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Talley UAC40-5/6-08 Technical Manual

Base mounted, air cooled, 208 vac, 3-phase, 60 hz
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TECHNICAL MANUAL
OPERATOR'S, ORGANIZATIONAL, DIRECT
SUPPORT, AND GENERAL SUPPORT
MAINTENANCE
MANUAL
AIR CONDITIONER,
BASE
MOUNTED, AIR COOLED,
Hz,
N S N
4 1 2 0 - 0 1 - 1 2 2 - 0 6 2 9
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
A R M Y
21 OCTOBER 1983

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Summary of Contents for Talley UAC40-5/6-08

  • Page 1 TECHNICAL MANUAL OPERATOR'S, ORGANIZATIONAL, DIRECT SUPPORT, AND GENERAL SUPPORT MAINTENANCE MANUAL AIR CONDITIONER, BASE MOUNTED, AIR COOLED, N S N 4 1 2 0 - 0 1 - 1 2 2 - 0 6 2 9 H E A D Q U A R T E R S , D E P A R T M E N T T H E A R M Y...
  • Page 3 TM5-4120-375-14 WARNINGS connector before attempting any electrical servicing of Disconnect main power a i r c o n d i t i o n e r . Dry cleaning solvent, P-D-680 or P-S-661, used to clean parts is potentially Avoid repeated and prolonged skin contact. dangerous to personnel and property.

  • Page 5: T100

    AIR CONDITIONER, BASE MOUNTED, AIR COOLED, 208 VAC, 3-PHASE, 60 HZ, SINGLE PACKAGE, 36,000 BTU/HR PART NO. 97403-13219E0790 MODEL UAC40-5/6-08, NSN 4120-01-122-0629 MODEL 2463T100-1 , NSN 4120-01-218-6912 DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited TM 5-4120-375-14, 21 October, 1983, is changed as follows: 1.
  • Page 11 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 PART NO. 97403-13219E0790 M O D E L UAC40-5/6-08 4120-01-122-0629 2463T100-1 4120-01-218-6912 TABLE OF CONTENTS Change 1...
  • Page 12 TM5-4120-375-14 TABLE CONTENTS (continued) Page Section Operation Under Unusual conditions --------------- CHAPTER OPERATOR’S MAINTENANCE INSTRUCTIONS Section Lubrication Instructions ------------------------- Section Troubleshooting ---------------------------------- CHAPTER ORGANIZATIONAL MAINTENANCE INSTRUCTIONS Section Repair Parts, Special Tools, TMDE, and Support Equipment ---------------------------- Section Service upon Receipt of Equipment ---------------- Section Preventive Maintenance Checks and Services ------- III.

