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Talley 2463T100-1, Technical Manual

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Talley 2463T100-1 Technical Manual Download Page 207

TM5-4120-375-14

REFRIGERANT TUBING (CONT.)

LOCATION/ITEM

ACTION

R E M A R K S  

INSTALLATION

9.

Tubing

a. Braze tubing in accordance with paragraph 5-15.

NOTE

When brazing refrigerant tubing or fittings near an insulated

wall of the air conditioner, fabricate 

a 

sheet metal shield to

deflect the flame of the torch away from the insulation. Perform

the operation in a well ventilated area.

NOTE

When brazing tubing from expansion valves, solenoid valves or
other components that could be warped or damaged by brazing

temperature. The component should be disassembled. If disassembly is

impractical or Impossible, the entire component except for the joints
to be heated, should be wrapped in wet cloth to act as a heat sink.

b .

Leak check, evacuate and charge system in

accordance with paragraphs 5-16 thru 5-18.

10.

Left Side Panel

a. Align holes in left side panel (18) and maintenance

panel (16) with holes in frame.

b .

Secure left side panel with twenty-seven
screws (17).

c .

Tighten bottom center turnlock fastener (15) on
maintenance panel.

Summary of Contents for 2463T100-1

Page 1: ...RATOR S ORGANIZATIONAL DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE AIR CONDITIONER MOUNTED AIR COOLED Hz N S N 4 1 2 0 0 1 1 2 2 0 6 2 9 MANUAL H E A D Q U A R T E R S D E P A R T M E N T O F T H E...

Page 2: ......

Page 3: ...on Connect one end of a number 6AWG American Wire Gage copper wire ground lead to an underground metallic water piping system or a driven metal ground rod or buried metal plate Connect the other end o...

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Page 5: ...d TM 5 4120 375 14 21 October 1983 is changed as follows 1 Remove and insert pages as indicated below New or changed text material is indicated by a vertical bar in the margin An illustration change i...

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Page 9: ......

Page 10: ......

Page 11: ...HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON D C 21 October 1983 OPERATOR S ORGANIZATIONAL DIRECT SUPPORT AIR CONDITIONER BASE MOUNTED AIR COOLED 208 VAC 3 PHASE 60 HZ SINGLE PACKAGE 36 000 BTU HR...

Page 12: ...d Support Equipment Service upon Receipt of Equipment Preventive Maintenance Checks and Services Troubleshooting Maintenance Procedures Preparation for Storage or Shipment DIRECT SUPPORT MAINTENANCE I...

Page 13: ...ng you a physical and functional description of those major equipment parts that you are likely to come in contact with INDEX I II III 1 2 3 4 5 6 7 8 9 General Information Equipment Description Techn...

Page 14: ...scribed by DA PAM 378 750 the Army Maintenance Management Systems TAMMS 1 3 DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE Refer to TM 750 244 3 Procedures for Destruction of Equipment to Prevent E...

Page 15: ...conditions necessary for the efficient operation of electronic equipment in the vans The air conditioner also provide for the comfort of operating personnel housed within the vans 1 7 CAPABILITIES AN...

Page 16: ...ON OF MAJOR COMPONENTS 1 2 3 4 5 6 7 8 9 10 11 12 Compressor Evaporator coil Evaporator fan motor Expansion valve Condenser coil Junction box Dual pressure switch Solenoid valve Condenser fan motor Dr...

Page 17: ...tioner nomenclature national stock number part number contract number serial number and weight Air Conditioner Base Mounting Unifab Industries Inc UAC 40 5 6 08 4120 01 122 0629 The Talley Corporation...

Page 18: ...0 BTU HR for cooling Once started it operates automatically due to the relationship of the components controls and instruments 1 12 VENTILATION Placing the selector switch in the FAN position energize...

Page 19: ...1 13 COOLING With the selector switch in the COOL position the fan motors and the compressor are energized The fan motors and compressor run continuously The thermostat controls the amount of cooling...

Page 20: ......

Page 21: ...of the major components of the air conditioner It explains how to operate the Air Conditioner For your convenience below is an index of this chapter SECTION I II III IV 2 1 GENERAL INDEX TITLE PAGE I...

Page 22: ...cts before the air 2 3 PMCS PROCEDURES a Item numbers conditioner is damaged or fails in the first column of Table 2 1 are the order in which inspections are to be done Column two Interval lists when...

Page 23: ...checked and serviced without disturbing operation Hake the complete checks and services when B Before Operation the equipment can be shut down D During Operation A After Operation ITEM INTERVAL ITEM T...

Page 24: ...NT NO B D A INSPECTED IS NOT READY AVAILABLE IF 3 Sight Glass Check for cloudy or bubbles 4 Damper Control Check for Freedom of movement 5 Noise or Vibration Listen for any unusual noise or vibration...

Page 25: ...enance level Be careful in serious when working with injury or death b Connect power c Perform preventive maintenance checks and services 2 5 STARTING THE EQUIPMENT Before you operate Always keep in m...

Page 26: ...erating NOTE For maximum cooling capacity when outside temperature is high set damper controls at full MIN position b Cooling mode 1 Set thermostat for desired 2 Turn rotary control switch room temper...

Page 27: ...diness If unit does not operate refer to troubleshooting procedures in Chapter 3 of this manual CAUTION Check sight glass for bubbles or yellow color If sight glass is bubbly yellow color notify Direc...

Page 28: ...0 375 14 2 7 STOPPING Turn rotary control switch to OFF position 2 8 OPERATIONAL INSTRUCTION WARNING PLATES DISCONNECT MAIN POWER PLUG BEFORE SERVICING ELECTRICAL SYSTEM OPERATE ONLY WITH PANEL INSTAL...

Page 29: ...REAS 2 12 OPERATION UNDER RAINY OR HUMID CONDITIONS a Keep unit clean and dry b Cover unit when not in use c Remove cover during dry periods and allow unit to dry 2 13 OPERATION IN SALT WATER AREAS a...

Page 30: ......

Page 31: ...3 1 There is no lubrication required for this air conditioner SECTION II TROUBLESHOOTING 3 2 GENERAL a Table 3 1 provides information useful in diagnosing and correcting malfunctions which you may fin...

Page 32: ...ING Be careful when working with high voltage Failure to comply can result in serious injury or death Step 1 Check to see if main power cord is plugged in Connect power cable to air conditioner Step 2...

Page 33: ...o see if selector switch is in COOL position Place selector switch in COOL position Step 2 Check to see if THERMOSTAT is in COOLER position Notify Organizational Maintenance Step 3 Inspect air filter...

Page 34: ......

Page 35: ...and Support Equipment 4 1 I I Service Upon Receipt I I I Preventive Maintenance Checks and Services IV Troubleshooting V Maintenance Procedures VI Preparation for Shipment or Storage For authorized co...

Page 36: ...s then ready for inspection b Depreservation Prepare the air conditioner for inspection and operation as outlined on DA Form 2258 depreservation Guide for Vehicles and Equipment 4 6 INSPECTING AND SER...

Page 37: ...omponent if damage prevents the air conditioner from working 2 Front Control Box a Check for broken or damaged knob Insure that switches move freely from position to position b Repair any component th...

Page 38: ...r filters and inspect the filter for accumulation of dirt c Clean filter 5 Side Return Air Damper a Check to see that the FRESH AIR control moves freely between the the MIN and MAX position and that t...

Page 39: ...trailer capable of withstanding a concentrated load of approximately 550 pounds 292 kg If the unit is to be mounted near a wall or partition allow clearance to permit removal of panels Follow the bas...

Page 40: ...lower right front corner of the unit WARNING The air conditioner must be grounded prior to operation Connect one end of a number 6AWG American Wire Gage copper wire ground lead to an underground metal...

Page 41: ...he corrective action taken on DA Fom 2404 Equipment Inspection and Maintenance Worksheet at the earliest opportunity If your equipment fails to operate troubleshoot with proper equipment Report any de...

Page 42: ...TED IS NOT READY AVAILABLE IF 1 Controls and Check for defective If damaged repair fittings or loose parts or replace controls in accordance with paragraph 4 16 2 3 Refrigeration Check for visable If...

Page 43: ...INTERVAL ITEM TO BE PROCEDURE EQUIPMENT NO M Q S INSPECTED IS NOT READY AVAILABLE IF 4 Screens and Grilles Check for dirt or If damaged damage repair or replace screens and grilles in accordance with...

Page 44: ...E PROCEDURE EQUIPMENT NO M Q S INSPECTED IS NOT READY AVAILABLE IF 6 Fans Check for security If damaged repair of attachment bent or replace fans or broken blades in accordance with paragraphs 4 25 7...

