Illinois Tool Works TRILECTRON AIR-A-PLANE RJ150-30 User manual

TECHNICAL 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 Only)

RJ150-30 / Operations and Maintenance Manual
Mobile Aircraft Air Conditioner
Trailer Mounted, Cool Mode Only
_________________________________________________________________
COVER JANUARY 20, 2004
PAGE 2
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its constituents
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
refrigerant to the atmosphere is not permitted.
Under no circumstances should refrigerant from
the system or Freon cylinders be vented to the
atmosphere. Always use a refrigerant recovery and
recycle system. Observe all local and national
statutes concerning the handling or refrigerant
chemicals.

RJ150-30 / Operations and Maintenance Manual
Mobile Aircraft Air Conditioner
Trailer Mounted, Cool Mode Only
_____________________________________________________________________________
JANUARY 20, 2004 RECORD OF CHANGES
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RECORD OF CHANGES
This Technical Manual is published by Trilectron 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/revisions or pages are missing, contact Trilectron Industries, Inc. for
additional copies.
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JANUARY 20, 2004 LIST OF EFFECTIVE PAGES
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Trailer Mounted, Cool Mode Only
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RJ150-30 / Operations and Maintenance Manual
Mobile Aircraft Air Conditioner
Trailer Mounted, Cool Mode Only
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JANUARY 20, 2004 INTRODUCTION
PAGE 1
INTRODUCTION
1. GENERAL:
This Technical Manual has been written using the information supplied to the
Technical Publications Department by the Engineering and Production
Departments at the time of publication. Every effort has been made to include
the most accurate and up-to-date information at the time of publication.
However, no warranty is made, expressed or implied, as to the accuracy of this
manual. It is intended to be used as a guide. Any technical or administrative
errors may be corrected in future Changes or Revisions of this manual.
2. CONTENTS:
This Technical Manual presents general data pertinent to the operation, servicing
and maintenance on aircraft ground support equipment manufactured by
Trilectron Industries, 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 followed by a reference
designation in parentheses, i.e., compressor motor (M2).
This Technical Manual is arranged in Chapters and Sections. The contents of
each are described briefly as follows:
Chapter 1 –General Information and Operating Instructions
Section 1-1 –Description: This section provides unit descriptive overview
and pertinent information on the major unit components installed by the
manufacturer.
Section 1-2 –Operation: Provides basic operations procedures and
includes step-by-step inspection, normal operation, and emergency
procedures.
Section 1-3 –Vehicle Specifications: Lists the unit’s dimensions; weight,
and other pertinent unit performance specifications.
Section 1-4 –Shipping/Receiving: Provides information required to
prepare the unit for shipping and for initial inspections at receiving facility.
Section 1-5 –Storage: Provides procedures for preparing the unit for short-
and long-term periods of time under varying climatic conditions.

RJ150-30 / Operations and Maintenance Manual
Mobile Aircraft Air Conditioner
Trailer Mounted, Cool Mode Only
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INTRODUCTION JANUARY 20, 2004
PAGE 2
Chapter 2 –Maintenance
Section 2-1 –Servicing: Provides periodic maintenance schedules and
procedures.
Section 2-2 –Troubleshooting: Provides unit fault/failure conditions,
probable causes, and recommended corrective actions. This section includes
all appropriate electrical and refrigeration diagrams/schematics.
Section 2-3 –Removal/Replacement: Provides procedures and precautions
for removing and installing components.
Section 2-4 –Repairs & Cleaning/Painting: Provides procedures and
methods for maintenance repairs, cleaning and painting.
Chapter 3 –Overhaul/Major Repair
This chapter provides information 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 of component vendors’ addresses.
Section 4-2 –Parts List Index: Provides index of all parts installed on the
unit.
Section 4-3 –Illustrated Parts List: Provides illustrations, drawings,
depictions, and instructions for locating and ordering replaceable parts/
components.
Chapter 5 –Manufacturers’ Appendices: Contains available manuals,
instruction bulletins, and illustrated parts lists issued by component original
equipment manufacturers (OEMs).
3. UNIT CONFIGURATION:
This manual may contain descriptions, procedures, and parts lists covering
several configurations of the basic unit. Refer to the Unit Configuration Matrix
and Specifications in Section 1-3 of this Technical Manual as required for
complete configuration details. Where indicated, refer to Supplemental Technical
Manuals for details on specific design configurations.