  • Page 13: Table Of Contents

    TM5-4120-375-14 CHAPTER 1 INTRODUCTION CHAPTER OVERVIEW The purpose of this chapter is twofold: a. To provide you with the standard data required in all manuals (i.e. forms and record data). To acquaint you with the air conditioner. This is done by giving you a physical and functional description of those major equipment parts that you are likely to come in contact with.
  • Page 14 General Support Maintenance. Inc. model number Model Number and Equipment Name: Unifab Industries UAC 40-5/6-08, Talley Corporation model number 2463T100-1, Air conditioner 36,000 BTU/HR, Base Mounted, 208 volt, 3 Phase, 50/60 Cycle, AC, Single Package. Purpose of Equipment: Provide filtered, cooled air to a desired predetermined range and circulating the air to provide cooling of equipment or personnel within the air conditioned area.
  • Page 15 TM5-4120-375-14 SECTION II. EQUIPMENT DESCRIPTION PURPOSE OF AIR CONDITIONER. 1-6. The air conditioner is used primarily in van type enclosures. The units provide filtered, cooled air, as required, to maintain the service 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.
  • Page 16 TM5-4120-375-14 1-8. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS. Compressor Evaporator coil Evaporator fan motor Expansion valve Condenser coil Junction box Dual pressure switch Solenoid valve Condenser fan motor Dryer Condensate drain exit Sight glass...
  • Page 17 It provides the Air Conditioner nomenclature, national stock number, panel. 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 2463T100-1 4120-01-218-6912 97403-13219E0790 36.92 IN. ( .93 m) 42.34 IN. (1.07 m) 27.85 IN. ( .70 m) 475 lbs.
  • Page 18 TM5-4120-375-14 SECTION III. TECHNICAL PRINCIPLES OF OPERATION GENERAL. 1-11. The air conditioner is a base mounted, self-contained, electric motor driven unit that provides for cooling. 36,000 BTU/HR Once started, it operates automatically due to the relationship of the components, controls and instruments.
  • Page 19 TM5-4120-375-14 COOLING. 1-13. 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. 1-7/(1-8 blank)
  • Page 21 TM5-4120-375-14 CHAPTER 2 OPERATING INSTRUCTIONS CHAPTER OVERVIEW This chapter contains a functional description of’ the major components of the a i r c o n d i t i o n e r . It explains how to operate the Air Conditioner. y o u r convenience, below is an index of’...
  • Page 22 TM5-4120-375-14 SECTION II. PREVENTATIVE MAINTENANCE CHECKS AND SERVICES 2-2. GENERAL. Preventative Maintenance Checks and Services (PMCS, Table 2-1.) are to be completed to ensure the air conditioner is ready to use at all times. These checks and services help you find and repair defects before the air conditioner is damaged or fails.
  • Page 23 TM5-4120-375-14 T a b l e 2 - 1 . Operator/Crew Preventive Maintenance Checks and Services NOTE If the equipment must be kept in continuous operation, check and service only those items that can be checked and serviced without disturbing operation. Hake the complete checks and services when the equipment can be shut down.
  • Page 24 T M 5 - 4 1 2 0 - 3 7 5 - 1 4 TABLE 2-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICE A-After Operation D-During Operation B-Before Operation -------------------- ------------------------- ------------------------ ----- EQUIPMENT PROCEDURE ITEM TO BE ITEM INTERVAL IS NOT READY/ INSPECTED B D A...
  • Page 25 TM5-4120-375-14 SECTION III. OPERATION UNDER USUAL CONDITIONS 2-4. PREPARATION FOR USE. a. Inspect the entire unit for external damage. Report any deficiencies to the proper maintenance level. Be careful when working with Failure to comply can result high voltage. in serious injury or death.
  • Page 26 TM5-4120-375-14 STARTING THE EQUIPMENT (cont.). 2-5. CAUTION Assure that crankcase heater is on six hours prior to operating. NOTE For maximum cooling capacity when outside temperature is high, set damper controls at full MIN position. Cooling mode. Set thermostat for desired room temperature.
  • Page 27 TM5-4120-375-14 2-6. OPERATION. Allow 15 minutes operation to ensure unit has stabilized, then check sight glass for cloudiness. 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 Direct Support Maintenance.
  • Page 28 TM5-4120-375-14 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 INSTALLED...
  • Page 29 SECTION IV OPERATION UNDER UNUSUAL CONDITIONS OPERATION IN EXTREME COLD. 2 - 9 . a. Keep entire unit free of snow and ice. Cover when not in use. unit Cut amount of fresh air used. 2-11. OPERATION IN DUSTY OR SANDY AREAS. 2-12.
  • Page 31 TM5-4120-375-14 CHAPTER OPERATOR'S MAINTENANCE INSTRUCTIONS CHAPTER OVERVIEW This chapter contains all the necessary maintenance instructions to keep your air conditioner in good repair. INDEX PAGE SECTION TITLE Lubrication Instructions. Operator Troubleshooting. III. Operator Troubleshooting Table. SECTION I.LUBRICATION INSTRUCTIONS There is no lubrication required for this air conditioner. 3-1.
  • Page 32 TM5-4120-375-14 SECTION III. OPERATOR TROUBLESHOOTING TABLE TABLE OPERATOR TROUBLE SHOOTING TABLE MALFUNCTION TEST OF INSPECTION CORRECTIVE ACTION VENTILATION MODE (ONLY) AIR CONDITIONER FAILS TO OPERATE. WARNING Be careful when working with high voltage. Failure to comply can result in serious injury or death. Step 1.
  • Page 33 TM5-4120-375-14 OPERATOR TROUBLESHOOTING TABLE (cont.) TABLE 3-1 ------------------------------------------------------------------------------- MALFUNCTION TEST OF INSPECTION CORRECTIVE ACTION ----------------------------------------------------------------------------- COOLING MODE INSUFFICIENT COOLING. Check to see if selector switch is in COOL position. Step 1. selector switch in COOL position. Place Step 2. Check to see if THERMOSTAT is in COOLER position. Notify Organizational Maintenance.
  • Page 35 TM5-4120-375-14 CHAPTER 4 ORGANIZATION MAINTENANCE INSTRUCTIONS used maintenance information. This chapter contains the following frequently T h e s y m p t o m index on page 4-12 is a guide to the troubleshooting information. There is also an index to the maintenance procedures on page 4-21.
  • Page 36 TM5-4120-375-14 SERVICE UPON RECEIPT SECTION II. 4-4. UNLOADING THE EQUIPMENT. The crated air conditioner may be unloaded and moved by any means, provided the unit weight is supported by the base platform. 4-5. UNPACKING THE EQUIPMENT. CAUTION So that the unit is protected, it should be left crated until moved to the location where it is to be installed.
  • Page 37 TM5-4120-375-14 4-7. SERVICE UPON RECEIPT CHECKLIST. Exterior a. Inspect for signs of rough Panels and Grilles handling and damage. Service or reject any component if damage prevents the air conditioner from working. Control Box Front Check for broken or damaged knob. Insure that switches move freely from position to position.
  • Page 38 TM5-4120-375-14 4-7. SERVICE UPON RECEIPT CHECKLIST. (cont.) LOCATION ITEM ACTION Remove air filters and inspect the filter for accumulation of dirt. Clean filter. Side Return Air Damper Check to see that the FRESH AIR control moves freely between the the MIN and MAX position and that the return air damper opens and closes properly.
  • Page 39 TM5-4120-375-14 4-8. INSTALLATION INSTRUCTIONS. The unit may be supported by, or suspended from, any convenient part of the van or 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.
  • Page 40 TM5-4120-375-14 (cont.) 4-8. INSTALLATION INSTRUCTIONS. Connect a 1/2 inch threaded pipe to the drain connections on the bottom right side of the unit to remove condensate water. Extend piping or hose to deposit water in a suitable location or container. Drain system must have "U" trap on exterior drain line.
  • Page 41 TM5-4120-375-14 SECTION III. ORGANIZATIONAL 4-9. G E N E R A L . To insure that the air conditioner is ready for operation at all times, it must be inspected systematically so that the defects may be discovered and oorrected before the result is serious damage or failure.
  • Page 42 TM5-4120-375-14 ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES. Table 4-1. M-Monthly Q-Quarterly S-Semiannually ITEM INTERVAL PROCEDURE EQUIPMENT ITEM TO BE M Q S INSPECTED IS NOT READY/ AVAILABLE IF: Controls and Check for defective If damaged repair fittings or loose parts. or replace controls in accordance with...
  • Page 43 TM5-4120-375-14 Table 4-1. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES. (cont.) Q-Quarterly S-Semiannually - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ITEM INTERVAL ITEM TO BE...
  • Page 44 TM5-4120-375-14 ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES. (cont.) Table 4-1. S-Semiannually Q-Quarterly M-Monthly —---- ------------------------- --------------------- -------------------- ------ EQUIPMENT PROCEDURE ITEM TO BE ITEM INTERVAL IS NOT READY/ INSPECTED M Q S AVAILABLE IF: If damaged repair Fans Check for security or replace fans of attachment, bent in accordance with...
  • Page 45 TM5-4120-375-14 Table 4 - 1 . ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES. (cont.) M-Monthly Q-Quarterly S - S e m i a n n u a l l y ITEM INTERVAL ITEM TO BE PROCEDURE EQUIPMENT M Q S INSPECTED IS NOT READY/ AVAILABLE IF: Evaporator coil...
  • Page 46 TM5-4120-375-14 SECTION IV. TROUBLESHOOTING 4-11. TROUBLESHOOTING. Table 4-2 contains troubleshooting information for locating and cor- recting most of the operating troubles which are the responsibility of organizational maintenance. Each malfunction for an individual component, unit, or system is followed by a list of tests or inspections which will help you to determine probable causes and corrective actions to take.
  • Page 47 TM5-4120-375-14 Table 4-2. TROUBLESHOOTING --------------------------------------------------------------------------- TEST OR INSPECTION CORRECTIVE ACTION ---------------------------------------------------------------------- VENTILATION MODE ONLY AIR CONDITIONER FAILS TO OPERATE. 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 is plugged in.
  • Page 48 TM5-4120-375-14 Table 4-2. TROUBLESHOOTING (cont.) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION COOLING MODE COMPRESSOR FAILS TO START. Step 1. Loosen eight turnlock fasteners on maintenance panel. Remove maintenance panel. Place circuit breaker in the ON position. If the air conditioner will not operate in the COOL position, check for a defective circuit breaker in accordance with paragraph 4-22.
  • Page 49 TM5-4120-375-14 Table 4-2. TROUBLESHOOTING (cont.) MALFUCTION TEST OR INSPECTION CORRECTIVE ACTION INSUFFICIENT COOLING. Step 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 operation of evaporator fan assembly.

  • Page 50: Fresh Air Dampers

    TM5-4120-375-14 Table 4-2. TROUBLESHOOTING (cont.) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Check for correct operation of condenser fan assembly. S t e p 3 . Replace or repair damaged condenser fan assembly in accordance with paragraph 4-26. Check fresh air dampers. Step Remove eight screws and eight rubber washers securing lifting ring covers to top panel and...