Page 45: ...M TO BE PROCEDURE EQUIPMENT No M Q S INSPECTED IS NOT READY AVAILABLE IF 8 Evaporator coil Check evaporator coil for cleanliness Check for visible and audible leaks 9 Condenser coil Check condenser co...

Page 46: ...ns If a malfunction is not listed or is not corrected by listed corrective actions notify your supervisor Onlv those functions within the scope of organizational maint enance are listed For troublesho...

Page 47: ...4 23 Replace defective main power connector in accordance with paragraph 4 23 Step 3 Check for loose electrical connections Tighten electrical connections Step 4 Check for defective wiring in accorda...

Page 48: ...Replace defective circuit breaker in accordance with paragraph 4 22 to see if dual pressure switch contacts are Push reset button at the dual pressure switch If compressor does not start stop air cond...

Page 49: ...ep 1 Check to see that thermostat temperature control is set correctly Place thermostat in cooler position Replace defective thermostat in accordance with paragraph 4 16 Step 2 Check for correct opera...

Page 50: ...dance with paragraph 4 26 fresh air dampers Remove eight screws and eight rubber washers securing lifting ring covers to top panel and frame Remove lifting ring covers Remove twenty three screws and e...

Page 51: ...n air filter panel door Open door Slide air filters out of unit and inspect filters Spray filters with a water hose in opposite direction of air flow see arrow on filter frame Shake water from filter...

Page 52: ...TM5 4120 375 14 Table 4 2 TROUBLESHOOTING cont Step 6 Check evaporator fan outlets for obstruction Remove obstruction 4 18...

Page 53: ...ble 5 2 Notify direct support maintenance Step 8 Check for moisture in system Notify Direct Support Maintenance CAUTION Check sight If sight glass is a glass for green color indicating unit is charged...

Page 54: ...OTE Resources required are not listed unless they apply to the procedure Personnel required are listed only if the task requires more than one If PERSONNEL is not listed it means one person can do the...

Page 55: ...h b Thermostat Dampers and Controls Evaporator Fan Motor and Housing Evaporator Fan Guard Junction Box a Circuit Breaker b Relays c Electrical Connectors Lifting Ring Covers Panels Power Wiring Harnes...

Page 56: ...References None Troubleshooting References None Special Environmental Conditions None General Safety Instructions Turn air conditioner OFF before performing maintenance LOCATION ITEM ACTION REMARKS R...

Page 57: ...for damage Repair or replace if damaged NOTE Rubber washers are to be placed between lifting ring cover and top panel 3 Lifting Ring Cover a b Align holes in and top panel Secure lifting lifting ring...

Page 58: ...onmental Conditions None General Safety Instructions Turn air conditioner OFF before performing maintenance LOCATIONS ITEM ACTION REMARKS REMOVAL 1 Evaporator Fan Guard a b 2 Control Box a b Remove fo...

Page 59: ...rews 7 securing front panel 8 to frame Remove front panel Remove thirty one screws 9 securing right side panel 10 Remove right side panel Remove eight screws 11 eight rubber washers 12 securing liftin...

Page 60: ...emove two screws 17 and loosen two turn lock fasteners 18 securing air filter panel 19 to frame Remove air filter panel Loosen eight turnlock fasteners 20 securing maintenance panel 21 to left side pa...

Page 61: ...table D 1 table D 1 table D 1 table D 1 TM5 4120 375 14 4 27...

Page 62: ...ial and secure insulation with adhesive in accordance with item 2 table D 1 c Inspect hinge for damage and freedom of movement d Lubricate hinge as required e Inspect information plates for damage f I...

Page 63: ...asket material and secure with adhesive in accordance with table D 1 for loose or damaged insulation damaged insulation material and secure insulation with adhesive in accordance with item 2 table D 1...

Page 64: ...e Panel a Align holes in left side panel 22 with holes in frame b Secure left side panel with twenty seven screws 23 14 Maintenance Panel a Align holes in maintenance panel 21 with holes in left side...

Page 65: ...Secure air filter panel with two screws 17 and two turnlock fasteners 18 16 Top Panel a Align holes in top panel with holes in frame b Secure top panel 14 with twenty three screws 16 and eight screws...

Page 66: ...ION 17 Right Side Panel a b a b 18 Front Panel Align holes in right side panel 10 with holes in frame Secure right side panel with thirty one screws 9 Align holes in front panel 8 with Secure front pa...

Page 67: ...ard a b Connect electrical connector P 6 to control box Align holes in control box 5 with holes in front panel and frame Secure control box with four screws 4 and four screws 3 Align holes in evaporat...

Page 68: ...18 References None Troubleshooting References None Special Environmental Conditions None General Safety Instructions Turn air conditioner OFF before performing maintenance LOCATION ITEM ACTION REMARKS...

Page 69: ...Loosen two set screws 6 securing rotary switch knob 7 to rotary switch 10 Remove knob 7 Remove nut 8 and washer 9 securing rotary switch to control box Tag and remove wires from rotary switch terminal...

Page 70: ...7 5 1 4 LOCATION ITEM ACTION REMARKS REMOVAL 4 Thermostat a Tag and remove wires from thermostat b Remove three flat nuts 14 and three star washers 15 securing thermostat 16 to control box c Remove t...

Page 71: ...ontinuity between terminals 11 and 12 11 and 13 and 12 and 13 c Place knob in the FAN position d Check for continuity between terminals 11 and 12 Check for lack of continuity between terminals 11 and...

Page 72: ...erature control on thermostat in the COOL position Check for continuity between terminals COM and NO If lack of continuity is found replace defective thermostat Place thermostat in ambient temperature...

Page 73: ...ial and secure with adhesive in accordance with table D 1 for loose or damaged insulation damaged insulation aterial and secure insulation with adhesive in accordance with item 2 table D 1 e Inspect i...

Page 74: ...RKS INSTALLATION 8 Thermostat a Align thermostat 16 with holes in control box 3 b Attach two wires to proper terminals on thermostat and one wire to thermostat mounting stud c Secure thermostat and wi...

Page 75: ...h 10 with hole in control box Secure rotary switch to control box with star washer 9 and retaining nut 8 Attach rotary switch knob to rotary switch Secure rotary switch knob 7 to tightening two set sc...

Page 76: ...4 42 TM5 4120 375 14 CONTROL BOX CONT LOCATION ITEM ACTION REMARKS INSTALLATION 110 Control Box a Align control box 3 with holes in frame b Secure control box with four screws 2 and four screws l...

Page 77: ...TM5 4120 375 14 4 43 4 17...

Page 78: ...TION REMARKS INSPECTION 2 Evaporator Fan Guard a Inspect for damage b Repair or replace if damaged INSTALLATION 3 Evaporator Fan Guard a Align evaporator fan guard 2 with holes in front panel 3 and fr...

Page 79: ...4 45 TM5 4120 375 14 4 18...

Page 80: ...ION REMARKS INSPECTION 2 Condenser Coil Guard a Inspect for damage INSTALLATION b Repair or replace if damaged 3 Condenser Coil Guard a Align condenser coil guard 3 with holes in frame b Secure conden...

Page 81: ...TM5 4120 375 14 4 47 4 19...

Page 82: ...water hose in opposite direction of air flow See arrow on filter frame b Shake water from filter and allow to dry before installing c Inspect for damage d Replace if damaged CAUTION Do not use oil on...

Page 83: ...nt None Tools TOOL KIT SC 5180 90 C N18 References None Troubleshooting References None Special Environmental Conditions None General Safety Instructions Turn air conditioner OFF before performing mai...

Page 84: ...3 and eight rubber washers 4 securing lifting ring cover 5 to top panel 6 and frame Remove lifting ring cover Remove twenty three screws 7 and eight screws 8 securing top panel 6 to frame Remove top...

Page 85: ...ost 14 securing control cable 15 to left return air damper 16 and fresh air damper Remove two screws 17 securing left return air damper to frame Loosen screw 18 securing control cable housing 19 to co...

Page 86: ...on mechanical post 22 securing control cable 23 to left return air damper and fresh air damper 24 Pull control cable through control cable housing until it clears mechanical post on left return air d...

Page 87: ...urn air damper 30 and fresh air damper 31 Loosen set screw 33 on control cable knob 34 Remove control cable knob Remove retaining nut 35 and control cable 37 to damper star washer 36 securing control...

Page 88: ...47 and four screws 48 securing control box 49 to frame and front panel Disconnect electrical connector P 6 from back of control box Remove control box Remove thirty four screws 50 and two screws 51 s...