RJ150-30 / Operations and Maintenance Manual
Mobile Aircraft Air Conditioner
Trailer Mounted, Cool Mode Only
______________________________________________________________________________
JANUARY 20, 2004 INTRODUCTION
PAGE 3
EQUIPMENT WARRANTY
1. TRILECTRON INDUSTRIES (hereinafter called TRILECTRON) warrants that each new and unused
TRILECTRON Equipment, (hereinafter called the PRODUCT) is of good workmanship and is free from
mechanical defects, provided that (1) the PRODUCT is installed and operated in accordance with the printed
instructions of TRILECTRON, (2) the PRODUCT is used under the normal operating conditions for which it is
designed, (3) the PRODUCT is not subjected to misuse, negligence or accident, and (4) the PRODUCT
receives proper care, lubrication, protection, and maintenance under the supervision of trained personnel.
2. This warranty expires 15 months after shipment by TRILECTRON to the first user, or 12 months after
installation, whichever first occurs.
3. This warranty does not apply to: primary and secondary switch contacts, carbon brushes, fuses, bulbs, and
filters unless found to be defective prior to use. Ground hose fittings, hose adapter, air delivery hoses, cables
and plugs are not included as part of this warranty with the exception that these components will comply with
all applicable specifications at the time of delivery of the unit.
4. TRILECTRON DOES NOT WARRANT THE FOLLOWING COMPONENTS: Compressors, pumps, valves
and other mechanical or electrical accessories, generators, engines, engine components; such as: starters,
alternators, regulators, governors, etc., and cable retrieving devices. Many of the foregoing components are
warranted directly by the manufacturer to the first user and serviced by a worldwide network of distributors
and others authorized to handle claims for component manufacturers. A first user's claim should be presented
directly to such an authorized component service outlet. In the event any component manufacturer has
warranted its component to TRILECTRON and will not deal directly with a first user then TRILECTRON will
cooperate with the first user in the presentation of a claim to such manufacturer. Under NO circumstances does
TRILECTRON assume any liability for any warranty claim against or warranty work done by or in behalf of
any manufacturer of the foregoing components.
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. This warranty is extended by TRILECTRON only to the purchaser of new PRODUCTS from TRILECTRON
or one of its authorized distributors. The PRODUCTS purchased under this warranty are intended for use
exclusively by the buyer and his employees and by no other persons and, therefore, there shall be no third party
beneficiary to this warranty.
7. A claim of defects in any PRODUCT covered by this warranty is subject to TRILECTRON factory inspection
and judgment. TRILECTRON’S liability is limited to repair of any defects found by TRILECTRON to exist,
or at TRILECTRON.S option the replacement of the defective product, F.O.B. factory, after the defective
product has been returned by the purchaser at its expense to TRILECTRON'S shipping place. Replacement and
exchange parts will be warranted for the remainder of the original Warranty, or for a period of ninety (90)
days, whichever is greater.
8. UNDER NO CIRCUMSTANCES whatsoever shall TRILECTRON and its authorized distributors be liable for
any special or consequential damages, whether based on lost goodwill, lost resale profits, work stoppage
impairment of other goods or otherwise, and whether arising out of breach of any express or implied warranty,
breach of contract, negligence or otherwise, except only in the case of personal injury as may be required by
applicable law.
9. Continued use of the PRODUCT(S) after discovery of a defect VOIDS ALL WARRANTIES.
10. Except as authorized in writing, this warranty does not cover any equipment that has been altered by any party
other than TRILECTRON.
11. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE
HEREOF. TRILECTRON MAKES NO WARRANTIES, EXPRESSED OR IMPLIED, OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
12. TRILECTRON neither assumes nor authorizes any person to assume for TRILECTRON any liability in
connection with the PRODUCTS sold, and there are no oral agreements or warranties collateral to or affecting
this written Warranty. This warranty and all undertakings of TRILECTRON thereunder shall be governed by
the laws of the State of Florida, United States of America.
WARNING
AT ALL TIMES, SAFETY MUST BE CONSIDERED AN IMPORTANT FACTOR IN THE INSTALLATION, SERVICING
AND OPERATION OF THE PRODUCT, AND SKILLED, TECHNICALLY QUALIFIED PERSONNEL SHOULD ALWAYS
BE EMPLOYED FOR SUCH TASKS.
FORM: WTY-TI

RJ150-30 / Operations and Maintenance Manual
Mobile Aircraft Air Conditioner
Trailer Mounted, Cool Mode Only
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INTRODUCTION JANUARY 20, 2004
PAGE 4
Warranty Inquiries:
Customer Services Department:
In the USA: Telephone [phone], FAX [phone]
Outside the USA: Telephone [phone], Fax [phone]
E-mail: [email protected]

