure 3.3: Commutator Excellent Condition Example...............................................................................39
Figure 3.4: Commutator Serviceable Condition Example ..........................................................................40
Figure 3.5: Commutator Unserviceable Condition Example......................................................................41
Figure 4 Belt Tensioning Reference ..............................................................................................................61
Figure 10001 Compressor Condenser Module Assembly 1134400-53.......................................................69
Figure 10001 Compressor Condenser Module Assembly (1134400-53) Details .......................................70
Figure 10001 Compressor Condenser Module Assembly (1134400-53) Details .......................................71
Figure 10002 Evaporator Module Assembly 1134200-42 (L) /-43 (C,R) ......................................................74
Figure 10002 Evaporator Module Assembly (1134200-42/-43) Details .......................................................75
Figure 10003 Evaporator Module Assembly 1134200-60/-61/-63 (-60 Shown)...........................................76
Figure 10003 Evaporator Module Assembly (1134200-60/-61/-63) Details.................................................77
LIST OF TABLES
Table 1 Standard Torque Values....................................................................................................................12
Table 2 Consumable Products .......................................................................................................................12
Table 3 Trouble Shooting List ........................................................................................................................22
Table 3 Trouble Shooting List ........................................................................................................................23
Table 3 Trouble Shooting List ........................................................................................................................24
Table 3.5 Compressor Condenser Module Inspection Schedule................................................................37
Table 3.6 Forward and Aft Evaporator Module Inspection Schedule.........................................................42
Table 4 Gates Sonic Tension Meter Data ......................................................................................................61
Table 5 Typical Operating Values...................................................................................................................79

Component Maintenance Manual
12037 N Highway 99
Seminole, OK 74868
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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.

Component Maintenance Manual
12037 N Highway 99
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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 21-00-23-99F-002
1.2 Acronyms, Abbreviations, and Symbols:
•CMM Component Maintenance Manual
•ATA Air Transport Association
•MTOSS Maintenance Task Oriented Support System
•EDP Electronic Data Processing
•IPL Illustrated Parts Listing
•BTUH British Thermal Unit per Hour (standard in U.S. heating and air-conditioning)
•Db Dry Bulb
•RH Relative Humidity
•CFM Cubic Feet per Minute
•In.w.g Inch of Water Gage
•VCS Vapor Cycle System
•MSDS Material Safety Data Sheet
•PSIG Pressure Per Square Inch, Gage
•SAE Society of Automotive Engineers
•CCW Counter Clockwise
•CW Clockwise
•FOD Foreign Object Damage
•OAT Outside Air Temperature

Component Maintenance Manual
12037 N Highway 99
Seminole, OK 74868
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SUBTASK 21-00-23-99F-003
1.3 Standard Torque Values:
TYPE FASTENER
DESCRIPTION/LOCATION
TORQUE
.25-28 SET SCREW
ALL OTHER LOCATIONS
40-50 IN LBS
.25-28 SET SCREW
EVAPORATOR BLOWER WHEEL
12-15 IN LBS
6-32 SCREW
AN500-6-6, MS35265-30/-43, MS35206-
228, ALL LOCATIONS
8-10 IN-LBS
8-32 SCREW
AN500-A8-6, MS35265-45, ALL
LOCATIONS
12-15 IN-LBS
10-32 SCREW/BOLT
ALL LOCATIONS
20-25 IN-LBS
M10X1.2525MM
COMPRESSOR BOLT
175-200 IN LBS
¼-28-UNF
ALL LOCATIONS
50-70 IN-LBS
5/16-24UNF
ALL LOCATIONS
100-140 IN-LBS
3/8-24UNF
AN6-10A, AN6-14A, ALL LOCATIONS
160-190 IN-LBS
5/8-18 PLUMBING
CONNECTIONS
RECEIVER DRYER INLET/DISCHARGE
PORT
132-156 IN-LBS
7/8-14 PLUMBING
CONNECTIONS
COMPRESSOR SUCTION PORT
252-324 IN-LBS
¾-16 PLUMBING
CONNECTIONS
COMPRESSOR DISCHARGE PORT
180-240 IN LBS
7/16-20 PLUMBING
CONNECTIONS
EXPANSION VALVE INLET PORT
100-140 IN LBS
¾-16 PLUMBING
CONNECTIONS
EXPANSION VALVE OUTLET PORT
270-350 IN LBS
Table 1 Standard Torque Values
SUBTASK 21-00-23-99F-004
1.4 Documents required:
•Illustrated Parts Listings (IPL) (included with this manual)
•Pilatus PC12 Aircraft Maintenance Manual
SUBTASK 21-00-23-99F-005
1.5 Consumable Products:
ENVIRO PART
NUMBER
DESCRIPTION
REMARKS/ALTERNATE
PILATUS PART
NUMBER
11602
SEALANT RTV
BLACK RTV 103
P08-045
7471
THREAD SEALANT PRIMER
LOCTITE 7471
569
THREAD SEALANT
LOCTITE 569
RL-100H
POE REFRIGERANT OIL
R-134A
P10-021
Table 2 Consumable Products