Page 89: ...TM5 4120 375 14 a b c d e 4 55...

Page 90: ...Screen a b c d e Loosen screws 40 on mechanical post 65 securing control cable 66 to right return air damper and fresh air damper 67 Pull control cable through control cable housing until it clears me...

Page 91: ...TM5 4120 375 14 Change 1 4 5 7...

Page 92: ...ovement lubricate if required Table D 1 Item 17 b Tighten loose mountings c Replace defective controls 13 Damper a Inspect for freedom of movement b Inspect for damage c Straighten bent louver blades...

Page 93: ...e control cable housing 88 to frame with one screw 80 and one locknut 81 and one clamp 8 2 d Align control cable 73 with damper box f Attach control cable knob to g Tighten set screw on control h Tigh...

Page 94: ...ght fresh air damper 67 and screen to frame b Secure right fresh air damper and screen to frame with four screws 68 and four locknuts 69 c Install grounding stud 69D flat washer 69C lock washer 69B an...

Page 95: ...lign right return air damper 59 to frame b Secure right return air damper to frame with two screws 60 c Slide control cable 58 into unit insuring that cable passes through mechanical post 57 on right...

Page 96: ...55 with holes in frame Secure damper box to frame with two screws 54 Align front panel 53 with holes in frame Secure front panel to frame with thirty four screws 50 and two screws 51 Connect electric...

Page 97: ...NOTE 32 b c d e f Align control cable with damper box 38 Secure control cable 29 to damper control box with retaining nut 35 and star washer 36 Attach control cable knob 34 to control cable 29 Tighten...

Page 98: ...Fresh Air Damper and Screen a Align left fresh air damper 24 and screen to frame b Secure left fresh air damper and screen to frame with four screws 25 and four locknuts 26 c Secure control cable 23 t...

Page 99: ...ame with two screws 17 Slide control cable 15 into unit insuring that cable passes through echanical post 14 on left return air damper and fresh air damper Secure control cable to left return air damp...

Page 100: ...ON ITEM ACTION REMARKS INSTALLATION 21 Left Side Panel a b c Align holes in left side panel 12 and maintenance panel 10 with holes in frame Secure left side panel with twenty seven screws 11 Tighten b...

Page 101: ...e screws 7 and eight screws 8 23 Lifting Ring Covers a Align four lifting covers 5 with top panel and frame NOTE Rubber washers are to be replaced between lifting ring cover and top panel b Secure lif...

Page 102: ...TOOL KIT SC 5180 90 C N18 References None Troubleshooting References None Special Environmental Conditions None General Safety Instructions Turn air conditioner OFF before performing maintenance LOCAT...

Page 103: ...N ITEM ACTION REMARKS REMOVAL 2 Left Side Panel a b c Loosen bottom center turnlock fastener 3 on maintenance panel 4 Remove twenty nine screws 5 securing left side panel 6 and maintenance panel to fr...

Page 104: ...c d e Loosen two clamps 7 securing drain lines 8 to drain connector Disconnect drain lines Remove two screws 9 and two locknuts 10 securing drain connector to frame Remove drain connector 11 from fra...

Page 105: ...clamp 15 securing drain line 16 to evaporator drain pan 14 h Slide long section of rubber hose through unit from left side i Loosen clamp 17 securing drain line 18 to evaporator drain pan j Remove dra...

Page 106: ...the air conditioner to tilt it slightly then pour about one pint one half liter of water into the drip pan below the evaporator coil Verify that the water flows out of the drip pan through the drain t...

Page 107: ...rain line b Tighten clamp 19 c Connect drain line d Tighten clamp 17 e Slide long section side of unit f Connect drain line g Tighten clamp 15 20 to evaporator on drain line 18 to evaporator on drain...

Page 108: ...ndensate Drain h Connect drain lines 13 to evaporator drain pan 14 i Tighten two clamps 12 on drain line j Align drain connector 11 with frame k Secure drain connector with two screws 9 and two locknu...

Page 109: ...ALLATION 7 Left Side Panel a b c Align left side panel 6 and with frame maintenance panel 4 Tighten bottom center turnlock fastener 3 on maintenance panel Secure left side panel with twenty nine screw...

Page 110: ...90 C N18 References None Troubleshooting References None Special Environmental Conditions None General Safety Instructions Turn air conditioner OFF before performing maintenance LOCATION ITEM ACTION R...

Page 111: ...cing with air conditioner attempting any electrical a Remove two screws 4 securing junction box 5 to junction box support plate slide junction box out to allow removal of clamps 6 b Release the two cl...

Page 112: ...LOCATION ITEM ACTION REMARKS REMOVAL 3 Circuit Breaker CB1 a b c Remove six screws 8 and circuit breaker shield 9 securing circuit breaker 10 to junction box 11 Tag and remove Remove circuit six wires...

Page 113: ...5 Terminal Board TB1 a b c Remove three screws 12 and three lock nuts 13 securing relays 14 15 and 16 to junction box 17 Tag and Remove wires from relay Remove relay Remove two screws 18 and two nuts...

Page 114: ...ews 21 and four nuts 22 securing electrical connectors 23 and 24 to junction box b Remove electrical connectors 7 Thermal Relay Assembly S 4 a b c Tag and remove wires from thermal relay assembly S 4...

Page 115: ...information plate for damage d If damaged notify Direct Support Maintenance 9 Circuit Breaker a Inspect circuit breaker for damage b Replace if damaged 10 Relays a Inspect relay for damage b Replace...

Page 116: ...Tag and remove wire from terminal number 8 b Check for continuity between terminals 8 and 10 c If continuity does not exist the relay is defective d Replace defective relay 16 Electrical Connectors J...

Page 117: ...ay assembly S 4 25 with mounting bracket 27 b Secure thermal relay assembly S 4 to mounting bracket with two screws 26 c Attach wires to appropriate terminals J4 J5 a b c Align electrical connectors 2...

Page 118: ...n box b Secure terminal board to junction box with two screws 18 and two lock nuts 19 c Attach any wires that may have been removed 21 Relays K 1 K 2 K 3 a Align relays 14 15 and 16 with holes in junc...

Page 119: ...N ITEM ACTION REMARKS 22 Circuit Breaker CB1 a b c Align circuit breaker 10 and circuit breaker shield 9 with juction box Secure circuit breaker to junction box with six screws 8 Attach wires to appro...

Page 120: ...LATION 23 Junction Box a b c d Align junction box 5 with junction box support panel Connect two electrical connectors 7 to junction box Secure junction box to junction box support panel with two screw...

Page 121: ...JUNCTION BOX CONT LOCATION ITEM ACTION REMARKS INSTALLATION 24 Maintenance Panel a Align maintenance panel 2 with frame b Secure maintenance panel to frame and left side panel 3 with eight turnlock f...

Page 122: ...vironmental Conditions None General Safety Instructions Turn air conditioner OFF before performing maintenance LOCATION ITEM ACTION REMARKS REMOVAL 1 Lifting Ring Covers a b 2 Top Panel a b Remove eig...

Page 123: ...maintenance panel to frame e Remove left side panel 4 Right Side Panel a Remove thirty one screws panel 12 b Remove right side panel a Remove four screws 13 11 securing right side to frame and four s...

Page 124: ...rom 1 Evaporator Fan Motor P 3 19 2 Condenser Fan Motor P 2 20 3 Pressure Switch P 9 21 4 Solenoid Valve P 8 22 5 Compressor P 1 23 b Remove one screw 24 and lock nut 25 securing clamp 26 to frame on...

Page 125: ...g Harness e h i Remove two screws 30 and lock nuts 31 securing two clamps 32 and main wiring harness to condenser fan housing brackets Remove clamps Remove two screws 33 securing two clamps 34 and mai...

Page 126: ...Main Wiring Harness a b c Using a multimeter test for continuity between connectors and accordance with wire list Appendix E Continuity does not exist the wiring harness is defective Repair or replac...

Page 127: ...e main wiring harness Align two clamp 34 and with frame to appropriate areas main wiring harness Secure two clamps to frame with two screws 33 Align two clamps 32 and main wiring harness with condense...

Page 128: ...ng Harness Align ground wire terminals with frame Secure wire terminals to frame with one screw 27 one starwasher 28 and lock nut 29 Align clamp 26 for ground wires with frame Secure clamp for ground...

Page 129: ...l with thirty four screws 16 and two screws 17 12 Control Box a Connect electrical connector P 6 to control box b Align holes in control box 15 with holes in front panel c Secure control box with four...

Page 130: ...left side panel with twenty nine screws 9 15 Top Side Panel 7 on a Align hole top panel 4 with holes in frame b Secure top side panel with twenty three screws 5 and eight screws 6 NOTE Rubber washers...