  • Page 51: Air Filter Panel

    TM5-4120-375-14 Table 4-2. TROUBLESHOOTING (cont.) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 5 . Check evaporator fresh air filter. Loosen two turnlock fasteners on 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) .
  • Page 52 TM5-4120-375-14 TROUBLESHOOTING (cont.) Table 4-2. Check evaporator fan outlets for obstruction. Step 6. Remove obstruction. 4-18...
  • Page 53 TM5-4120-375-14 Table 4-2. TROUBLESHOOTING (cont.) M A L F U N C T I O N TEST OR INSPECTION CORRECTIVE ACTION --------------------------------------------------------------- Check for correct system pressures in accordance Step 7. with Table 5-2. Notify direct support maintenance. Step 8. Check for moisture in system.
  • Page 54 TM5-4120-375-14 ORGANIZATIONAL MAINTENANCE PROCEDURES SECTION V. 4-13. GENERAL INSTRUCTIONS. Most maintenance instructions in this section will list resources required, personnel required and equipment for the start of the procedure. NOTE Resources required are not listed unless they apply to the procedure.
  • Page 55 TM5-4120-375-14 ORGANIZATIONAL MAINTENANCE PROCEDURES INDEX Paragraph Page Air Filters 4-19 4-47 Condensate Main and Fittings 4-21 4-68 Condenser Fan Motor and Housing 4-26 4-114 Condenser Coil Guard 4-18 4-45 Control Box 4-16 4-34 4-16 a. Rotary Control Switch 4-35 b. Thermostat 4-16 4-36 Dampers and Controls...
  • Page 56 TM5-4120-375-14 4-14. LIFTING RING COVER This task cover: a. Removal Inspection Installation -------------------------------------------------------------------------------- INITIAL SETUP Test Equipment None Tool 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. ACTION REMARKS LOCATION/ITEM...
  • Page 57 TM5-4120-375-14 LIFTING RING COVER (CONT. ) REMARKS ACTION LOCATION/ITEM Lifting Ring Cover Inspect for damage. Repair or replace if damaged. NOTE Rubber washers are to be placed between lifting ring cover and top panel. Lifting Ring Cover lifting ring cover (3) with frame Align holes in and top panel.
  • Page 58 TM5-4120-375-14 PANELS 4-15. ------------------------ ------------------------ -------------------- ------------ This tasks covers: Removal Inspection, service and repair Installation ------------------------ ------------------------ ------------------------ -------- INITIAL SETUP Test Equipment 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 maintenance.
  • Page 59 TM5-4120-375-14 PANELS (CONT. ) LOCATIONS/ITEM ACTION REMARKS REMOVAL Front Panel Remove thirty-four screws (6) and two screws (7) securing front panel (8) to frame . Remove front panel. Panel Right Side Remove thirty-one screws (9) securing right side panel (10). Remove right side panel.
  • Page 60 TM5-4120-375-14 PANELS (CONT.) REMARKS ACTION LOCATIONS/ITEM REMOVAL Air Filter Panel Remove two screws (17) and loosen two turn lock fasteners securing air filter panel (19) (18) to frame. Remove air filter panel. Maintenance Panel Loosen eight turnlock fasteners (20) securing maintenance panel left side panel (22) (21) to...
  • Page 61 TM5-4120-375-14 4 - 2 7...
  • Page 62 TM5-4120-375-14 PANELS (CONT.) REMARKS ACTION LOCATION/ITEM INSPECTION, SERVICE AND REPAIR 11. Air Filter Panel Inspect for loose or damaged insulation. Replace damaged insulation material and secure insulation with adhesive in accordance with item 2, table D-1. Inspect hinge for damage and freedom of movement.
  • Page 63 TM5-4120-375-14 PANELS (CONT. ) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - LOCATION/ITEM ACTION REMARKS...
  • Page 64 TM5-4120-375-14 PANELS (CONT.) REMARKS ACTION LOCATION/ITEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INSTALLATION 13.
  • Page 65 TM-4120-375-14 PANELS (CONT.) ACTION REMARKS LOCATION/ITEM INSTALLATION 15. Air Filter Panel a. Align holes in air filter panel (19) with holes in frame. 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. Secure top panel (14) with twenty-three screws (16) and eight screws (15).
  • Page 66 TM5-4120-375-14 PANELS (CONT.) REMARKS ACTION LOCATION/ITEM INSTALLATION 17. Right Side Panel Align holes in right side panel (10) with holes in frame. Secure right side panel with thirty-one screws (9). 18. Front Panel in frame. holes Align holes in front panel (8) with screws (6) Secure front panel with thirty-four and two screws (7).
  • Page 67 TM5-4120-375-14 PANELS (CONT.) ACTION REMARKS LOCATION/ITEM 19. Control Box 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). 20.
  • Page 68 TM5-4120-375-14 4-16. CONTROL BOX ------------------------ --------------------- --------- -------------------------- This task covers: Removal Test/Inspection Installation -------------------- ------------------------ ------------------------ ------------ INITIAL SETUP Test Equipment 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 maintenance.
  • Page 69 TM5-4120-375-14 CONTROL BOX (CONT.) ---------------------------------------------------------------------------- LOCATION/ITEM ACTION REMARKS REMOVAL Rotary Switch Remove eight screws (4) securing control box back panel (5) to control box. 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.
  • Page 70 T M 5 - 4 1 2 0 - 3 7 5 - 1 4 LOCATION/ITEM ACTION REMARKS REMOVAL Thermostat a. Tag and remove wires from thermostat. b. Remove three flat nuts (14) and three star (16) washers (15) securing thermostat to control box .
  • Page 71 T M 5 - 4 1 2 0 - 3 7 5 - 1 4 CONTROL BOX (CONT.) LOCATION/ITEM ACTION REMARKS TESTING/INSPECTION Rotary Switch a. Place knob in the OFF position. Check for the lack of continuity between terminals 11 and 12, 11 and 13, and 12 and 13. c.
  • Page 72 TM5-4120-375-14 CONTROL BOX (CONT.) REMARKS ACTION LOCATION/ITEM TESTING/INSPECTION Thermostat Place thermostat in ambient temperature of 80 -90 F (28-32 C). Place temperature control on thermostat in WARM position. Check for continuity between terminals COM and NC. If lack of continuity is found replace defective thermostat.
  • Page 73 TM5-4120-375-14 CONTROL BOX (CONT.) ACTION REMARKS LOCATION/ITEM TESTING/INSPECTION Control Box for loose or damaged gaskets. a . I n s p e c t Replace damaged gasket material and secure gaskets with adhesive in accordance with item 2, table D-1. for loose or damaged insulation.
  • Page 74 TM5-4120-375-14 CONTROL BOX (CONT.) ACTION LOCATION/ITEM REMARKS INSTALLATION 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 wires with three flat nuts (14) and three star washers (15).
  • Page 75 TM5-4120-375-14 CONTROL BOX (CONT.) LOCATION/ITEM ACTION R E M A R K S INSTALLATION Rotary Switch Attach wires to terminal numbers 11,12 and 13. Align rotary switch (10) with hole in control box. Secure rotary switch to control box with star washer (9) and retaining nut (8).
  • Page 76 TM5-4120-375-14 CONTROL BOX (CONT.) ACTION LOCATION/ITEM REMARKS -------------------------------------------------------------------------------- INSTALLATION Control Box a. Align control box (3) with holes in frame. b. Secure control box with four screws (2) and four screws (l).
  • Page 78 TM5-4120-375-14 EVAPORATOR FAN GUARD (CONT.) LOCATION/ITEM ACTION REMARKS INSPECTION Evaporator Fan Guard a. Inspect for damage. b. Repair or replace if damaged. INSTALLATION Evaporator Fan Guard a. Align evaporator fan guard (2) with holes in front panel (3) and frame. b.
  • Page 80 TM5-4120-375-14 CONDENSER COIL GUARD (CONT.) ------------------------- ------------------------ -------------------------- ----- ACTION REMARKS LOCATION/ITEM -------------------- -------------------- ------------------------- --------------- INSPECTION Condenser Coil Guard a. Inspect for damage. b. Repair or replace if damaged. INSTALLATION Condenser Coil Guard (3) with a. Align condenser coil guard h o l e s i n f r a m e .
  • Page 82 TM5-4120-375-14 AIR FILTERS (CONT.) REMARKS ACTION LOCATION/ITEM INSPECTION AND SERVICE Air Filters a. Spray filters with a water hose in opposite direction of air flow (See arrow on filter frame) b. Shake water from filter and allow to dry before installing.
  • Page 83 TM5-4120-375-14 4-20 DAMPERS AND CONTROLS THIS TASKS COVERS: a. Removal b. Inspection and repair c . I n s t a l l a t i o n INITIAL SETUP Test Equipment None Tools TOOL KIT (SC 5180-90-C-N18) References None Troubleshooting References None Special Environmental Conditions...
  • Page 84 TM5-4120-375-14 DAMPERS AND CONTROLS (CONT.) -------------------- ------------------------ ------------------------- ----------- LOCATION/ITEM ACTION REMARKS -------------------------------------------- ------------------------ ------------ REMOVAL Lifting Ring Covers Remove eight screws and eight rubber washers (4) securing lifting ring cover (5) to top panel (6) and frame. Remove lifting ring cover. Top Panel Remove twenty-three screws (7) and eight screws (8) securing top panel (6) to frame.

