AirComm Corporation Cessna 182T T182T Maintenance Manual

							Products, Inc. 
CR-182-10 System Service Manual 
 
21-50-01 
Page 3 
October 15, 2009 
 
 
GENERAL ELECTRIC LAYOUT 
60 AMP ALTERNATOR  
						

							Products, Inc. 
CR-182-10 System Service Manual 
 
21-50-01 
Page 101 
September 20, 2002 
ES53025-2 
ELECTRICAL 
CONNECTOR
ELECTRICAL 
 
TROUBLESHOOTING 
1. GENERAL 
 
The following procedures are used for troubleshooting the electrical system and 
the electrical interface with the other assemblies of the air-conditioning system.  
The procedures systematically check every reasonable cause of the failure, 
starting from the power source that might result in the inoperation of the 
evaporator blower, condenser blower, and compressor clutch.  If the problem 
causing the component to fail is suspected, the suspected cause should be 
checked first.  The sequence of checks may be varied to increase the 
convenience of the checker as desired.  If the aircraft is equipped with a 95 amp 
alternator some of the troubleshooting steps may not apply. 
 
  A.  TOOLS AND EQUIPMENT 
 
DESIGNATION REF. NO. QTY. REMARKS 
Service pressure gauge  Comm. Avail  1  None 
Multi-meter Comm. Avail 1 None 
28 VDC source    A/R  None 
 
 
2. Evaporator Blower Doesn’t Operate 
 
‰ With the engine inoperative turn on the battery power 
‰ Turn the AIR COND/OFF/FAN switch to FAN. 
‰ Set the fan speed to high. 
‰ Disconnect the ES53025-2 Electrical Connector from the 
blower.  
‰ Check for power at pin 3 and pin 4 of the power side of the connector.  Both 
terminals should have a voltage reading between 26.0V and 29.0V.  Use a 
suitable aircraft ground when checking the power. 
‰ If correct power is present at Pin 3, and Pin 4, and ground is present at Pin 6, the 
problem lies with the evaporator/blower assembly. 
‰ If power is not present at pin 3 and Pin 4, the problem is due to a failed electrical 
component, a broken electrical connection, or a broken wire on the power side of 
the connector.   
 
1.  Check the 30 Amp fuse (if applicable) for continuity.  Replace as 
necessary 
2.  Check for power at the Circuit breaker.  If power is not present, check 
the KAC-MBA-10 wire for continuity.  Replace/repair as necessary.  
						

							Products, Inc. 
CR-182-10 System Service Manual 
 
21-50-01 
Page 102 
September 20, 2002 
3.  Check the 20 Amp Circuit Breaker for continuity between the two wire 
terminals.  Check the wire terminals for good connections to the 
wires.  Replace/repair as necessary. 
4.  Check for power at the AIR COND/OFF/FAN Switch.  If power is not 
present, check the KAC-MMB-16 wire for continuity.  Replace/repair 
as necessary. 
5.  Check the operation of the AIR COND/OFF/FAN Switch.  Check the 
wire terminals for good connections.  Replace/repair as necessary. 
6.  Check for power at the Fan Speed Potentiometer.  If power is not 
present, replace/repair the connecting wire as necessary. 
7.  If power is present at the Fan Speed Potentiometer and not at pin 3 
of the evaporator blower connector, check the KAC-CCE-16 wire for 
continuity.  Replace/repair as necessary. 
 
‰ If power is present at pin 3, but is not present at pin 4, the problem is due to a 
failed electrical component, a broken electrical connection, or a broken wire.   
1.  Check the Fan Speed Potentiometer for correct operation.  Replace 
or rewire as necessary. 
2.  Check resistance of the 5KΩ Resistor.  Replace as necessary. 
3.  Check the connections and wires from the Fan Speed Potentiometer 
to the 5KΩ Resistor, and from the 5KΩ Resistor to ground.  
Replace/repair as necessary. 
4.  Check for continuity from the wiper of the Fan Speed Potentiometer 
to the pin 4 of the evaporator blower connector.  Replace/repair KAC-
SCB-20 wire as necessary.  
 
 
 
Evaporator Electrical Schematic 
  
						