Page 131: ...5180 90 C N18 References None Troubleshooting References None Special Environmental Conditions None General Safety Instructions Turn air conditioner OFF before performing maintenance LOCATION ITEM ACT...

Page 132: ...s 4 and two screws 5 securing front panel 6 to frame b Remove front panel 3 Right Side Panel a Remove thirty one screws 7 securing right side panel 8 b Remove right side panel 4 Maintenance Panel a Lo...

Page 133: ...RING HARNESS TM5 4120 375 14 CONT LOCATION ITEM ACTION REMARKS REMOVAL 5 Power Wiring Harness I a Remove four screws 12 and four locknutS 13 securing power wiring harness 14 and cap 15 to power box 16...

Page 134: ...two screws 17 and two locknuts 18 and two clamps 19 securing power wiring harness to condenser fan housing mounting brackets d Disconnect electrical connector P 4 from junction box 20 e Remove wiring...

Page 135: ...ring Harness a b c d e 7 Power Box a b Inspect for damage Repair or replace if damaged Using a multimeter test for continuity If continuity does not exist power wiring harness is defective Repair or r...

Page 136: ...x to frame with two screws 21 c Install power wiring harness to appropriate areas d Connect electrical connector P 4 to junction box 20 e Align two clamps 19 and power wiring harness with condenser fa...

Page 137: ...4 103 TM5 4120 375 14...

Page 138: ...right side panel with thirty one screws 7 11 Front Panel a Align holes in front panel 6 with holes in frame b Secure front panel with thirty four screws 4 and two screws 5 12 Control Box a Connect el...

Page 139: ...E Tools NONE References NONE Troubleshooting References Environmental Conditions Safety Instructions air conditioner OFF before performing maintenance ACTION REMARKS REMOVAL 1 Lifting Ring Covers a Re...

Page 140: ...d twenty three screws 5 securing top panel 6 to frame Remove top panel Remove eight screws 7 securing evaporator fan guards 8 to frame Remove evaporator fan guards Remove four screws 9 and four screws...

Page 141: ...T LOCATION ITEM ACTION REMARKS REMOVAL 6 Evaporator Fan Motor and Housing Assembly a Remove four screw 15 and four lock washers 16 securing evaporator fan housing 17 to evaporator drain pan CAUTION Be...

Page 142: ...23 to frame d Remove evaporator fan motor and housing assembly e Remove eight screws 27 securing outer inlet rings 28 to the fan housings f Loosen set screws 24 in hubs of both impellers g Slide impel...

Page 143: ...r damage Repair or replace if damaged Inspect for damage Repair or replace if damaged Using an ohmmeter or other continuity testing device check continuity between connector pins A B A C and B C If co...

Page 144: ...a coating of light oil to ease assembly CAUTION Be careful to avoid damaging fans during installation CAUTION Center impeller in fan housing and spin shafts to be sure no parts are rubbing Install mot...

Page 145: ...TM5 4120 375 14 j Secure evaporator fan housing with eight screws 19 to frame k Align evaporator fan housing mounting brackets 18 with evaporator drain pan holes change 1 4 1 1 1...

Page 146: ...nel a Align holes in front panel 14 with holes in frame b Secure front panel with thirty four screws 12 and two screws 13 14 Control Box a Connect electrical connector P 6 to control box b Align holes...

Page 147: ...orator fan guards to front panel and frame with eight screws 7 Align holes in top panel 6 with holes in frame Secure top panel with twenty three screws 5 and eight screws 4 17 Lifting Ring Covers NOTE...

Page 148: ...es NONE Troubleshooting References NONE Special Environmental Conditions NONE General Safety Instructions Turn air conditioner OFF before performing maintenance LOCATION ITEM ACTION REMARKS REMOVAL 1...

Page 149: ...CATION ITEM ACTION REMARKS 3 Right Side Panel REMOVAL 2 Front Panel a b b Remove screws frame Remove Remove twenty three 6 securing front panel screws 5 and eight front panel to thirty one screws 11 s...

Page 150: ...urnlock fastener 9 maintenance panel 10 Remove left side panel and maintenance panel 5 Junction Box a Remove two screws 13 securing junction box to support plate b Release the two clamps that secure t...

Page 151: ...OUSIMG CONT LOCATION ITEM ACTION REMOVAL 6 Condenser Fan Motor and Housing a b Remove five screws 14 that secure outer inlet ring 15 to left condenser fan housing 16 Remove inlet ring c Loosen set scr...

Page 152: ...d Housing d e f g h Remove two clamps 18 securing condensate drain lines to evaporator drip pan 19 Move condensate drain line out of the way to allow access to impeller Disconnect electrical connector...

Page 153: ...ION ITEM ACTION REMARKS REMOVAL 6 Condenser Fan Motor and Housing 1 Remove five screws 23 that secure outer inlet ring 24 to right condenser fan housing 25 Remove inlet ring Remove both impellers 26 f...

Page 154: ...MOTOR AND HOUSING CONT LOCATION ITEM ACTION REMARKS REMOVAL 6 Condenser Fan Motor and Housing m Remove two screws 27 and nuts 28 securing left condenser fan housing to junction box support n Remove ju...

Page 155: ...n Motor and Housing o Remove eight screws 30 and nuts securing condenser fan housings bottom to the frame Remove two screws 31 and nuts 32 securing right condenser fan housing to condenser fan housing...

Page 156: ...Housing r Remove three screws 34 securing dual pressure switch 35 to frame NOTE Take special care not to bend or side while removing motor bolts kink tubing Place switch to one s t u v Remove four bol...

Page 157: ...ing NOTE housing and fan motor must be removed before right housing can be removed w x y z aa Remove right condenser fan housing Remove four screws 38 securing inlet ring to fan housing 39 Remove inle...

Page 158: ...or damage b Repair or replace if damage TEST 11 Condenser Fan Motor a Using an ohmmeter or other continuity testing device check continuity between connector pins A B A C and B C b If continuity does...

Page 159: ...All arrows should of unit Install shaft Rotate by Housing NOTE show clockwise rotation when viewed from left side impeller hubs so they are even with ends of motor hand to assure running clearance a A...

Page 160: ...Align inside inlet rings with fan housing 39 d Secure inlet ring to fan housing with four screws 38 NOTE Install right fan housing before fan motor and left fan housing f g Align right condenser fan h...

Page 161: ...condenser fan housing 16 with holes in bottom of unit Align condenser fan motor with holes in frame Secure motor with four ounting k 1 bolts 36 Align dual pressure switch 35 holes with frame Secure du...

Page 162: ...enser fan motor and dual pressure switch n Slide both impellers into motor shaft CAUTION Do not hammer the impeller onto the motor shaft In case of difficulty dress out rough spots on the shaft with a...

Page 163: ...REMARKS INSTALLATION 12 Condenser Fan Motor Housing q Secure left condenser fan housing to junction box stiffener 29 with two screws 27 and nuts 28 NOTE Be sure to install junction box stiffener plate...

Page 164: ...ARKS INSTALLATION 12 Condenser Fan Motor Housing t Align inlet ring 15 with left housing 16 u Secure inlet ring to left housing with five screws 14 v Tighten set screws 17 on both hubs 26 NOTE Center...

Page 165: ...l connectors P 4 P 5 Align junction box with holes in junction box support plate Secure junction box to junction box support plate with two screws 13 Align left side panel 8 and maintenance panel 10 w...

Page 166: ...N REMARKS INSTALLATION 16 Right Side Panel a Align right side panel 12 with holes in frame b Secure right side panel with thirty one screws 11 17 Front Panel a Align front panel 4 with holes in frame...

Page 167: ...14 CONDENSER FAN MOTOR AND HOUSING CONT LOCATION ITEM A C T I O N R E M A R K S INSTALLATION 18 Control Box a b Align control box 3 with holes in front panel and frame Secure control box with four scr...

Page 168: ...move the external power connector and secure to inside of the maintenance panel 3 Prepare the air conditioner assembly for storage in accordance with TM 740 90 1 4 26 Shipment CAUTION Keep unit vertic...

Page 169: ...m that is included to assist maintenance of refrigerant components For your convenience below is an index of this chapter INDEX SECTION PAGE I Repair Parts Special Tools TMDE and Support Equipment 5 1...

Page 170: ...a malfunction is not listed or is not corrected by listed corrective actions notify your supervisor Only those functions within the scope of direct support maintenance are listed For troubleshooting p...

Page 171: ...glass in accordance with paragraph 5 33 Step 2 Feel dehydrator filter drier to see whether it is cold to the touch or is frosted or sweating Cold discharge indicates obstruction Replace dehydrator fi...