  • Page 85: Return Air Damper

    TM5-4120-375-14 DAMPERS AND CONTROL (CONT.) R E M A R K S ACTION LOCATION/ITEM REMOVAL Left Return Air Damper Loosen two screws (13) on mechanical post (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.
  • Page 86 TM5-4120-375-14 DAMPERS AND CONTROLS (CONT.) --------------------------------------------- ---------------------------- ------- ACTION REMARKS LOCATION/ITEM -------- --------------------------------- ----------------------------- ---------- REMOVAL Left Fresh Air Damper and Screen Loosen screws (21) 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 damper.
  • Page 87 TM5-4120-375-14 DAMPERS AND (CONT.) CONTROLS ACTION REMARKS L O C A T I O N / I T E M REMOVAL Loosen screws (27) on mechanical post (28) securing control cable (29) to left return air damper (30) and fresh air damper (31). Loosen set screw (33) on control cable knob (34).
  • Page 88 TM5-4120-375-14 DAMPERS AND CONTROLS (CONT.) REMARKS LOCATION/ITEM ACTION REMOVAL Damper Box Remove four screws (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) securing front panel...
  • Page 89 TM5-4120-375-14 4-55...
  • Page 90 TM5-4120-375-14 DAMPERS AND CONTROLS (CONT) ____________________________________________ _________________________ LOCATION/ITEM ACTION REMARKS _______________________________________________________________________________ REMOVAL 10. Right Fresh Air Damper and Screen a. 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 mechanical post on right return air damper.
  • Page 91 Change 1 4 - 5 7...
  • Page 92 TM5-4120-375-14 DAMPERS AND CONTROLS (CONT.) LOCATION/ITEM REMARKS ACTION INSPECTION AND REPAIR 12. Damper Control and Cable Inspect for freedom, of movement, lubricate if required (Table D-1, Item 17). Tighten loose mountings. R e p l a c e d e f e c t i v e c o n t r o l s . 13.
  • Page 93 TM5-4120-375-14 DAMPERS AND CONTROLS (CONT.) REMARKS ACTION L O C A T I O N / I T E M NOTE Secure control cable housing (88) to frame with one screw (80) and one locknut (81) and one clamp ( 8 2 ) . Align control cable (73) with damper box.
  • Page 94 TM5-4120-375-14 DAMPERS AND CONTROLS (CONT.) --------------------------------------------------------------------------- LOCATION/ITEM ACTION REMARKS ------------------------------------------------------------------------------------------ INSTALLATION 15. Right Fresh Air Damper and Screen a. Align right fresh air damper (67) and screen to frame. Secure right fresh air damper and screen to frame with four screws (68) and four locknuts (69).
  • Page 95 TM5-4120-375-14 DAMPERS AND CONTROLS (CONT.) LOCATION/ITEM REMARKS ACTION INSTALLATION Right Return Air Damper a. Align right return air damper (59) to frame. 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 return air damper.
  • Page 96 TM5-4120-375-14 DAMPERS AND CONTROLS (CONT.) REMARKS ACTION LOCATION/ITEM INSTALLATION Damper Box Align damper box (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).
  • Page 97 TM5-4120-375-14 REMARKS L O C A T I O N / I T E M ACTION INSTALLATION NOTE 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) .
  • Page 98 TM5-4120-375-14 DAMPERS AND CONTROLS (CONT.) -------------------------------------------------------------------------------- REMARKS ACTION LOCATION/ITEM —----- -------------------------------------------------------------------------- INSTALLATION Left Fresh Air Damper and Screen a. Align left fresh air damper (24) and screen to frame. Secure left fresh air damper and screen to frame with four screws (25) and four locknuts (26).
  • Page 99 TM5-4120-375-14 DAMPERS AND CONTROL (CONT.) LOCATION/ITEM ACTION REMARKS 20. Left Return Air Damper Align left return air damper (16) to frame. Secure left side return air damper to frame 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.
  • Page 100 TM5-4120-375-14 DAMPERS AND CONTROLS (CONT.) REMARKS ACTION LOCATION/ITEM ------------------------ --------------------- --------------------------- -------- INSTALLATION 21. Left Side Panel (12) and maintenance Align holes in left side panel panel (10) with holes in frame. Secure left side panel with twenty-seven screws (11). Tighten bottom center turnlock fastener on maintenance panel.
  • Page 101 DAMPERS AND CONTROLS (CONT.) REMARKS ACTION LOCATION/ITEM INSTALLATION 22. Top Panel a. Align holes in top panel (6) with holes in frame. Secure top panel with twenty-three screws (7) and eight screws (8). Ring Covers 23. Lifting a. Align four lifting covers (5) with top panel and frame.
  • Page 102 TM5-4120-375-14 CONDENSATE DRAIN AND FITTINGS 4-21. ------------------------------------------------------------------------------- This tasks covers: Removal Inspection c. Installation ------------------------- ------------------------ ------------------------- ------ INITIAL SETUP Test Equipment 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 maintenance.
  • Page 103 TM5-4120-375-14 CONDENSATE DRAIN AND FITTINGS (CONT.) --------------------------------------------------------------------------- REMARKS ACTION LOCATION/ITEM - — — - - - - — ------------------------------------------------------------ REMOVAL Left Side Panel Loosen bottom center turnlock fastener (3) on maintenance panel (4). Remove twenty-nine screws securing left side panel and maintenance panel to frame.
  • Page 104 TM5-4120-375-14 CONDENSATE DRAIN AND FITTINGS (CONT.) ACTION REMARKS LOCATION/ITEM REMOVAL Condensate Drain 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 frame. Loosen clamps (12) securing drain lines (13) to evaporator drain pan (14).
  • Page 105 TM5-4120-375-14 CONDENSATE DRAIN AND FITTINGS (CONT.) LOCATION/ITEM ACTION REMARKS REMOVAL Condensate Drain Remove drain line clamp (15) securing drain line (16) to evaporator drain pan (14). Slide long section of rubber hose through unit from left side. Loosen clamp (17) securing drain line (18) to evaporator drain pan.
  • Page 106 TM5-4120-375-14 CONDENSATE DRAIN AND FITTINGS (CONT.) LOCATION/ITEM ACTION REMARKS INSPECTION Condensate Drain Assembly Place a 2 x 4 inch board under one side of 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.
  • Page 107 TM5-4120-375-14 CONDENSATE DRAIN AND FITTINGS (CONT.) REMARKS ACTION LOCATION/ITEM Condensate Drain drain pan (14) a. Connect drain line to evaporator (20) on drain line. Tighten clamp (19) drain pan. c. Connect drain line (18) to evaporator Tighten clamp on drain line. (17) side to right e .
  • Page 108 TM5-4120-375-14 CONDENSATE DRAIN AND FITTINGS (CONT.) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ACTION REMARKS LOCATION/ITEM...
  • Page 109 TM5-4120-375-14 CONDENSATE DRAIN AND FITTINGS (CONT.) INSTALLATION Left Side Panel Align left side panel (6) and maintenance panel (4) with frame. Tighten bottom center turnlock fastener (3) on maintenance panel. Secure left side panel with twenty-nine screws ( 5 ) . Right Side Panel a.
  • Page 110 TM5-4120-375-14 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-22.