RJ150-30 / Operations and Maintenance Manual
Mobile Aircraft Air Conditioner
Trailer Mounted, Cool Mode Only
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JANUARY 20, 2004 TABLE OF CONTENTS
PAGE 1
TABLE OF CONTENTS
HEADING PAGE
RECORD OF CHANGES ............................................................................ROC 1
LIST OF EFFECTIVE PAGES ....................................................................LOEP 1
INTRODUCTION .........................................................................................INTRO 1
EQUIPMENT WARRANTY..........................................................................INTRO-3
CHAPTER 1 -GENERAL INFORMATION & OPERATING INSTRUCTIONS
SECTION 1 DESCRIPTION
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/Shutdown .....................................................8
G. Pre-Conditioned Air (PCA) Components.....................................9
H. Electrical Controls Box.................................................................9
I. Operator Controls.........................................................................14
J. Canopy Lighting ...........................................................................16
3. AIR CONDITIONER SYSTEM DESCRIPTION .................................16
A. Air Conditioner System Components...........................................16
B. Protective Devices.......................................................................20
4. PRE-CONDITIONED AIR CONTROLS.............................................21
A. Cooling Air Flow Volume..............................................................21
B. Refrigeration System Defrost Cycle.............................................21
C. Temperature Control Functions -Cooling....................................22
SECTION 2. OPERATION
1. GENERAL ........................................................................................1
2. NORMAL OPERATING PROCEDURES...........................................1

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HEADING PAGE
A. Pre-Operational Inspection...........................................................1
B. Position the Unit for Aircraft Servicing..........................................5
C. Connect Pre-Conditioned 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/CHASSIS/FRAME .............................................................1
3. ENGINE/GENERATOR SET..............................................................1
4. AIR CONDITIONING SYSTEM..........................................................1
5. UNIT CONFIGURATION MATRIX.....................................................2
SECTION 4. SHIPPING/RECEIVING
1. GENERAL .........................................................................................1
2. PREPARATION FOR SHIPMENT ....................................................1
3. RECEIVING ......................................................................................2
A. Initial Inspection ..........................................................................2
B. Return To Service .......................................................................2
SECTION 5. STORAGE
1. GENERAL .........................................................................................1
2. PREPARATION FOR STORAGE .....................................................1
A. Short-Term Storage ....................................................................1
B. Long-Term Storage .....................................................................2

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Trailer Mounted, Cool Mode Only
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JANUARY 20, 2004 TABLE OF CONTENTS
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HEADING PAGE
CHAPTER 2 -MAINTENANCE
SECTION 1. SERVICING
1. GENERAL ........................................................................................1
2. UNIT MAINTENANCE / SERVICING AND INSPECTIONS ..............1
A. Preparation for Maintenance/Servicing .......................................2
B. Return To Service........................................................................2
C. Periodic Preventive Maintenance Schedules...............................4
3. AIR CONDITIONING SYSTEM .........................................................9
A. Special Tools and Equipment......................................................9
B. Refrigeration System 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. Preventing Moisture and Air Entry................................................21
K. Servicing the Expansion Valves...................................................24
L. Servicing the Filter-Drier...............................................................24
M. Servicing the Blower Assembly...................................................24
4. RUNNING GEAR...............................................................................25
SECTION 2. TROUBLESHOOTING
1. GENERAL ........................................................................................1
2. TROUBLESHOOTING CHART ........................................................2
A. Using the Troubleshooting Chart ................................................2
B. Support Test Equipment Required ..............................................3
C. Component Failure......................................................................3
3. SCHEMATICS AND WIRING DIAGRAMS .......................................6
SECTION 3. REMOVAL / REPLACEMENT
1. GENERAL ........................................................................................1
2. AIR CONDITIONING SYSTEM ........................................................1
A. Inlet Air Filters..............................................................................6
B. Blower Assembly.........................................................................7
C. Condenser Fan............................................................................9
3. BATTERIES.......................................................................................10
4. RADIATOR / CONDENSER COIL ASSEMBLY.................................10

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Mobile Aircraft Air Conditioner
Trailer Mounted, Cool Mode Only
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TABLE OF CONTENTS JANUARY 20, 2004
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HEADING PAGE
SECTION 4. ADJUSTMENT AND TEST
1. GENERAL .........................................................................................1
2. ELECTRONIC COMPONENT TEST AND ADJUSTMENT ...............1
A. Cooling System Settings & Adjustment .......................................7
3. AIR CONDITIONING THERMOSTAT & CONTROL 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 PARTS LIST
SECTION 1. LIST OF VENDORS
1. GENERAL .........................................................................................1
2. TO ORDER PARTS OR OBTAIN TECHNICAL ASSISTANCE .........1
SECTION 2. NUMERICAL PARTS LIST
SECTION 3. ILLUSTRATED PARTS LIST
1. GENERAL .........................................................................................1
2. DESCRIPTION OF FIGURES/TABLES ............................................1
A. Fig/Item No...................................................................................1
B. Trilectron Part No.........................................................................1
C. Vendor Part No............................................................................1
D. Airline Part No..............................................................................1
E. Description...................................................................................2
F. Quantity........................................................................................2
3. TO ORDER PARTS OR REQUEST TECHNICAL ASSISTANCE .....2
CHAPTER 5 -MANUFACTURERS’ APPENDICES