Page 172: ...B C and D E Continuity should be indicated Test points A B C to compressor casing or common ground No continuity should be indicated Replace compressor that does not meet continuity requirements in ac...

Page 173: ...nary thermometer If pressures are too low check for leaks and add refrigerant if too high bleed off refrigerant until pressure is normal Step 3 Pressure reset button on pressure switch Test pressure s...

Page 174: ...ep 1 Check sight glass for bubbles If bubbles exist leak check system in accordance with paragraph 5 16 Replace sight glass in accordance with paragraph 5 33 Step 2 Install gauges in accordance with p...

Page 175: ...unless some other condition is required besides the power being OFF 5 11 MAINTENANCE PROCEDURE INDEX REFRIGERATION SYSTEM Brazing Charging the System Compressor Compressor Motor Burnout Condenser Coi...

Page 176: ...rom coming in contact with exposed skin and eyes Provide adequate ventilation when discharging the system in a confined area NOTE Prior to opening the refrigerant system for maintenance the system mus...

Page 177: ...e recovery recycling unit must be by AUTHORIZED PERSONNEL 0NLY e Connect and operate a recovery recycling unit in accordance with the manufacturer s instructions f Connect a cylinder of dry nitrogen i...

Page 178: ...lacement is necessary The cause of failure must be determined before replacement is made a SYSTEM DISCHARGE Discharge system in accordance with paragraph 5 12 and 5 13 b DEBRAZING JOINTS 1 Connect a c...

Page 179: ...away from d BRAZING sharp fine file Hold tubing so filings will tube opening Braze joints in accordance with paragraph 5 15 e LEAK CHECK Leak check in accordance with paragraph 5 16 f SYSTEM EVACUATIO...

Page 180: ...cloth or wire brush Do not under any circumstances use sandpaper emery cloth or steel wool for this purpose 4 Flux female end of tubing 5 Slip tubing into fitting until it seats properly b BRAZING 1...

Page 181: ...refrigerant cylinder b Connect a cylinder of dry nitrogen item 8 table D 1 to the dis charge service valve Open the cylinder shutoff valve and the discharge service valve and pressurize the system to...

Page 182: ...tch for bubbles Follow a definite sequence to avoid missing any joints that should be tested Wipe the solution from all joints and mark any point at which a leak is found 3 Discharge the system after...

Page 183: ...iate modifications to these instructions a Connect a vacuum pump to the suction service valve and a vacuum gauge to the discharge service valve Start the pump and open both service valves Operate the...

Page 184: ...alve somewhat loose and open the nitrogen cylinder shutoff valve slightly for a few seconds to purge the line of air Tighten the connection and crack the suction service valve open slightly to break t...

Page 185: ...th refrigerant When charging the system use a manifold assembly similar to that shown below Connect a manifold and a cylinder of refrigerant item 11 table D l loosely to the service valves and open th...

Page 186: ...ant cylinders are in general use One is equipped with a single shutoff valve and must be inverted when charging liquid refrigerant The other is equipped with a vapor valve and a liquid valve which mak...

Page 187: ...essures begin to equalize When pressures have equalized or 10 pounds 4 48 kg of refrigerant gas have flowed into the refrigerant system close the suction service valve and the cylinder shutoff valve C...

Page 188: ...the refrigerant charge as follows 5 20 1 With the air conditioner compressor operating open the suction service valve and the cylinder shutoff valve to charge refrigerant gas into the system Continue...

Page 189: ...5 19 5 20 Table 5 2 TM5 4120 375 14 NOTE Dry bulb temperatures are measured with an ordinary thermometer Change 1 5 21...

Page 190: ...rate thermometer directly in front of guard making sure that the thermometer is shaded light to record outdoor ambient temperature the evaporator to unit the condenser coil from direct sun Loosen eigh...

Page 191: ...lowly open the suction line and discharge line service valves to which pressure gauges have been connected c Let the air conditioner operate for at least 15 minutes in the cooling retie so that all pa...

Page 192: ...m in accordance with paragraph 5 18 and repeat the pressure test in accordance with paragraphs 5 19 thru 5 24 b If pressures are too high Close the suction service valve remove the pressure gauge and...

Page 193: ...rigeration service manifold from the suction and discharge service valves c Secure service valve caps 5 to service valves d Maintenance panel 1 Align holes in maintenance panel 2 with holes in left si...

Page 194: ...tion Test d Installation INITIAL SETUP Test Equipment NONE Tools SC 5180 90 C N18 References NONE Troubleshooting References NONE Special Environmental Conditions NONE General Safety Instructions Turn...

Page 195: ...1 Control Box 2 Front Panel a Remove four screws 1 and four screws 2 securing control box 3 to frame and front panel 4 b Disconnect electical connector plug P 6 c Remove a Remove screws b Remove contr...

Page 196: ...eners 7 securing maintenance panel 8 to left side panel 9 b Remove maintenance panel WARNING All refrigerant gas must be discharged from the system before proceeding with the removal of the pressure s...

Page 197: ...rews 10 securing pressure switch 11 to frame Disconnect electrical connector P 9 12 Discharge unit in accordance with paragraph 5 3 Tag and disconnect sampling tubing by loosening flare nuts on low pr...

Page 198: ...auges on pressure switch are not accurate DO NOT rely on readings 7 Pressure Switch a Remove one screw securing pressure switch cover to pressure switch b Install wires in accordance with Appendix F c...

Page 199: ...5 31 TM5 4120 375 14 table D 1...

Page 200: ...Align pressure switch 11 with holes in frame c Secure pressure switch with three screws 10 CAUTION Assure sampling tubing is reinstalled in proper location to prevent damaging d Connect sampling tubi...

Page 201: ...URE SWITCH CONT LOCATION ITEM ACTION REMARKS INSTALLATION 9 Maintenance Panel a Align holes in maintenance panel 8 with holes in left side panel 9 and frame b Secure maintenance panel with eight turnl...

Page 202: ...with holes in frame b Secure front panel 4 to frame with thirty four screws 5 and two screws 6 11 Control Box a Align holes in control box 3 with holes in front panel b Secure control box with four s...

Page 203: ...al Conditions NONE General Safety Instructions Turn air conditioner OFF before performing maintenance LOCATION ITEM ACTION REMARKS REMOVAL 1 Lifting Ring Covers a Remove eight screws 1 and eight rubbe...

Page 204: ...ng right side panel 8 to frame b Remove right side panel 4 Control Box 5 Front Panel a Remove four screws 9 and four screws 10 securing control box 11 to front panel 12 b Disconnect electrical connect...

Page 205: ...nance panel 16 7 Tubing b Remove twenty seven screws 17 securing left side panel 18 to frame c Remove left side panel and maintenance panel WARNING All refrigerant gas must be discharged with the remo...

Page 206: ...m the insulation Per form the operation in a well ventilated area NOTE When debrazing tubing from expansion valves solenoid valves or other components that could be warped or damaged by brazing temper...

Page 207: ...from expansion valves solenoid valves or other components that could be warped or damaged by brazing temperature The component should be disassembled If disassembly is impractical or Impossible the e...

Page 208: ...n frame b Secure front panel with thirty four screws 13 and two screws 14 12 Control Box a Align control box 11 with holes in front Panel b Secure control box with four screws 10 and four screws 9 13...

Page 209: ...in frame b Secure top panel with twenty three screws 4 and eight screws 5 15 Lifting Ring Covers a Align holes in lifting ring covers 3 with frame and top panel b Secure lifting ring covers with eigh...

Page 210: ...NONE References NONE Troubleshooting References NONE Special Environmental Conditions NONE General Safety Instructions Turn air conditioner OFF before performing maintenance LOCATION ITEM ACTION REMA...

Page 211: ...scharging system to remove refrigeration component Discharge the system in accordance with paragraph 5 12 Remove 1 4 inch flare nuts 4 from service valves 5 Remove two screws 6 two lock nuts 7 and two...

Page 212: ...th service valve mounting bracket Secure service valves with two screws 10 and two lock washers 11 to service valve mounting bracket Align service valve mounting bracket with frame Secure service valv...

Page 213: ...RKS INSTALLATION 5 Maintenance Panel a Align holes in maintenance panel 2 with holes in left side panel 3 and frame 6 Pressure Test Pressure test air conditioner in accordance with paragraph 5 19 thru...

Page 214: ...8 References NONE Troubleshooting References NONE Special Environmental Conditions NONE General Safety Instructions Turn air conditioner OFF before performing maintenance LOCATION ITEM ACTION REMARKS...