  • Page 111: Main Power Connector

    TM5-4120-375-14 JUNCTION BOX (CONT.) LOCATION/ITEM ACTION REMARKS REMOVAL Junction Box WARNING Disconnect main power connector before attempting any electrical servicing with air conditioner. a. Remove two screws (4) securing junction box junction box support plate, slide junction box out to allow removal of clamps ( 6 ) .
  • Page 112 TM5-4120-375-14 JUNCTION BOX (CONT.) REMARKS ACTION LOCATION/ITEM REMOVAL Circuit Breaker (CB1) Remove six screws and circuit breaker shield (9) securing circuit breaker (10) to junction box (11). Tag and remove six wires from circuit breaker. Remove circuit breaker. 4-78...
  • Page 113 TM5-4120-375-14 JUNCTION BOX (CONT.) REMARKS LOCATION/ITEM ACTION REMOVAL Relays (K1, K2, & K3) 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. Terminal Board (TB1) Remove two screws (18) and two nuts (19) securing terminal board (20) to junction box.
  • Page 114 TM5-4120-375-14 JUNCTION BOX (CONT.) LOCATION/ITEM ACTION REMARKS REMOVAL Electrical Connectors (J4 & J5) Remove four screws (21) and four nuts (22) securing electrical connectors (23 and 24) to junction box. Remove electrical connectors. Thermal Relay Assembly (S-4) Tag and remove wires from thermal relay assembly S-4 (25).
  • Page 115 TM5-4120-375-14 JUNCTION BOX (CONT. ) ACTION R E M A R K S LOCATION/ITEM INSPECTION Junction Box a. Inspect all components and wiring connections for security of attachments. Tighten any loose component or wiring connectors. c. Inspect information plate for damage. If damaged notify Direct Support Maintenance.
  • Page 116 TM5-4120-375-14 JUNCTION BOX (CONT.) LOCATION/ITEM ACTION REMARKS TEST 14. Circuit Breaker a. Use a multimeter and test between terminals 1 and 4, 2 and 5, and 3 and 6 with the circuit breaker in the ON position. If continuity does not exist in any of the three test positions the circuit breaker is defective.
  • Page 117 TM5-4120-375-14 JUNCTION BOX (CONT.) R E M A R K S ACTION LOCATION/ITEM INSTALLATION 18. Thermal Relay Assembly (S-4) a. Align thermal relay assembly S-4 (25) with mounting bracket (27). Secure thermal relay assembly S-4 to mounting bracket with two screws (26). c.
  • Page 118 TM5-4120-375-14 JUNCTION BOX (CONT.) LOCATION/ITEM ACTION REMARKS INSTALLATION 20. Terminal Board (TB-1) a. Align terminal board (20) with junction box. 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.
  • Page 119 TM5-4120-375-14 JUNCTION BOX (CONT.) REMARKS ACTION LOCATION/ITEM Circuit Breaker (CB1) 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 appropriate terminals on circuit b r e a k e r . 4-85...
  • Page 120 TM5-4120-375-14 JUNCTION BOX (CONT.) LOCATION/ITEM ACTION REMARKS INSTALLATION 23. Junction Box Align junction box (5) with junction box support panel. Connect two electrical connectors junction box. Secure junction box to junction box support panel with two screws (4). Secure wiring harness to junction box by tightening clamps (6).
  • Page 121 TM5-4120-375-14 JUNCTION BOX (CONT.) LOCATION/ITEM ACTION REMARKS INSTALLATION 24. Maintenance Panel a. Align maintenance panel (2) with frame. Secure maintenance panel to frame and left side panel (3) with eight turnlock fasteners (l). 4-87...
  • Page 122 TM5-4120-375-14 WIRING HARNESS 4-23. ------------------------------------------------------------------------------- This task covers: a Removal b. Inspection c. Test d. Installation INITIAL SETUP Test Equipment 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 maintenance. LOCATION/ITEM ACTION REMARKS...
  • Page 123 TM5-4120-375-14 WIRING HARNESS (CONT.) LOCATION/ITEM ACTION REMARKS REMOVAL Left Side Panel a. Loosen bottom center turnlock fastener maintenance panel (8). Remove twenty-nine screws (9) securing left side panel (10) and maintenance panel to frame. e. Remove left side panel. Right Side Panel a.
  • Page 124 TM5-4120-375-14 WIRING HARNESS (CONT.) -------------------------------------------------------------------------------- LOCATION/ITEM ACTION REMARKS -------------------------------------------------------------------------------- REMOVAL Main Wiring Harness Disconnect electrical connectors from: Evaporator Fan Motor P-3 (19). Condenser Fan Motor P-2 (20). Pressure Switch P-9 (21). Solenoid Valve P-8 (22). Compressor P-1 (23). Remove one screw (24) and lock nut (25) securing clamp (26) to frame on electrical ground wires.
  • Page 125 WIRING HARNESS (CONT.) REMARK ACTION LOCATION/ITEM Main Wiring Harness 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 main wiring harness to frame.
  • Page 126 TM5-4120-375-14 WIRING HARNESS (CONT.) LOCATION/ITEM ACTION REMARKS INSPECTION Main Wiring Harness Inspect for damage. Repair or replace if’ damaged. TEST Main Wiring Harness Using a multimeter test for continuity between connectors and accordance with wire list (Appendix E). Continuity does not exist. the wiring harness is defective.
  • Page 127 TM5-4120-375-14 WIRING HARNESS (CONT.) ------------------------------------------------------------------------------- ACTION REMARKS LOCATION/ITEM INSTALLATION 10. Main Wiring Harness to appropriate areas. Slide main wiring harness Align two clamp (34) and main wiring harness with frame. Secure two clamps to frame with two screws (33). Align two clamps (32) and main wiring harness with condenser fan housing brackets.
  • Page 128 TM5-4120-375-14 WIRING HARNESS (CONT.) LOCATION/ITEM ACTION REMARKS INSTALLATION 10. Main Wiring 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 wires to frame with one screw (24) and one lock nut (25).
  • Page 129 TM5-4120-375-14 HIRING HARNESS (CONT.) LOCATION/ITEM ACTION REMARKS -------------------------------------------------------------------------------- INSTALLATION 11. Front Panel a. Align holes in front panel (18) with holes in frame. Secure front panel with thirty-four screws (16) and two screws (17). 12. Control Box Connect electrical connector (P-6) to control box .
  • Page 130 TM5-4120-375-14 WIRING HARNESS (CONT.) LOCATION/ITEM ACTION REMARKS INSTALLATION 14. Left Side Panel Align holes in left side panel (10) and maintenance panel (8) with frame. Tighten bottom center turnlock fastener (7) on maintenance panel. Secure left side panel with twenty-nine screws (9).
  • Page 131 4-24. POWER WIRING HARNESS This task covers: a Removal b. Inspection c. Test d. Installation INITIAL SETUP Test Equipment 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 maintenance. REMARKS ACTION LOCATION/ITEM...
  • Page 132 TM5-4120-375-14 ACTION LOCATION/ITEM REMARKS REMOVAL Front Panel Remove thirty–four screws (4) and two screws (5) securing front panel (6) to frame. Remove front panel. Right Side Panel Remove thirty–one screws (7) securing right side panel (8). Remove right side panel. Maintenance Panel a.
  • Page 133 TM5-4120-375-14 POWER WIRING HARNESS (CONT. ) LOCATION/ITEM ACTION REMARKS REMOVAL Power Wiring Harness a. Remove four screws (12) and four locknutS (13) securing power wiring harness (14) and cap (15) to power box (16). Remove cap.
  • Page 134 TM5-4120-375-14 REMARKS ACTION LOCATION/ITEM REMOVAL Power Wiring Harness c. Remove two screws (17) and two locknuts (18) and two clamps (19) securing power wiring harness to condenser fan housing mounting brackets. Disconnect electrical connector (P-4) from junction box (20). e. Remove wiring box. Remove two screws (21) securing power box (22) to frame.
  • Page 135 TM5-4120-375-14 POWER WIRING HARNESS (CONT.) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ACTION REMARKS LOCATION/ITEM...
  • Page 136 TM5-4120-375-14 POWER WIRING HARNESS (CONT.) LOCATION/ITEM ACTION REMARKS —---- ------------------------ ------------------------ ------------------------ -- INSTALLATION Power Wiring Harness a. Align power box (22) with frame. Secure power box to frame with two screws (21). Install power wiring harness to appropriate areas. Connect electrical connector (P-4) to junction box (20).
  • Page 138 TM5-4120-375-14 POWER WIRING HARNESS (CONT.) REMARKS ACTION LOCATION/ITEM INSTALLATION Side Panel 10. Right Align holes in right side panel (8) with holes in frame. Secure right side panel with thirty-one screws (7). 11. Front Panel Align holes in front panel (6) with holes in frame.
  • Page 139 TM5-4120-375-14 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-25.
  • Page 140 TM5-4120-375-14 EVAPORATOR FAN MOTOR AND HOUSING (CONT.) REMARKS ACTION LOCATION/ITEM REMOVAL Top Panel Remove eight screws (4) and twenty-three screws (5) securing top panel (6) to frame. Remove top panel. Evaporator Fan Guards Remove eight screws (7) securing evaporator fan guards (8) to frame. Remove evaporator fan guards.