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DESCRIPTION AND OPERATION
TASK 21-00-23-99F-802
2.0 R-134A AIR CONDITIONING SYSTEM DESCRIPTION AND OPERATION
SUBTASK 21-00-23-99F-006
2.1 General:
2.1.1 The air conditioning system installed on the Pilatus PC12 Aircraft is not considered a
primary flight system. However, an air conditioning system does perform the important
function of providing passenger and flight crew comfort during aircraft movement on the
ground and while in flight. Aircraft air conditioning systems not only provide effective
passenger cooling, but must also maintain a high level of reliability to minimize aircraft
downtime due to unscheduled repairs.
2.1.2 In order to ensure component reliability and achieve a long service life for which the system
is designed, periodic inspection and preventive maintenance must be performed. Failure to
complete periodic inspections, service, or maintenance schedules may reduce product life
and potentially void manufacturer’s warranty.
2.1.3 Inspections, servicing, and/or maintenance schedules are presented in the following
sections. This will ensure component and/or system reliability and performance are
maintained when performed at the specified intervals.
WARNING: SERVICE TECHNICIANS ARE ADVISED TO OBSERVE STANDARD SAFETY
PRECAUTIONS, SUCH AS WEARING PERSONAL SAFETY GEAR, TO PREVENT INJURY WHILE
PERFORMING SERVICE TO THE UNIT. LIQUID REFRIGERANT CAN CAUSE FROSTBITE AND/OR
BLINDNESS.
WARNING: PROPER VENTILATION IS REQUIRED. KEEP REFRIGERANTS AND OILS AWAY FROM
OPEN FLAMES. REFRIGERANTS CAN PRODUCE POISONOUS GASSES IN THE PRESENCE OF A
FLAME. WORK IN A WELL VENTILATED AREA AND AVOID BREATHING REFRIGERANT /LUBRICANT
VAPOR MIST IF ACCIDENTAL DISCHARGE OCCURS.
WARNING: AVOID USE OF COMPRESSED AIR. DO NOT INTRODUCE COMPRESSED AIR OR
OXYGEN INTO AN AIR CONDITIONING SYSTEM OR REFRIGERANT CONTAINER. R-134A IN THE
PRESENCE OF AIR OR OXYGEN ABOVE ATMOSPHERIC PRESSURE MAY FORM A COMBUSTIBLE
MIXTURE.
2.1.4 Do not discharge R-134A refrigerant into the atmosphere. Although its ozone depletion
potential is zero, it can have an effect on global warming. In the United States recovery and
recycling are mandated by the Clean Air Act.

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2.1.5 Refrigerant recovery/recycling service equipment must be approved for use with R-134A
refrigerant. Recycling machines must be approved by Underwriters Laboratories (UL) and
meet SAE standard J2210 and SAE standard J2099 for refrigerant purity.
SUBTASK 21-00-23-99F-007
2.2 System Description and Operation:
2.2.1 The cabin cooling system installed in the Pilatus PC12 Aircraft operates using a closed
vapor cycle concept using refrigerant R-134A as the heat absorption media. The R-134A
air conditioning system cools the aircraft in a similar manner as systems found in an
automobile or home. However, aircraft air conditioning systems contain components which
are designed to be light weight, compact, provide high performance, and provide the ability
to operate at extreme altitudes and ambient temperatures.
2.2.2 The concept of air conditioning a room, cabin or cockpit is straight forward. An example of a
system is shown in Figure 1 (refer to Schematic and Wiring Diagrams, Section 4).
Refrigerant is the media which absorbs and rejects the room or cabin heat. By continuous
recirculation of the warm cabin air, heat is absorbed in the evaporator module(s) and is
rejected to the outside through the system condenser. When the system is turned on, the
electric motor drives the R-134A compressor at a constant speed and capacity which
compresses the R-134A refrigerant gas to a high pressure. The hot, high pressure gas then
passes through the condenser coil where it is cooled and condensed into a warm liquid at
constant pressure. The warm liquid is then routed into a receiver-dryer container where the
liquid and any remaining gas are separated and any moisture is absorbed. The warm, dry
liquid is then directed to the evaporator module expansion valve where the high pressure
liquid is expanded to a low pressure. The expansion process creates a super cool gas
which passes through the evaporator coil and absorbs heat from the warm cabin air passing
over the coils. The warm low pressure refrigerant then enters the R-134A compressor
where the process starts all over again. In addition to cooling the cabin air, a refrigerant
type system also removes a large percentage of the moisture in the air as well as removing
dust and pollen particles in the air. Thus, the system conditions the air as well as cooling it.
As a safety feature, the unit is also equipped with a binary pressure switch. This switch
prevents the unit from operating if the discharge pressure becomes excessively high. The
switch also prevents the unit from operating if the internal pressure is very low due to
leakage or low ambient temperatures.