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JANUARY 20, 2004 TABLE OF CONTENTS
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TABLE OF CONTENTS
LIST OF FIGURES
HEADING PAGE
CHAPTER 1 -GENERAL INFORMATION & OPERATING INSTRUCTIONS
SECTION 1. DESCRIPTION
Figure 1. RJ150 Mobile Aircraft Air Conditioner ....................................2
Figure 2. Genset Major Components.....................................................6
Figure 3. Fuel Level Gauge...................................................................6
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. Refrigeration System Major Components...............................17
SECTION 2. OPERATION
Figure 1. Operator Control Station.........................................................2
Figure 2. Genset Control Panel.............................................................3
Figure 3. Fuel Level Gauge...................................................................5
Figure 4. Genset Emergency Stop Controls..........................................8
SECTION 4. SHIPPING/RECEIVING
Figure 1. Normalize Control Panels ......................................................3
CHAPTER 2 -MAINTENANCE
SECTION 1. SERVICING
Figure 1. Operator Controls...................................................................2
Figure 2. Refrigeration System Schematic............................................7/8
Figure 3. Refrigeration System Component Locations..........................10
Figure 4. Compressor Crankcase..........................................................16

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TABLE OF CONTENTS JANUARY 20, 2004
PAGE 6
HEADING PAGE
SECTION 2. TROUBLESHOOTING
Figure 1. Refrigeration System Schematic ............................................7/8
Figure 2. Unit Electrical Schematic .......................................................9-20
SECTION 3. REMOVAL / REPLACEMENT
Figure 1. RJ150 Mobile Aircraft Air Conditioner ....................................2
Figure 2. Inlet Air Filters ........................................................................6
Figure 3. Blower Inlet Transition............................................................7
Figure 4. Blower Outlet Transition..........................................................8
Figure 5. Blower 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 TEST
Figure 1. Component Locations ............................................................2
Figure 2. Electrical Controls Box ...........................................................5
Figure 3. Hot Gas Bypass Valve ...........................................................9
CHAPTER 4 -ILLUSTRATED PARTS LIST
SECTION 3. ILLUSTRATED PARTS LIST
Figure 1. RJ150-30 Complete Assembly ..............................................3
Figure 2. Canopy / Frame Assembly .....................................................9
Figure 3. Air Intake / Blower Assembly..................................................12
Figure 4. Discharge Air / Evaporator Assembly .....................................14
Figure 5. Dual Compressors & Condenser / Radiator Assemblies ........18
Figure 6. Single Compressor Assembly.................................................20
Figure 7. Running Gear .........................................................................22
Figure 8. Fuel System............................................................................24
Figure 9. Battery Set Assembly .............................................................26
Figure 10 Electrical Controls Box...........................................................27

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Trailer Mounted, Cool Mode Only
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JANUARY 20, 2004 SECTION 1 -1
PAGE 1
CHAPTER 1
GENERAL INFORMATION & OPERATING INSTRUCTIONS
SECTION 1
DESCRIPTION
1. GENERAL:
The Model RJ150-30 Mobile Aircraft Air Conditioner (See Figure 1) is enclosed,
self-contained, trailer-mounted, and designed to deliver pre-conditioned air (PCA;
cool mode only) consistent with servicing a variety of regional-jet (RJ) sized fixed
wing and/or rotary wing aircraft. The unit includes a Diesel 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 unit description, operation procedures, periodic
maintenance schedules and procedures, and illustrated parts lists for the major
components and subassemblies. Several model configurations are available
with user-specified engine/generator sets (gensets), air conditioning system
configuration, and accessory/optional items. Refer to appropriate Supplemental
Technical Manual(s) as required for additional details.
• RJ150-CUM-01: Cummins/Marathon 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

RJ150-30 / Operations and Maintenance Manual
Mobile Aircraft Air Conditioner
Trailer Mounted, Cool Mode Only
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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 Grille
Electrical Controls Box
Access Door
Fuel Tank
Unit Operator
Control Station
PCA Hose
Stowage Tray
Air Conditioning
System
Access Door
Genset and Compressor
Access Door

RJ150-30 / Operations and Maintenance Manual
Mobile Aircraft Air Conditioner
Trailer Mounted, Cool Mode Only
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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
Station
Discharge Air
Duct
Fuel Level
Gauge
PCA Hose
Stowage Tray
Fuel Tank
Tow Bar / Running
Gear
Genset Access Doors
Fuel Fill Station

RJ150-30 / Operations and Maintenance Manual
Mobile Aircraft Air Conditioner
Trailer Mounted, Cool Mode Only
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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
Coil Assembly
Blower
Assembly
Evaporator Coil
Discharge Air Duct
Fuel Tank
(Under Unit)
Air Damper Valve
Inlet Air Filter
Assembly
Diesel Engine
(Typical)