  • Page 141 TM5-4120-375-14 EVAPORATOR FAN MOTOR AND HOUSING (CONT.) --------------------------------------------------------------------------------------------- REMARKS LOCATION/ITEM ACTION ----------------------------------------------------------------------- REMOVAL Evaporator Fan Motor and Housing Assembly a. Remove four screw (15) and four lock washers (16) securing evaporator fan housing (17) evaporator drain pan. CAUTION Be careful to avoid damaging fans during removal. 4-107...
  • Page 142 TM5-4120-375-14 EVAPORATOR FAN MOTOR AND HOUSING (CONT.) REMARKS LOCATION/ITEM ACTION REMOVAL Evaporator Fan Motor and Housing Assembly Remove eight screws (19) securing evaporator fan housing to frame. Remove four bolts (20), eight flat washers (21) and four locknuts (22) securing evaporator fan motor (23) to frame.
  • Page 143 TM5-4120-375-14 EVAPORATOR FAN MOTOR AND HOUSING (CONT.) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ACTION R E M A R K S LOCATION/ITEM...
  • Page 144 TM5-4120-375-14 EVAPORATOR FAN MOTOR AND HOUSING (CONT.) LOCATION/ITEM ACTION REMARKS INSTALLATION CAUTION Do not hammer the impeller onto the motor shaft. In case of difficulty, dress out rough spots on the shaft with a fine file, stone or abrasive cloth. Apply a coating of light oil to ease assembly.
  • Page 145 Secure evaporator fan housing with eight to frame. screws (19) Align evaporator fan housing mounting brackets (18) with evaporator drain pan holes. change 4 - 1 1 1...
  • Page 146 TM5-4120-375-14 EVAPORATOR FAN MOTOR AND HOUSING (CONT.) LOCATION/ITEM ACTION REMARKS INSTALLATION 13. Front Panel 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 Connect electrical connector (P-6) to control box .
  • Page 147 TM5-4120-375-14 EVAPORATOR FAN MOTOR AND HOUSING (CONT.) REMARKS ACTION LOCATION/ITEM INSTALLATION 15. Evaporator Fan Guard Align evaporator fan guards (8) with front panel and frame. Secure evaporator fan guards to front panel and frame with eight screws (7). 16. Top Panel Align holes in top panel (6) with holes in frame.
  • Page 148 TM5-4120-375-14 4-26 CONDENSER FAN MOTOR AND HOUSING This task covers: a. Removal b. Inspection c. Test d. Installation INITIAL SETUP Test Equipment NONE Tools NONE References NONE Troubleshooting References NONE Special Environmental Conditions NONE General Safety Instructions Turn air conditioner OFF before performing maintenance. LOCATION/ITEM ACTION REMARKS...
  • Page 149 TM5-4120-375-14 CONDENSER FAN MOTOR AND HOUSING (CONT.) ACTION REMARKS LOCATION/ITEM REMOVAL Front Panel screws (5) and eight Remove twenty-three screws (6) securing front panel to frame. Remove front panel. 3. Right Side Panel Remove thirty-one screws (11) securing right side panel (12) to frame. Remove right side panel.
  • Page 150 TM5-4120-375-14 CONDENSER FAN MOTOR AND HOUSING (CONT.) LOCATION/ITEM ACTION REMARKS REMOVAL Left Side Panel Remove twenty-nine screws (7) securing left side panel (8) to frame. Loosen bottom center turnlock fastener (9) maintenance panel (10). Remove left side panel and maintenance panel. 5.
  • Page 151 TM5-4120-375-14 CONDENSER FAN MOTOR AND HOUSIMG (CONT.) LOCATION/ITEM ACTION REMOVAL Condenser Fan Motor and Housing Remove five screws (14) that secure outer inlet ring (15) to left condenser fan housing (16). Remove inlet ring. Loosen set screws (17) in both impeller hubs (Right and Left) (26).
  • Page 152 TM5-4120-375-14 (CONT.) AND HOUSING CONDENSER FAN MOTOR LOCATION/ITEM ACTION REMARKS REMOVAL 6. Condenser Fan Motor and Housing 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 (P-8) (20) from solenoid valve.
  • Page 153 TM5-4120-375-14 CONDENSER FAN MOTOR AND HOUSING (CONT.) -------------------------------------------------------------------------------- LOCATION/ITEM ACTION REMARKS ----------------------------------------------------------------------------- REMOVAL 6. Condenser Fan Motor and Housing Remove five screws (23) that secure outer inlet ring (24) to right condenser fan housing (25). Remove inlet ring. Remove both impellers (26) from shaft. Disconnect electrical connector (P-2) from fan motor (35).
  • Page 154 TM5-4120-375-14 CONDENSER FAN 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 junction box stiffener (29). 4-120...
  • Page 155 TM5-4120-375-14 CONDENSER FAN MOTOR AND HOUSING (CONT.) REMARKS ACTION LOCATION/ITEM REMOVAL 6. Condenser Fan 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 mounting brackets (33).
  • Page 156 TM5-4120-375-14 CONDENSER FAN MOTOR AND HOUSING (CONT.) LOCATION/ITEM ACTION REMARKS REMOVAL 6. Condenser Fan Motor and Housing r. Remove three screws (34) securing dual pressure switch (35) to frame. NOTE Take special care not to bend or kink tubing. Place switch to one side while removing motor bolts.
  • Page 157 CONDENSER FAN MOTOR AND HOUSING (CONT.) ACTION LOCATION/ITEM REMARKS REMOVAL 6. Condenser Fan Motor and Housing NOTE housing and fan motor must be removed before right housing Left can be removed. Remove right condenser fan housing. Remove four screws (38) securing inlet ring to fan housing ( 3 9 ) .
  • Page 158 TM5-4120-375-14 CONDENSER FAN MOTOR AND HOUSING (CONT.) REMARKS ACTION LOCATION/ITEM INSPECTION 7. Condenser Fan Motor Inspect for damage. Repair or replace if damaged. Condenser Fan Housing a. Inspect for damage. b. Repair or replace if damage. Inlet Ring Inspect for damage. Repair or replace if damage.
  • Page 159 CONDENSER FAN MOTOR AND HOUSING (CONT.) ACTION REMARK LOCATION/ITEM INSTALLATION 12. Condenser Fan Motor Housing & NOTE All arrows should show clockwise rotation when viewed from left side o f u n i t . I n s t a l l impeller hubs so they are even with ends of motor s h a f t .
  • Page 160 TM5-4120-375-14 CONDENSER FAN MOTOR AND HOUSING (CONT.) ACTION REMARKS LOCATION/ITEM INSTALLATION 12. Condenser Fan Motor & Housing c. 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. Align right condenser fan housing with holes in bottom of unit.
  • Page 161 TM5-4120-375-14 CONDENSER FAN MOTOR AND HOUSING (CONT.) LOCATION/ITEM ACTION REMARKS INSTALLATION 12. Condenser Fan Motor & Housing Align left condenser fan housing (16) with holes in bottom of unit. Align condenser fan motor with holes in frame. Secure motor with four ounting bolts (36).
  • Page 162 TM5-4120-375-14 (CONT.) CONDENSER FAN MOTOR AND HOUSING REMARKS LOCATION/ITEM ACTION INSTALLATION 12. Condenser Fan Motor & Housing m. Connect electrical connectors to con- denser 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 fine file, stone or abrasive cloth.
  • Page 163 TM5-4120-375-14 CONDENSER FAN MOTOR AND HOUSING (CONT.) LOCATION/ITEM ACTION 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 between left condenser fan housing and junction box mounting plate.
  • Page 164 TM5-4120-375-14 CONDENSER FAN MOTOR AND HOUSING (CONT.) LOCATION/ITEM ACTION REMARKS 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 impeller in fan housing and spin shafts to be sure no parts are rubbing.
  • Page 165 TM5-4120-375-14 CONDENSER FAN MOTOR AND HOUSING (CONT.) LOCATION/ITEM A C T I O N R E M A R K Connect two electrical 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).
  • Page 166 TM5-4120-375-14 CONDENSER FAN MOTOR AND HOUSING (CONT.) LOCATION/ITEM ACTION REMARKS INSTALLATION Right Side Panel a. Align right side panel (12) with holes in frame. b. Secure right side panel with thirty- one screws (11). Front Panel a. Align front panel (4) with holes in frame.
  • Page 167 TM5-4120-375-14 CONDENSER FAN MOTOR AND HOUSING (CONT.) R E M A R K S A C T I O N LOCATION/ITEM INSTALLATION Control Box Align control box with holes in front panel and frame. Secure control box with four screws four screws (1).
  • Page 168 TM5-4120-375-14 SECTION PREPARATION FOR STORAGE OR SHIPMENT 4-25 Preparation For Storage source before Make sure the power supply is off at the disconnecting the power supply line. by performing The air conditioner is prepared for storage or movement the following: and disconnect Turn off electrical power supply to air conditioner power cable from unit.
  • Page 169 T M 5 - 4 1 2 0 - 3 7 5 - 1 4 CHAPTER 5 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS INTRODUCTION This chapter is for the use of direct support maintenance personnel. It contains a section on troubleshooting and maintenance procedures for discharge, leak testing, evacuation, charging, pressure testing of the air conditioner after the replacement of components that require system discharge.
  • Page 170 TM5-4120-375-14 SECTION II TROUBLESHOOTING TROUBLESHOOTING. 5-4. Table 5-1 contains troubleshooting information for locating and correcting most of the operating troubles which are the responsibility of direct support maintenance. Each malfunction for an individual component, unit, or system is followed by a list of tests or inspections which will help you to determine probable causes and corrective actions to take.