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SUBTASK 21-00-23-99F-008
2.3 System Component Description and Operation:
2.3.1 The R-134A air conditioning system installed on the Pilatus PC12 Aircraft uses the following
major system components:
•Compressor Condenser Module Assembly 1134400-13
1134400-53 Supersedes-13
1134400-56 Limited Serial Numbers
1134400-59 Improved Brush Life
•Evaporator Module Assembly 1134200-42 (L) / -43 (C&R)
Superseded by 1134200-60 (L)/-61 (R)/-63 (C)
2.3.2 The COMPRESSOR CONDENSER MODULE ASSEMBLY (PN 1134400-13/-53/-56/-59)
has a rated cooling capacity of 17,350 BTUH when operating with the other components in
the Pilatus PC12 Aircraft at an ambient temperature of 95°F OAT. Under this condition, the
nominal current draw is 100 AMPS at 28 VDC.
2.3.3 The Compressor Condenser Module Assembly is packaged to meet the aircraft installation
requirements and contains the following major components (refer to Figure 10001):
•Compressor Drive Motor (10C)
•Compressor Assembly (40A)
•Condenser Coil (120A)
•Receiver Dryer Assembly (50C)
•Binary Pressure Switch (60A)
2.3.3.1 COMPRESSOR DRIVE MOTOR: The compressor drive motor has a double-ended
shaft and operates on 27.5 VDC power with a rated current draw of 115 AMPS max.
One output shaft drives the R-134A compressor and the other end drives the motor
cooling fan. The motor design power is 3.2 HP at 5000-5250 RPM and is specially
designed to provide a high starting torque to overcome the compressor startup
requirements. The motor is a brush commutated permanent magnet design and was
selected for its efficiency, excellent controllability, long life, and low vibration. The
shaft is supported on high speed ball bearings for reliability and friction reduction.
2.3.3.2 COMPRESSOR ASSEMBLY: The compressor assembly contains an R-134A
compressor and 5.01 inch pitch diameter pulley assembly. The compressor also
features a six piston wobble plate design as well as anti-slugging features that
eliminate the need for a suction trap/accumulator. The compressor has a light-weight
aluminum housing. The pulley assembly is designed for a high strength, positive grip
240L100 timing belt and contains a radial bearing to assure no side loads are
transmitted into the compressor input shaft. The assembly is designed for continuous
operation.

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2.3.3.3 CONDENSER COIL ASSEMBLY: The condenser coil assembly is a copper tube and
aluminum fin configuration with 6061-T6 aluminum support brackets. The coil heat
rejection is 30,400 BTUH based on a 95°F ambient day. Condenser cooling airflow
and coil sizes are based on the design cooling capacity and compressor input
horsepower. This assembly requires airflow of 900 CFM for proper operation.
2.3.3.4 RECEIVER DRYER ASSEMBLY: The receiver-dryer assembly consists of a
refrigerant container, Schrader valve, high pressure charging port and a binary
pressure switch. The receiver-dryer is constructed of aluminum alloy and contains a
standpipe, wire filter, and desiccant. The receiver dryer assembly is provided with a
corrosion resistant baked enamel finish. The receiver volume is approximately 40
cubic inches and can store up to 1.8 pounds of refrigerant at 240 PSIG. The Schrader
valve located in the container inlet port allows for the binary pressure switch to be
removed without venting the system refrigerant charge.
2.3.3.5 BINARY PRESSURE SWITCH: The binary pressure switch performs two major
functions. The first function prevents the R-134A compressor from operating if the
system charge is lost or the ambient temperature is too low. The second function
stops the compressor from operating if the head pressure increases to an unsafe
level. The high pressure cutout is at 275-335 PSIG on rise and the low pressure
cutout is at 15-29 PSIG falling.
2.3.4 The EVAPORATOR MODULE ASSEMBLY (PN 1134200-60/-61/-63, Supersedes 1134200-
42/-43) has a rated cooling capacity of 7000 BTUH at an ambient air temperature of 80° F
(db), and 50% RH (relative humidity). The assembly provides an air flow of 225 CFM (cubic
feet per minute) in order to maintain these performance specifications.
2.3.5 The Evaporator Module Assembly is packaged to meet the aircraft installation requirements
and contains the following major components (refer to Figure 10002/10003):
•Coil Assembly
•Blower Motor
•Blower Wheel
•Blower Scroll
•Expansion Valve
•Evaporator Housing
2.3.5.1 COIL ASSEMBLY: The evaporator coil assembly contains the evaporator coil,
mounting hardware, and refrigerant plumbing connections. The coil is constructed of
copper tube and aluminum fins with aluminum support brackets made of 6061-T6
Aluminum.The assembly receives its air (return air) from the suction created by the
blower assembly. This air is conditioned and returned to the cabin.