Page 215: ...ction test and adjustment before discharging system to remove refrigeration component 2 Dehydrator a Filter Drier b c d Discharge the system in accordance with paragraph 5 12 Loosen screw 4 that secur...

Page 216: ...uts 6 at each end of the dehydrator filter drier and tighten tubing flare nuts c Leak check evacuate and charge accordance with paragraphs 5 16 5 Maintenance Panel 6 Pressure Test system in thru 5 18...

Page 217: ...ITIAL SETUP Test Equipment NONE Tools SC 5180 90 C N18 References NONE Troubleshooting References NONE Special Environmental Conditions NONE General Safety Instructions Turn air conditioner OFF before...

Page 218: ...nd adjustment before discharging system to remove refrigeration component Thermal Expansion Valve a b c d e Discharge the system in accordance with paragraph 5 12 Remove insulation 4 and band clamps 5...

Page 219: ...e NOTE Replace flanged base only if damaged f Debraze copper tubing at valve joints 11 in accordance with paragraph 5 15 CAUTION Maintain a 1 2 cpm 0 1 0 2 M 3 Min flow of dry nitrogen through the ref...

Page 220: ...n a container of ice water or crushed ice 32 F or 0 C CAUTION Do not let liquid refrigerant flood back into the compressor any longer than 1 2 seconds The expansion valve will be wide open during the...

Page 221: ...is the refrigerant gas does not become warm before reaching the end of the coil which would reduce the coils cooling capacity and the refrigerant does not remain in the liquid state after passing com...

Page 222: ...n position and cover with insulating material Connect a suitable pressure gauge to the suction service valve and open the valve Operate the air conditioner in the cooling mode for about 30 minutes obs...

Page 223: ...TM5 4120 375 14 Table 5 3 THERMAL EXPANSION VALVE CONT LOCATION ITEM ACTION R E M A R K S ADJUSTMENT 4 Thermal Expansion Valve 5 55...

Page 224: ...F Turn clockwise to raise and counterclock wise to lower the superheat setting Do not turn more than two full turns then wait ten minutes for temperature to stabilize before observing temperature and...

Page 225: ...e the power assembly to the flanged base 9 and separate the two b Braze in accordance with paragraph 5 15 c Install the flanged base in the support bracket d Install power assembly on flanged base bei...

Page 226: ...with insulating tape Item 6 table D 1 being careful to avoid kinking tube NOTE position as it was removed Carefully install the sensing bulb to its position on the suction line Clamp into position on...

Page 227: ...ATION ITEM ACTION REMARKS 6 Right Side Panel a Align holes in right side panel with holes in frame b Secure right side panel 1 with thirty one screws 2 7 Pressure Test Pressure test air conditioner in...

Page 228: ...eshooting References NONE Special Environmental Conditions NONE General Safety Instructions Turn air conditioner OFF before performing maintenance LOCATION ITEM ACTION REMARKS REMOVAL 1 Left Side Pane...

Page 229: ...TM5 4120 375 14 5 Condenser Fan Motor Remove in accordance with paragraph 4 20 and Housing 6 Junction Box Remove in accordance with paragraph 4 24 5 61...

Page 230: ...ent before discharging system to remove refrigeration component a Discharge the system in accordance with paragraph 5 12 NOTE Note position of bulb on removal and be sure to replace in same position b...

Page 231: ...rdance with paragraph 5 15 at inlet and outlet CAUTION Maintain a 1 2 cpm 01 0 2M3 MIN flow of dry refrigeration system to prevent oxidation and debrazing components ADJUSTMENT 8 Quench Valve a nitrog...

Page 232: ...17 to the power with two cap screws 15 d Wrap the capillary tube 19 with insulating tape Item 6 table D 1 being careful to avoid kinking the tube e Carefully install the sensing tube 18 to its positio...

Page 233: ...holes in right side panel 12 with holes in frame b Secure right side panel with thirty one screws 11 13 Front Panel a Align holes in front panel 8 with holes in frame 14 Control Box b Secure front pan...

Page 234: ...t Side Panel a Align holes in left side panel 1 with holes in frame b Secure left side panel with twenty nine screws 2 c Tighten bottom center turnlock fastener 3 on maintenance panel 4 16 Pressure Te...

Page 235: ...ONE Troubleshooting References NONE Special Environmental Conditions NONE General Safety Instructions Turn air conditioner OFF before performing maintenance LOCATION ITEM ACTION REMARKS REMOVAL 1 Main...

Page 236: ...stment before discharging system to remove refrigeration component a Discharge the system in accordance with paragraph 5 12 b Remove flare nut 8 on drier 4 c Remove four screws 6 securing receiver mou...

Page 237: ...ce with paragraph 5 15 Install band clamp 10 around receiver and receiver mounting bracket Tighten band clamp Align receiver and receiver mounting bracket with holes in frame Secure receiver and recei...

Page 238: ...RKS INSTALLATION 4 Maintenance Panel a Align holes in maintenance panel 2 with holes in left side panel 3 b Secure maintenance panel with eight turnlock fasteners 1 5 Pressure Test Pressure test air c...

Page 239: ...nces NONE Troubleshooting References NONE Special Environmental Conditions NONE General Safety Instructions Turn air conditioners OFF before performing maintenance LOCATION ITEM ACTION REMARKS REMOVAL...

Page 240: ...rged from the system before proceeding with the removal of the pressure relief valve NOTE Always perform inspection test and adjustment before discharging system to remove refrigeration component a Di...

Page 241: ...e b C Secure pressure relief valve to receiver Leak check evacuate and charge system in accordance with paragraphs 5 16 thru 5 18 Panel a Align maintenance panel 3 with holes in left side panel l b Se...

Page 242: ...ces NONE Special Environmental Conditions NONE General Safety Instructions Turn air conditioners OFF before performing maintenance LOCATION ITEM ACTION REMARKS REMOVAL 1 Left Side Panel a b c Loosen b...

Page 243: ...perform inspection test and to remove refrigeration component from the system before proceeding adjustment before discharging system a Remove two screws 6 two locknuts 7 and two clamps 8 securing sigh...

Page 244: ...Glass a Braze sight glass in accordance with paragraph 5 15 b Align sight glass 5 with condenser coil 9 c Secure sight glass to condenser coil with two screws 6 two locknuts 7 and two clamps 8 d Leak...

Page 245: ...left side panel 4 and maintenance panel 2 with frame b Secure left side panel to frame with twenty seven screws 3 c Tighten bottom center turnlock fastener 1 on maintenance panel 5 Pressure Test Pres...

Page 246: ...5180 90 C N18 References NONE Troubleshooting References NONE Special Environmental Conditions NONE General Safety Instructions Turn air conditioners OFF before performing maintenance LOCATION ITEM A...

Page 247: ...d adjustment to remove refrigeration component before discharging system a Disconnect solenoid valve electrical connector P 8 b Remove retaining nut 4 washer nameplate and lift over the coil 5 from so...

Page 248: ...e a Inspect for damage b Repair or replace if damaged TESTING 4 Solenoid Valve a Using ohmmeter or other continuity testing device check for continuity between pins A and B on electrical connector J 8...

Page 249: ...enoid valve 3 with solenoid valve mounting bracket 7 Secure solenoid valve to solenoid valve mounting bracket with two U bolts 6 Align coil 5 with solenoid valve Secure coil to solenoid valve with nam...

Page 250: ...ACTION REMARKS INSTALLATION 6 Right Side Panel a Align holes in right side panel 1 with holes in frame b Secure right side panel with thirty one screws 2 7 Pressure Test Pressure test air conditioner...

Page 251: ...NE Tools SC 5180 90 C N18 References NONE Troubleshooting References NONE pecial Environmental Conditions NONE General Safety Instructions Turn air conditioners OFF before performing maintenance LOCAT...

Page 252: ...from the system before proceeding with the removal of the compressor NOTE Always perform inspection test and adjustment before discharging system to remove refrigeration component a b c d Disconnect...

Page 253: ...TM5 4120 375 14 5 85...

Page 254: ...r 12 to compressor c Remove compressor junction box cover CAUTION Schematic is not correct red white and black wires are yellow wires striped with red white and black respectively d Using a multimeter...

Page 255: ...n the two crankcase heater pins and compressor housing If any one of the pins indicates it is grounded to compressor housing replace crankcase heater 4 THERMAL OVERLOAD Crankcase heater a b e Install...

Page 256: ...g gas within the compressor resulting in gradual overheating of the motor and failure of the winding c High Head Pressure High head pressures can be caused by clogged or dirty condenser coils or scree...