  • Page 171: Thermostat

    TM5-4120-375-14 Table 5-1. DIRECT SUPPORT MAINTENANCE TROUBLESHOOTING ------------------------------------------------------------------------------ MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ----------------------------------------------------------------------------- INSUFFICIENT COOLING. Step Check sight glass for bubbles.If bubbles exist. leak check system in accordance with paragraph 5-16. Repair or replace sight glass in accordance with paragraph 5-33.

  • Page 172: Maintenance Panel

    TM5-4120-375-14 Table 5-1. DIRECT SUPPORT MAINTENANCE TROUBLESHOOTING (cont.) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION COMPRESSOR FAILS TO START. Step 1. Check pressure reset button on pressure switch. Test pressure switch in accordance with 5-24. paragraphs 5-19 thru Step 2. Disconnect plug, from compressor receptacle. Using an ohmmeter or continuity tester, test compressor Continuity...
  • Page 173 TM5-4120-375-14 5-2. Table NORMAL TEMPERATURE-PRESSURE RELATIONSHIPS 95 F (36 C) dry bulb return air to unit Outdoor ambient 100F 11OF 125F temperature 4.35C Gauge Pressures Suction (psig) 60-75 62-72 65-75 58-65 58-70 4.1-4.6 4.4-5.1 (Kg/Cm 2) 4.1-4.9 4.2-5.3 4.6-5.3 Discharge (psig) 120-155 170-205 250-290...
  • Page 174 TM5-4120-375-14 Table 5-1. DIRECT SUPPORT MAINTENANCE TROUBLESHOOTING (cont.) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION COMPRESSOR RUNS BUT DOES NOT COOL. Step 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.
  • Page 175 TM5-4120-375-14 MAINTENANCE PROCEDURES SECTION III 5-10. GENERAL INSTRUCTIONS. Most maintenance instructions in this section will list resources required, personnel required and equipment condition for the start of the procedure. Note the following: * Resources required are not listed unless they apply to the procedure. *Personnel required are listed only if the task requires more than one of PERSONNEL is not listed, it means one person can do the task.
  • Page 176 TM5-4120-375-14 5-12. SYSTEM DISCHARGE. WARNING Refrigerant-22 is contained in the refrigerant system under high pressure. Extreme care must be exercised to prevent refrigerant from 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 must be discharged.
  • Page 177 TM5-4120-375-14 5-13. DISCHARGING THE REFRIGERANT (cont.). c. Remove caps from discharge (4) and suction (5) service valves. d. Install changing manifold hoses to air conditioner service valves. NOTE In accordance with Environmental Protection Agency regulations refrigerants cannot be discharged into the atmosphere. A refrigerant recovery & recycling unit must be used whenever discharging the refrigerant system.
  • Page 178 TM5-4120-375-14 5-14. REPLACING TUBING, FITTINGS OR REFRIGERANT COMPONENTS. WARNING dry nitrogen prior to Purge system with soldering refrigerant heated phosgene gas. to 1200 F creates WARNING Dry nitrogen is always used to purge the refrigeration system during brazing or debrazing of connections to prevent internal oxidation scaling.
  • Page 179 TM5-4120-375-14 5-14. REPLACING TUBING, FITTINGS OR REFRIGERANT COMPONENTS (cont.). c. CUTTING COPPER TUBING. ( 1 ) . Use a tubing cutter. Cut tubing square and remove all burrs from inside and (2) . sharp fine file. Hold tubing so filings will outside with a tube opening.
  • Page 180 TM5-4120-375-14 5-15. BRAZING. WARNING soldering refrigerant heated Purge system with dry nitrogen prior to to 1200 F creates phosgene gas. PREPARATION FOR BRAZING. Cut tubing using a tube cutter. (1). If not perfectly round, size the end of the tube with a (2).
  • Page 181 5-16. Leak Checking. a. Connect a pressure gauge to the suction service valve and a cylinder of refrigerant (item 21,table D-1) to the discharge service valve. Open both service valves and the cylinder shutoff valve. Let refrigerant flow into the system until the pressure gauge indicate 50 psig (3.5 kg/cm 2).
  • Page 182 TM5-4120-375-14 5-16. Leak Checking (cont.). ELECTRONIC LEAK DETECTOR. Turn the electronic unit on and (1). slowly pass the probe around all points of the refrigeration system at which a leak could exist. Depending upon the type of detector used, a leak will be indicated by an audible signal light, or by meter deflections.
  • Page 183 TM5-4120-375-14 5-17. EVACUATING THE SYSTEM. Before the system is charged with refrigerant, it must be completely evacuated to exhaust water vapor, non-condensible gases and other impurities which would prevent the system from operating. NOTE The following instructions are provided for use by refrigeration shops furnished with only the most basic equipment.
  • Page 184 TM5-4120-375-14 5-17. EVACUATING THE SYSTEM (cont.). Presence of water vapor in the system. Continued pumping (1). will correct this condition. Leaks in the refrigeration system. Break the vacuum with dry (2). nitrogen (item 8,table D-1) and retest for leaks in accord- ance with paragraph 5-16.
  • Page 185 TM5-4120-375-14 5-18. CHARGING THE SYSTEM. Avoid contact with refrigerant. Acid burns could result from contact with 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 the cylinder shutoff valve for a few seconds to purge the line of air.
  • Page 186 TM5-4120-375-14 5-18. CHARGING THE SYSTEM (cont.). CAUTION Do not attempt to charge liquid refrigerant into the suction line. The compressor would be damaged. NOTE Two kinds of refrigerant cylinders are in general use. One is equipped with a single shutoff valve, and must be inverted when charging liquid refrigerant.
  • Page 187 TM5-4120-375-14 5-18. CHARGING THE SYSTEM (cont.). a. Place the refrigerant cylinder on a scale of sufficient capacity. Weigh the cylinder and record the weight. service valve and slightly open the cylinder Open the suction shutoff valve. Gas refrigerant will be sucked into the refri- g e r a t i o n s y s t e m r a p i d l y a t f i r s t , t h e n m o r e s l o w l y a s p r e s s u r e s begin to equalize.
  • Page 188 TM5-4120-375-14 5-18. CHARGING THE SYSTEM. (cont.) With power connected to the air conditioner, turn the rotary selector switch to COOL and the temperature control thermostat to the maximum COOLER position. Let the air conditioner operate for m i n u t e s i n t h i s m o d e , t h e n o b s e r v e t h e s i g h t - g l a s s l i q u i d i n d i c a t o r w h i l e t h e I f b u b b l e s o r m i l k i n e s s a p p e a r s , t o p o f f a i r c o n d i t i o n e r i s r u n n i n g .
  • Page 189 TM5-4120-375-14 NOTE Dry bulb temperatures are measured with an ordinary thermometer. Change 1 5-21...
  • Page 190 TM5-4120-375-14 5-21. SET UP. Prepare the air conditioner for pressure-testing as shown below. and as directed in accordance with paragraph 5-21 steps a thru g. Make sure that the return air damper is completely closed, and that the fresh air damper is open. the evaporator Hang an accurate thermometer directly in front of fresh air damper to register,"dry bulb return air...