							Products, Inc. 
CR-182-10 System Service Manual 
 
21-50-01 
Page 103 
September 20, 2002 
 
3. Condenser Blower Doesn’t Operate 
 
‰ With the engine inoperative turn on the battery power. 
‰ Turn the AIR COND/OFF/FAN switch to AIR COND. 
‰ Turn the taxi light, prop de-ice and pitot heat off. 
‰ Check for power between the terminals of the EMI filter on the Condenser Blower 
Assembly. 
‰ If the voltage measured at the EMI filter terminals is between 24.0-29.0 VDC and 
the blower is not operating, the blower needs to be returned for replacement/repair. 
‰ If no voltage is measured at the EMI filter terminals, the problem is due to a failed 
electrical component, a broken electrical connection, or a broken wire.   
1.  Check the 30 Amp fuse for continuity.  Replace as necessary 
2.  Check for power at the Circuit breaker.  If power is not present, check 
the KAC-MBA-10 wire for continuity.  Replace/repair as necessary. 
3.  Check the 20 Amp Circuit Breaker for continuity between the two wire 
terminals.  Check the wire terminals for good connections to the 
wires.  Replace/repair as necessary. 
4.  Check for power at the ES56052-1 Relay.  If power is not present, 
Check the KAC-LSB-16 wire for continuity.  Replace/repair as 
necessary. 
5.  Check the terminals of the ES56052-1 Relay.  If there is no continuity 
between the KAC-LSB-16 and KAC-LSA-16 (NC and COM) wires, 
check for power at the relay terminal that connects to wires KAC-
LSF-16, KAC-LSE-16, and KAC-LSD-16.  There should be no power 
at this terminal.  If there is no power, check the relay for correct 
wiring and replace if necessary. 
6.  Check for power at the AIR COND/OFF/FAN Switch.  If power is not 
present, check the KAC-LSA-16 wire for continuity.  Replace/repair 
as necessary. 
7.  Check the operation of the AIR COND/OFF/FAN Switch.  Check the 
wire terminals for good connections.  Replace/repair as necessary. 
8.  Check for continuity from the AIR COND/OFF/FAN Switch to the 
positive terminal of the EMI filter.  Repair/replace as necessary. 
9.  Check for continuity from the Negative terminal of the EMI filter to 
ground.  Repair/replace as necessary.  
						

							Products, Inc. 
CR-182-10 System Service Manual 
 
21-50-01 
Page 104 
September 20, 2002 
 
 
Condenser Electrical Schematic 
60 Amp Alternator  
						

							Products, Inc. 
CR-182-10 System Service Manual 
 
21-50-01 
Page 105 
September 20, 2002 
3.  Compressor Clutch Doesn’t Engage 
 
NOTE: If the ambient temperature is less than 65ºF the temperature controller 
may disable the compressor clutch.  If the ambient temperature is less 
than 45ºF the freeze switch may disable the compressor clutch.  In order 
to troubleshoot an inoperative compressor clutch at temperatures between 
45ºF and 65ºF, use a short wire as a jumper between Pin 7 and Pin 8 of 
the ES53026-2 Electrical Connector on the evaporator assembly.  This will 
bypass the temperature probes. 
 
‰ With the engine inoperative turn on the battery power. 
‰ Turn the AIR COND/OFF/FAN switch to AIR COND. 
‰ Turn the taxi light, prop de-ice, and pitot heat off. 
‰ Turn the cooling control knob to MAX. 
‰ Check the voltage at the positive terminal of the compressor clutch. 
‰ If the voltage measured at the positive terminal of the compressor clutch is 
between 24.0-29.0 VDC, and the clutch does not engage, (it can be rotated without 
the compressor pulley rotating) the clutch and coil need to be returned for 
replacement/repair. 
‰ If no voltage is measured at the positive terminal of the compressor clutch, the 
problem is due to a failed electrical component, a broken electrical connection, a 
broken wire, or low temperature measured by the temperature probes.   
 
1.  Check the 30 Amp fuse for continuity.  Replace as necessary 
2.  Check for power at the Circuit breaker.  If power is not present, check 
the KAC-MBA-10 wire for continuity.  Replace/repair as necessary. 
3.  Check the 20 Amp Circuit Breaker for continuity between the two wire 
terminals.  Check the wire terminals for good connections to the 
wires.  Replace/repair as necessary. 
4.  Check for power at the ES56052-1 Relay.  If power is not present, 
Check the KAC-LSB-16 wire for continuity.  Replace/repair as 
necessary. 
5.  Check the terminals of the ES56052-1 Relay.  If there is no continuity 
between the KAC-LSB-16 and KAC-LSA-16 (NC and COM) wires, 
check for power at the relay terminal that connects to wires KAC-
LSF-16, KAC-LSE-16, and KAC-LSD-16.  There should be no power 
at this terminal.  If there is no power, and NC to COM is an open 
circuit, check the relay for correct wiring and replace if necessary. 
6.  Check for power at the AIR COND/OFF/FAN Switch.  If power is not 
present, check the KAC-LSA-16 wire for continuity.  Replace/repair 
as necessary. 
7.  Check the operation of the AIR COND/OFF/FAN Switch.  Check the 
wire terminals for good connections.  Replace/repair as necessary.  
						