Page 257: ...THE REFRIGERATION SYSTEM AFTER BURNOUT WARNING Avoid contact with refrigerant Acid from contact with refrigerant burns could result You must clean the entire refrigeration system after a burnout has...

Page 258: ...Remove the pump reservoir filter and filter drier jumper Place an empty container below the compressor connection and connect a cylinder of dry nitrogen Item 8 table D 1 to each filter drier connecti...

Page 259: ...der washers 10 Slide compressor and compressor tray into unit Align compressor tray with holes in frame Secure compressor tray with four bolts 4 and nuts 5 and four counter sunk screws 6 to frame Braz...

Page 260: ...ondensate Drain Line Replace in accordance with paragraph 4 21 8 Right Side Panel a Align holes in right side panel 1 with holes in frame b Secure right side panel with thirty one screws 2 0 Pressure...

Page 261: ...ools SC 5180 90 C N18 References NONE Troubleshooting References NONE Special Enviromental Conditions NONE General Safety Instructions Turn air conditioner OFF before performing maintenance LOCATION I...

Page 262: ...s 3 and two screws 4 securing condenser coil guard 5 to frame Remove condenser coil guard Remove twenty seven screws 6 securing left side panel 7 to frame Loosen bottom center turnlock fastener 8 on m...

Page 263: ...tment before discharging system to remove refrigeration component a b c d e Discharge paragraph system in accordance with 5 12 Debraze condenser coil 12 in accordance with paragraph 5 15 Remove two co...

Page 264: ...r Coil f Remove two countersunk screws 18 and two lock nuts 19 securing outside lower condenser coil bracket 20 to frame g Remove two screws 21 and two flat washers 22 securing outside lower condenser...

Page 265: ...Remove two countersunk screws 27 and two lock nuts 28 securing right side lower condenser coil bracket to frame Remove lower inside right condenser coil bracket Remove two screws 30 securing upper ins...

Page 266: ...ims 37 Remove two countersunk screws 38 and two lock nuts 39 securing lower inside left condenser coil bracket to frame Remove lower inside left condenser coil bracket Remove two screws 40 securing up...

Page 267: ...two lock nuts 45 and two clamps 46 securing sight glass to condenser coil x Remove two bolts 47 and two lock nuts 48 securing cover support 49 to frame y Remove cover support z Remove six bolts 50 and...

Page 268: ...or damage b Repair or replace if damaged INSTALLATION 7 Condenser Coil a Align condenser coil 12 with frame b Secure condenser coil with six bolts 50 and six flat washers 51 c Align cover support 49 w...

Page 269: ...denser coil and frame Secure upper bracket with Secure upper bracket with to condenser inside left condenser coil two screws 40 to frame inside left condenser coil one bolt 42 and one washer 43 coil A...

Page 270: ...rews 30 to frame p Secure upper inside right condenser coil bracket with one bolt 32 and one washer 33 to condenser coil q Align lower inside right condenser coil bracket 25 with condenser coil and fr...

Page 271: ...ondenser coil bracket to condenser coil with two screws 21 and two flat washers 22 Align upper outside condenser coil bracket 15 to frame and condenser coil Secure upper outside condenser coil bracket...

Page 272: ...cover 11 with frame Secure condenser coil cover with five countersunk screws 10 Align holes in left side panel 7 with holes in frame Secure left side panel with twenty seven screws 6 Tighten bottom ce...

Page 273: ...ON R E M A R K S INSTALLATION 11 Right Side Panel a Align holes in right side panel 1 with 12 Pressure Test holes in frame b Secure right side panel with thirty one screws 2 Pressure test air conditio...

Page 274: ...tallation INITIAL SETUP Test Equipment NONE Tools SC 5180 90 C N18 References NONE Troubleshooting References NONE Special Environmental Conditions NONE General Safety Instructions Turn air conditione...

Page 275: ...b Remove rubber covers Remove Remove eight screws 1 and eight washers 2 securing lifting ring 3 to frame t h e f o u r l i f t i n g r i n g c o v e r s twenty three screws 4 and eight screws 5 secur...

Page 276: ...nance panel 12 b Remove twenty seven screws 10 securing left side panel 11 to frame c Remove 5 Fresh Air Filters a Loosen filter left side panel and maintenance panel two turnlock fasteners 13 on air...

Page 277: ...ion test and adjustment before discharging system to remove refrigeration component Discharge system in accordance with paragraph 5 12 Debraze evaporator coil 16 in accordance with paragraph 5 15 Remo...

Page 278: ...securing lower evaporator coil bracket 25 to coil g Remove two screws 26 two flat washers 27 two lock nuts 28 and one plate washer 29 securing lower evaporator coil bracket to frame h Remove lower ev...

Page 279: ...th frame Secure evaporator coil with twelve bolts 30 and twelve washers 31 to frame Align upper evaporator coil bracket 20 with evaporator coil and frame Secure upper evaporator coil bracket with two...

Page 280: ...ower evaporator bracket coil with two screws 26 two flat washers 27 one plate washer 29 and two lock nuts 28 to frame h Secure lower evaporator coil bracket to evaporator coil with two screws 23 and t...

Page 281: ...te position arrow on filter frame when installing air filters Arrow must point toward evaporator coil 12 Left Side Panel a b a b Slide fresh air filters 15 into unit Secure fresh air filter door with...

Page 282: ...8 with holes in frame Secure right side panel with thirty one screws 7 Align holes in top panel 6 with holes in frame Secure top panel with twenty three screws 4 and eight screws 5 Align holes in lif...

Page 283: ...ES Test Equipment NONE Tools SC 5180 90 C N18 References NONE Troubleshooting References NONE Special Environmental Conditions NONE General Safety Instructions Turn air conditioner OFF before performi...

Page 284: ...trical connector P 6 Remove control box Remove twenty three screws 5 and two screws 6 securing front panel 4 to frame Remove front panel 1 2 3 4 5 Identification Plate 7 Damper Directional Information...

Page 285: ...TM5 4120 375 14 5 117...

Page 286: ...Top Panel a Remove twenty three screws 16 and eight screws 17 securing top panel 18 to main frame b Remove top panel 1 Operation Information Plate 10 2 Warning Information Plate 19 A Drill out rivets...

Page 287: ...stener 20 on maintenance panel 21 b Remove twenty seven screws 22 securing left side panel 23 to main frame c Remove left side panel 1 Sight Glass Information Plate 24 2 Operation Information Plate 10...

Page 288: ...r Filter Panel a b Remove two screws 25 and loosen two turnlock fasteners 26 securing air filter panel 27 to frame Remove air filter panel Air Filter Panel Information Plate 28 A Drill out rivets 12 t...

Page 289: ...urnlock fasteners 29 securing maintenance panel 30 to left side panel 23 b Remove maintenance panel 1 Main Power Information Plate 11 2 Operational Information Plate 10 3 Electrical and Refrigeration...

Page 290: ...8 Control Box a Remove four screws 32 and four screws 33 securing control box 34 to front panel b Disconnect electrical connector P 6 c Remove control box Instruction Plate 35 A Drill out rivets 12 t...

Page 291: ...EMOVAL 9 Frame a Loosen bottom center turnlock fastener 36 on maintenance panel 37 b Remove twenty seven screws 38 securing left side panel 39 to main frame c Remove left side panel Instruction Plate...

Page 292: ...Instruction Plate 36 1 Align instruction plate with holes in frame 2 0 Install instruction plate with blind b c rivets 12 Align holes in left side panel 23 with Secure left side panel with twenty sev...

Page 293: ...ALLATION 11 Control Box a Instruction Plate 35 1 Align instruction plate with holes in frame 2 Install instruction plate with blind rivets 12 b Connect electrical connector P 6 c Align holes in contro...

Page 294: ...b Operation Information Plate 10 c Electrical and Refrigeration Schematic Plate 31 1 Align instruction plate with holes in frame 2 Install instruction plate with blind rivets 12 d Align maintenance p...

Page 295: ...r Filter Panel a A i r F i l t e r P a n e l I n f o r m a t i o n P l a t e 2 8 l Align instruction plate with holes in frame 2 Install instruction plate with blind rivets 12 b Align holes in air fra...

Page 296: ...b Operation Information Plate 10 c Weight Information Plate 15 1 Align instruction plate with holes in frame 2 Install instruction plate with blind rivets 12 d Align holes in left side panel 23 with...

Page 297: ...RKS INSTALLATION 15 Top Panel a Warning Information Plate 19 b Operation Information Plate 10 1 Align instruction plate with holes in frame 2 Install instruction plate with blind rivets 12 c Secure to...