Component Maintenance Manual
12037 N Highway 99
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2.3.5.2 BLOWER MOTOR: The blower motor operates on 28 VDC with a rated current draw
of 10 AMP and has a design RPM of 5250-6250. The blower motor is a brushless
design with an integrated controller and was selected for its efficiency, excellent
controllability, long life and low vibration at high speeds. The motor has two speeds,
low speed designed for the heating recirculation requirement and high speed
designed for maximum system cooling. It was designed for continuous operation.
2.3.5.3 BLOWER WHEEL: The blower wheel is the component that is used in concert with
the blower motor and provides for the movement of air. It is made of lightweight
aluminum that provides superior strength and durability.
2.3.5.4 BLOWER SCROLL: The blower scroll is constructed of high impact, fire retardant,
self-extinguishing, and corrosion resistant, lightweight polycarbonate material (Lexan
F-6000). It is nickel plated to give it superior strength and durability qualities. The
blower scroll has successfully passed blower wheel containment testing.
2.3.5.5 EXPANSION VALVE: The expansion valve is an automatic thermostatic type. The
valve provides the proper refrigerant flow while maintaining constant return gas
superheat at all evaporator heat load conditions. Controlling the evaporator
refrigerant flow based on cooling demand prevents coil freeze up. This allows the
system cooling capacity to best meet transient aircraft heat load demands.
2.3.5.6 EVAPORATOR HOUSING: The evaporator housing is constructed of high impact, fire
retardant, self-extinguishing, and corrosion resistant, lightweight polycarbonate
material (Lexan F-6000).

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TESTING AND FAULT ISOLATION
TASK 21-00-23-70-801
3.0 R-134A AIR CONDITIONING SYSTEM COMPONENT – TESTING AND FAULT ISOLATION
SUBTASK 21-00-23-99F-009
3.1 General:
3.1.1 Testing and Fault Isolation of the R-134A Air Conditioning System may be necessary if the
system does not operate and/or perform in accordance with information contained herein.
Therefore it is necessary for the service personnel to diagnose the discrepancy by
troubleshooting the system and its components. To assist in this diagnoses, refer to table 3
(Trouble Shooting List)
SUBTASK 21-00-23-70-001
3.2 Compressor Condenser Module Assembly Testing Procedures
(refer to Figure 10001):
3.2.1 Ensure that power is applied to the aircraft and that the air conditioning system is switched
on using the cockpit mounted selector switch. Gain access to the Compressor Condenser
Module (refer to the aircraft maintenance manual for removal of access panels and other
hardware that might need to be removed). Verify that these components are operating and
perform the following:
3.2.1.1 Verify that system is running smoothly and that there is no excessive noise and/or
vibration coming from the assembly.
3.2.1.2 Verify that the system is cooling properly.
3.2.2 If there is excessive noise and/or vibration coming from the Compressor Condenser Module
assembly or the system is not cooling, refer to Fault Isolation, Section 3.6, Disassembly
procedures in section 5 and Check (inspection) procedures in section 7. This will help in
identifying whether one or more components are dirty or damaged and are in need of repair
or replacement.
SUBTASK 21-00-23-70-002
3.3 Evaporator Module Assembly Testing Procedures
(refer to Figure 10002):
3.3.1 Verify blower motor operation in both low and high speed positions using cockpit mounted
selector switch.
3.3.2 While blower motor is operating in both positions, listen carefully for the following:

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3.3.2.1 Verify that there is a distinct and noticeable change in sound of blower motor when
changing from low to high speed positions. This indicates that the cockpit selector
switch is functioning properly and that the blower motor is responding accordingly.
3.3.2.2 Verify that there is a smooth transition when changing from low to high speed
positions, and that there is no excessive noise or vibration coming from the blower
motor during the change. Excessive noise could indicate that the blower wheel is
rubbing against the blower scroll.
3.3.3 If there is excessive noise and/or vibration coming from blower motor/wheel assembly
during this test, please refer to Fault Isolation, Section 3.6, Disassembly procedures in
section 5 and Inspection procedures in section 7. This will help in identifying whether the
blower motor wheel is dirty or damaged and is need of repair or replacement, the blower
scroll is dirty or damaged and is need of repair or replacement, or the blower motor itself is
in need of replacement.
3.3.4 Verify that the system is cooling properly. If not, the expansion valve(s) might need
aligning. Refer to Special Procedures, Section 12, for Expansion Valve Alignment
procedures.
NOTE: If a failure has occurred to the evaporator module assembly, a fault LED light will sometimes
illuminate inside the blower motor (1134200-60/-61/-63 evaporators only) and may be seen through the vent
cap/screen on the side of the motor. If technician observes the fault LED light, component must be removed
and replaced (refer to Disassembly, Section 5 and Assembly, Section 9).
SUBTASK 21-00-23-70-003
3.4 System Leak Check Testing Procedure:
3.4.1 A leak check of the refrigerant plumbing system is important to ensure the system maintains
its charge to provide the designed performance and reduce damage to system components.
A periodic check of the system charge is required to determine if any loss of refrigerant has
occurred.
3.4.2 A system leak check is required any time one or more of the following conditions occur:
•New system plumbing installation
•Component replacement in the plumbing system
•Line or hose rupture
3.4.3 Special Tools and/or Equipment Required:
•Gaseous dry nitrogen, regulated source (0-500 psig)
•R-134A refrigerant charging manifold with gauges and hoses (low pressure gauge, 0-300
PSIG), (high pressure gauge, 0-600 PSIG)
•Leak check fluid (soap solution), (Spec MS-SNOOP-GAL)
•Assorted hand tools
•Hand and eye protection

Component Maintenance Manual
12037 N Highway 99
Seminole, OK 74868
Phone [phone]
Fax [phone]
http://www.enviro-ok.com
Copyright © 2017
ATA 21-00-23
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•Thread sealant primer, PN 7471 (Loctite)
•Thread sealant, PN 569 (Loctite)
•Hose adapter (1/2 in. male acme to ¼ in. female flare)
3.4.3.1 Remove, if required, all panels, doors, shrouds, etc, to gain access to
system/component being leak checked (refer to aircraft maintenance manual).
3.4.3.2 Remove, if required, any enclosures or access doors to expose all tubing, hoses,
fittings, etc. to the system components.
3.4.3.3 Verify all plumbing connections are tight.
3.4.3.4 Verify that power is removed from aircraft. If it is not practical to remove aircraft
power, technician must pull and collar applicable circuit breakers.
CAUTION: HIGH PRESSURE HOSE (RED) IS CONNECTED TO PORT MARKED “D” AND THE LOW
PRESSURE HOSE (BLUE) IS CONNECTED TO THE SERVICE PORT MARKED “S”. INCORRECT
CONNECTION COULD RESULT IN MANIFOLD DAMAGE AND/OR INCORRECT PRESSURE READINGS.
3.4.3.5 Remove service port caps from the A/C system. Service ports are located on the
compressor.
3.4.3.6 Close all manifold gauge valves and verify hose connections are tight.
3.4.3.7 Connect R-134A refrigerant charging manifold. R-134A service gauges contain quick-
connect fittings to minimize refrigerant loss. To install quick-connect, push on firmly
until locked (a "clicking" sound is heard). Hold the grip ring and pull to remove quick-
connect fittings.
3.4.3.8 Connect yellow charging hose to a regulated dry nitrogen source
NOTE: An adapter is required to connect yellow charging hose to the nitrogen source.
CAUTION: APPLY NITROGEN PRESSURE SLOWLY DURING THIS PROCEDURE OR DAMAGE TO
SYSTEM COULD RESULT.
CAUTION: DO NOT EXCEED 200 PSIG NITROGEN PRESSURE DURING PROCEDURE OR DAMAGE TO
EXPANSION VALVE WILL RESULT.
3.4.3.9 Slowly regulate nitrogen source to a pressure of 200 PSIG maximum.
3.4.3.10 Slowly open high pressure (red) manifold valve and allow system pressure to increase
gradually until a pressure of 200 psig is achieved. Allow time for system pressure to
equalize across expansion valve and note final system pressure.
CAUTION: DO NOT USE ANY LEAK DYE IN R-134A SYSTEM OR DAMAGE TO SYSTEM MAY RESULT.
CAUTION: DO NOT OVER TIGHTEN PLUMBING CONNECTIONS. STRIPPED THREADS OR CRACKED
FLARES MAY RESULT.