							Products, Inc. 
CR-182-10 System Service Manual 
 
21-50-01 
Page 106 
September 20, 2002 
8.  Check for power at the JBS2020-5 Pressure Switch.  If power is not 
present, check the KAC-CCB-16 wire for continuity.  Replace/repair 
as necessary. 
9.  Check for continuity of the pressure switch.  If there is no continuity at 
the pressure switch, check the refrigerant pressure.  If the discharge 
pressure is between 35 and 340 PSIG, discharge the air-conditioning 
system and replace the JBS2020-5 Pressure Switch.  If the pressure 
is less than 35 PSIG or greater than 340 PSIG add/remove 
refrigerant to the proper level. 
10. Check for power at the Freeze Switch (Pin 3) on the evaporator 
assembly.  If power is not present, check the KAC-CCA-16 wire for 
continuity.  Replace/repair as necessary. 
11. Check for continuity between Pin 3 and Pin 2.  If there is no continuity 
between Pin 3 and Pin 2, and the ambient air temperature is greater 
than 45ºF, replace the Freeze Switch. 
12. Check for power at the ES56128-1 Relay.  If power is not present, 
check the KAC-CCC-16 wire for continuity.  Replace/repair as 
necessary. 
13. Check for continuity between Pin 1 and Pin 2 of the relay.  If the 
ambient air temperature is greater than 65ºF and there is no 
continuity between Pin 1 and 2 continue as follows: 
  Check for power at Pin 4.  If there is no power at Pin 4, replace the ES56128-1 
Relay. 
  If there is power at Pin 4, the temperature controller is powering the relay to 
disengage the clutch.  Using a short piece of wire create a short circuit between Pin 7 
and Pin 8 on the power side of the evaporator blower connector. 
  If the ES56128-1 Relay then disengages, replace the ES52126-1 Temperature 
Probes. 
  If the ES56128-1 does not engage, check the temperature controller for correct 
wiring and replace the ES62117-1 Temperature Controller as necessary. 
14. If there is power at pin 2 of the ES56128-1 Relay, and there is not 
power at the compressor clutch coil, repair/replace the KAC-CCD-16 
wire. 
  
 
 
 
  
						

							Products, Inc. 
CR-182-10 System Service Manual 
 
21-50-01 
Page 107 
September 20, 2002  
 
 
 
 
Compressor Clutch Electrical Schematic 
60 Amp Alternator  
						

							Products, Inc. 
CR-182-10 System Service Manual 
 
21-50-02 
Page 1 
April 5, 2002 
PLUMBING 
 
DESCRIPTION AND OPERATION 
 
1. GENERAL 
 
The plumbing system consists of flexible nylon lined refrigerant hose with 
permanent swaged on fittings.  All connections are tube o-ring type with sealant 
on the fitting mating surfaces to ensure leak-free operation.  Hose, o-ring 
material, and sealants are specially designed to work with refrigerant R134a and 
polyolester oil viscosity grade ISO 68.  Two service valves are located on the 
right side of the aircraft near the evaporator installation.  They are sized 
differently to avoid incorrect connection when servicing the system.  A 
receiver/drier bottle is located downstream of the condenser to remove moisture 
from the liquid refrigerant. The receiver/drier bottle is mounted in the tailcone of 
the aircraft.  A binary pressure switch monitors the refrigerant gas pressure.  This 
switch will open at a compressor discharge over-pressure of 384 ±29 psi and 
under-pressure conditions of 30 ±5 psi. This will interrupt the power to the 
compressor clutch and stop the compressor. 
 
The second overpressure safety device is a fuse plug, which will vent the system 
refrigerant in the event of a system pressure in excess of 425 PSIG.  The R134a 
gas would then be sucked into the condenser blower and forced out the exhaust 
duct on the right side of the aircraft.  It is located on the receiver/drier. 
 
 
This section of the maintenance manual discusses maintenance practices used 
for the plumbing portion of the air-conditioning system. Refer to 182-0800 for 
parts list and schematics.  
						

							Products, Inc. 
CR-182-10 System Service Manual 
 
21-50-02 
Page 201 
April 5, 2002 
PLUMBING 
 
MAINTENANCE PRACTICES 
 
 
 
1.0 GENERAL 
 
The following procedures are used to perform typical maintenance on the air-
conditioning system plumbing. 
 
CAUTION:  Do not operate air-conditioning system with condenser air inlet or 
outlet blocked. 
 
A.  Connection to components, o-ring replacement: 
 
1.  Place the appropriate o-ring (reference 182-0800 drawing) over the 
tube “O” end of the fitting. 
2.  Lubricate o-ring with polyolester oil or ES49000-1 sealant prior to 
assembly. 
3.  Apply sealant to all fitting-mating surfaces prior to assembly. 
4.  “Dry” torque recommendations for all fittings are as follows: 
 
Liquid hoses    11-13 ft/lbs 
Discharge hoses  15-20 ft/lbs 
Suction hoses  21-27 ft/lbs 
    
  It is recommended to torque to the low side of the torque range to 
prevent fitting twisting or damage. 
 
B.  Receiver/drier bottle replacement: 
 
1.  Replace receiver/drier bottle whenever the compressor is replaced 
or when the air-conditioning system plumbing is left open to the 
atmosphere for a period of time greater than one half (1/2) hour.