Page 298: ...16 Right Side Panel a b c d Weight Information Plate 15 Operation Information Plate 10 1 2 Align Align instruction plate with holes in frame Install instruction plate with blind rivets 12 holes right...

Page 299: ...c Main Power Plug Information Plate 9 d Operation Information Plate 10 e Main Power Information Plate 11 1 Align instruction plate with holes in frame 2 Install instruction plate with blind rivets 12...

Page 300: ...LOCATION ITEM ACTION REMARKS INSTALLATION 18 Control Box a Connect electrical connector P 6 b Align holes in control box 3 with front panel 4 and frame c Secure control box to front panel and frame wi...

Page 301: ...eneral Safety Instructions Turn air conditioner OFF before performing maintenance LOCATION ITEM ACTION REMARKS REMOVAL 1 Lifting Ring Covers a 2 Top Panel b a Remove rubber covers Remove Remove eight...

Page 302: ...oosen eight turnlock fasteners 7 securing maintenance panel 8 to left side panel 9 and frame Remove maintenance panel Remove twenty seven screws 10 securing left side panel Remove left side panel Remo...

Page 303: ...Remove thirty one screws 14 securing right side panel 15 to frame Remove right side panel Remove four screws 16 and four screws 17 securing control box 18 to front panel 19 and frame Disconnect elect...

Page 304: ...and scraping process as required d Clean up metal surface with a cloth moistened in acetone or MEK INSPECTION 10 Insulation REPAIR 11 Insulation a Inspect for damage b Repair or replace if damaged a...

Page 305: ...l with thirty four screws 20 and two screws 21 13 Control Box a Connect electrical connector P 6 b Align holes in control box 18 with holes in front panel and frame c Secure control box with four scre...

Page 306: ...filter door panel to frame with two screws 11 and two turnlock fasteners 12 a Align holes in left side panel 9 with holes in frame b Secure left side panel with twenty seven screws 10 a Align holes i...

Page 307: ...op Panel a b b Align holes in top panel 6 with holes in frame Secure top panel with twenty three screws 4 and eight screws 5 Align holes in lifting ring covers 3 with holes in top panel Secure lifting...

Page 308: ......

Page 309: ...it is also extensive enough to have caused significant damage to major components In such a case it is necessary to procure a new frame assembly and to dismantle the damagd unit completely test all c...

Page 310: ...determine whether internal components such as coils wiring piping or other components or sub assemblies have been damaged If damage is apparent leak test all parts of refrigerant system and make an op...

Page 311: ...the metal more than necessary Fill gouges with body putty fiberglass epoxy filler or weld Weld cuts or tears Sand paint to a feather edge around the repair and paint as directed in TM 43 0139 b Drill...

Page 312: ......

Page 313: ...Field Maintenance Management Use System Motor and Generator Repair TM 5 4120 375 24P Organizational Direct Support and General Support Maintenance Repair Parts and Special Tools List for Air Conditio...

Page 314: ...PIN 054090 001...

Page 315: ...ntenance function B 2 Maintenance functions Maintenance functions will be limited to and defined as follows a Inspect To determine serviceability of an item by comparing its physical mechanical or ele...

Page 316: ...isassembly assembly 3 Procedures and maintenance actions 4 To identify troubles and restore serviceability to an item correcting specific damage fault malfunction or failure in a part subassembly modu...

Page 317: ...maintenance significant components assemblies subassemblies and modules with the next higher assembly End item group number shall be 00 2 Column 2 Component Assembly Column contains the names of compo...

Page 318: ...l and test equipment reference code correlates with a maintenance function on the identified end item or component Column 2 Maintenance Level The lowest level of maintenance authorized to use the tool...

Page 319: ...EENS Lifting Ring Cover Inspect 10 Service 25 Replace 15 Panels Inspect Service Repair Replace Information Plates Control Panel Control Switches Thermostat Guards Screens Inspect Service Replace Inspe...

Page 320: ...ect 25 Adjust 25 Repair 1 5 Replace 50 Condensate Drains and Fittings Inspect 10 Service 25 Replace 75 JUNCTION BOX AND WIRING HARNESS Junction Box Relays Inspect Repair Replace Inspect Test Replace C...

Page 321: ...ondenser Fan Housing REFRIGERATION SYSTEM Pressure Switches Valves Tubing and Dehydrator Compressor Inspect Service Replace Inspect Test Repair Replace Inspect Replace Inspect Service Replace Inspect...

Page 322: ...O FHD 05 REFRIGERATION SYSTEM CONT 06 Condenser Coil Evaporator Coil FRAME AND ATTACHING PARTS Frame Insulation Fittings Tie Down Lifting Rings Inspect Repair Replace Inspect Repair Replace Inspect Re...

Page 323: ...18 Recovery and Recycling Unit Refrigerant 4 National NATO Stock Number 5180 00 596 3439 00 930 474 1638 5 Tool Number 4130 01 338 2707 17500B 07295 SECTION IV REMARKS MAINTENANCE ALLOCATION CHART Re...

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Page 325: ...removed and separately packaged for transportation or shipment As part of the end item these items must be with the end item whenever it is issued or transferred between property accounts Illustratio...

Page 326: ...scription Indicates the Federal item name and if required a minimum description to identify and locate the item The last line for each item indicates the FSCM in parentheses followed by the part numbe...

Page 327: ...st level of maint enance that requires the listed item C Operator Crew O Organizational Maintenance F Direct Support Maintenance H General Support Maintenance c COLUMN 3 NATIONAL STOCK NUMBER This is...

Page 328: ...860 0042 ACETONE 8040 00 ADHESIVE TYPE MM A 1617 664 4318 TYPE II DRY CLEANING SOLUTION PD 680 FIBERGLASS CLOTH FILTER KOTE INSULATING TAPE METHYL ETHYL KETONE MEK NITROGEN DRY OIL MIL SPEC 0 2104 REF...

Page 329: ...106R32 6P P4 E MS3106R32 6P P4 K MS3106R32 6P P4 O MS3106R32 6P P4 A MS3106R32 6P P4 B MS3106R32 6P P4 C MS3106R32 6P P4 P MS3106R32 6P P4 R MS3106R32 6P P4 T MS3106R32 6P P4 D MS3106R32 6P P4 H MS310...

Page 330: ...J4 S MS25036 108 K2 4 MS25036 108 K2 3 MS25036 108 K2 2 MS25036 108 K2 2 MS25036 108 K2 3 MS25036 108 K2 4 MS25036 112 CB1 4 MS25036 112 CB1 5 MS25036 112 CB1 6 MS25036 108 K1 9 MS25036 112 K1 5 MS25...

Page 331: ...TM 5 4120 375 14 Change3 E 3...

Page 332: ...TM 5 4120 375 14 Pin 0 5 4 0 9 0 0 0 3 E 4 U S GOVERNMENT PRINTING OFFICE 1995 655 121 20084...

Page 333: ...Removes any traces of moisture before it enters the room from the refrigerant system HIGH PRESSURE CUTOUT Interrupts power to the compressor when the refrigerant system pressure becomes too high LIQUI...

Page 334: ......

Page 335: ...ndensate Drain Connector Condenser Coil Gurard Condenser Coil Replacement Condenser Fan Assembly Control Box Control Box Wiring Harness Cooling Crankcase Heater Cutting Copper Tubing D Damper Control...

Page 336: ...h Air Screen Front Panel G General Description and Use of Operator s Controls and Indicators Direct Support Maintenance Instructions General Support Maintenance Instructions Maintenance Procedures Ope...

Page 337: ...Altitudes Dusty or Sandy Areas Extreme Cold Extreme Heat Under Rainy or Humid Conditions in Saltwater Area Operational Instruction Warning Plates Organizational PMCS Organizational Troubleshooting Pa...

Page 338: ...cope Screen Fresh Air Selector Switch Rotary S1 Service Upon Receipt Service Valves Shipment Sight Glass Special Tools MTDE and Support Equipment Solenoid Valve Starting the Equipment Stopping the Equ...

Page 339: ...al Expansion Valve Termal Expansion Valve Quench Termal Relay Assy S4 u Unpacking v Valves Pressure Relief Solenoid Thermal Expansion Quench Ventilation w Wiring Harness Control Miring Harness Main 4...

Page 340: ......

Page 341: ...e Secretary of the Army JOHN A WICKHAM JR General United States Army Chief of Staff DISTRIBUTION To be distributed in accordance with DA Form 12 25C Operator Maintenance requirments for 36 000 BTU Tru...

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Page 353: ...it They did not even scan it Why should they get your money Why are not letting you give those free manuals to your friends I am setting this document FREE This document was made by the US Government...

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