Enviro PILATUS PC12 Setup guide

Component Maintenance Manual
12037 N Highway 99
Seminole, OK 74868
Phone [phone]
Fax [phone]
http://www.enviro-ok.com
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
Phone [phone]
Fax [phone]
http://www.enviro-ok.com
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]
http://www.enviro-ok.com
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]
http://www.enviro-ok.com
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
Phone [phone]
Fax [phone]
http://www.enviro-ok.com
Copyright © 2017
ATA 21-00-23
Page | 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
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
Phone [phone]
Fax [phone]
http://www.enviro-ok.com
Copyright © 2017
ATA 21-00-23
Page | 7
Revision 10
June 1, 2017
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
Phone [phone]
Fax [phone]
http://www.enviro-ok.com
Copyright © 2017
ATA 21-00-23
Page | 8
Revision 10
June 1, 2017
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
Phone [phone]
Fax [phone]
http://www.enviro-ok.com
Copyright © 2017
ATA 21-00-23
Page | 9
Revision 10
June 1, 2017
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
Phone [phone]
Fax [phone]
http://www.enviro-ok.com
Copyright © 2017
ATA 21-00-23
Page | 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.