  • Page 191 T M 5 - 4 1 2 0 - 3 7 5 - 1 4 5-22. PROCEDURE. Perform the pressure test in the following manner: a. Turn the rotary selector switch to COOL, and the temperature control thermostat to maximum DECREASE at 65 degrees F (18 degrees C) or g r e a t e r .
  • Page 192 TM5-4120-375-14 5 - 2 3 . A n a l y s i s o f D i s c r e p a n c i e s . I f a c t u a l p r e s s u r e - t e m p e r a t u r e r e l a t i o n s h i p s d i f f e r f r o m t h o s e s h o w n i n T a b l e 5 - 2 , c o n s i d e r t h e f o l l o w i n g r e a s o n s , a n d t a k e a p p r o p r i a t e a c t i o n .
  • Page 193 TM5-4120-375-14 5−24. COMPLETION. a. Close both service valves (4). Remove refrigeration service manifold from the suction and discharge service valves. c. Secure service valve caps (5) to service valves. Maintenance panel A l i g n h o l e s i n m a i n t e n a n c e p a n e l ( 2 ) w i t h h o l e s i n l e f t s i d e (1).
  • Page 194 TM5-4120-375-14 5-26 PRESSURE SWITCH This task covers: a. Removal Adjustment Inspection/Test 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 air conditioner OFF before performing maintenance. ACTION REMARKS LOCATION/ITEM 5-26...
  • Page 195 TM5-4120-375-14 PRESSURE SWITCH (CONT.) - - — —---------------------------------------------------------------------- LOCATION/ITEM ACTION REMARKS -------------------------------------------------------------------------- REMOVAL Control Box a. Remove four screws (1) and four screws (2) securing control box (3) to frame and front panel (4). Disconnect electical connector plug (P-6). c. Remove control box.
  • Page 196 TM5-4120-375-14 PRESSURE SWITCH (CONT.) LOCATION/ITEM ACTION REMARKS REMOVAL Loosen eight turnlock fasteners (7) securing Maintenance Panel a. maintenance panel (8) to left side panel (9). Remove maintenance panel. WARNING All refrigerant gas must be discharged from the system before proceeding with the removal of the pressure switch.
  • Page 197 TM5-4120-375-14 SWITCH (CONT.) PRESSURE ----------------------------------------------------------------------------- LOCATION/ITEM REMARKS ACTION REMOVAL Pressure Switch Remove three screws (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 pressure (13) and high pressure lines (14).
  • Page 198 TM5-4120-375-14 PRESSURE SWITCH (CONT.) LOCATION/ITEM ACTION REMARKS INSPECTION Pressure Switch Inspect for damage. Repair or replace if damaged. TEST Pressure Switch a. Using a multimeter check for continuity between pins, A-B, T1-T2, L1-A and L2-B. If continuity does not exist pressure switch is defective.
  • Page 200 TM5-4120-375-14 PRESSURE SWITCH (CONT.) REMARKS LOCATION/ITEM ACTION INSTALLATION Pressure Switch Connect. electrical connector to pressure (P-9)(12) switch. Align pressure switch (11) with holes in frame. Secure pressure switch with three screws (10). CAUTION — — — . . . Assure sampling tubing is reinstalled in proper location to prevent damaging.
  • Page 201 TM5-4120-375-14 PRESSURE SWITCH (CONT.) -------------------------------------------------------------------- REMARKS ACTION LOCATION/ITEM INSTALLATION Maintenance Panel a. Align holes in maintenance panel (8) with holes in left side panel (9) and frame. Secure maintenance panel with eight turnlock fasteners (7). 5-33...
  • Page 202 TM5-4120-375-14 PRESSURE SWITCH (CONT.) LOCATION/ITEM ACTION REMARKS INSTALLATION 10. Front Panel Align holes in front panel with holes in frame. 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.
  • Page 203 TM5-4120-375-14 REFRIGERANT TUBING 5-27 This task covers: Removal c. Installation Inspection ------------------------------------------------------------------------------ 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 conditioner OFF before performing maintenance. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - . - - - - - - - - - - - - - - - - - - - - - - REMARKS ACTION LOCATION/ITEM...
  • Page 204 TM5-4120-375-14 REFRIGERANT TUBING (CONT.) LOCATION/ITEM ACTION REMARKS REMOVAL Right Side Panel Remove thirty-one screws (7) securing right side panel (8) to frame. Remove right side panel. Control Box a. Remove four screws (9) and four screws (10) securing control box (11) to front panel (12). Disconnect electrical connector (P-6).
  • Page 205 T M 5 - 4 1 2 0 - 3 7 5 - 1 4 REFRIGERANT TUBING (CONT.) REMARKS LOCATION/ITEM ACTION REMOVAL Left Side Panel a. Loosen bottom center turnlock fastener (15) on maintenance panel (16). Remove twenty-seven screws (17) securing left side panel (18) to frame.
  • Page 206 TM5-4120-375-14 REFRIGERANT TUBING (CONT.) LOCATION/ITEM ACTION REMARKS REMOVAL Tubing Discharge the system in accordance with paragraph 5-12. Debraze tubing in accordance with paragraph 5-14. WARNING Polyurethane foam insulation breaks down to form toxic gases when heated to brazing temperature. NOTE When debrazing refrigerant tubing or fittings near an insulated wall of the air conditioner, fabricate a sheet metal shield Per form...
  • Page 207 TM5-4120-375-14 REFRIGERANT TUBING (CONT.) LOCATION/ITEM ACTION R E M A R K S INSTALLATION 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.
  • Page 208 TM5-4120-375-14 REFRIGERANT TUBING (CONT.) REMARKS ACTION LOCATION/ITEM Align holes in front panel (12) with holes Front Panel in frame. Secure front panel with thirty-four screws (13) and two screws (14). Align control box (11) with holes in front Panel. Control Box Secure control box with four screws (10) and four screws (9).
  • Page 209 TM5-4120-375-14 REFRIGERANT TUBING (CONT.) --------------------------------------------------------------------------------- ACTION REMARKS LOCATION/ITEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INSTALLATION a.
  • Page 210 TM5-4120-375-14 SERVICE VALVES 5-28 This task covers: Removal Inspection Installation LOCATION/ITEM ACTION REMARKS INITIAL SETUP Test Equipment NONE Tools NONE References NONE Troubleshooting References NONE Special Environmental Conditions NONE General Safety Instructions Turn air conditioner OFF before performing maintenance. LOCATION/ITEM ACTION REMARKS REMOVAL...
  • Page 211 TM5-4120-375-14 SERVICE VALVE (CONT.) LOCATION/ITEM ACTION REMARKS REMOVAL Service Valve WARNING All refrigerant gas must be discharged from the system before proceeding with the removal of the service valves. NOTE Always perform inspection/test and adjustment before discharging system to remove refrigeration component. Discharge the system in accordance with paragraph 5-12.
  • Page 212 TM5-4120-375-14 SERVICE VALVE (CONT.) REMARKS ACTION LOCATION/ITEM INSPECTION Inspect for damage. Service Valve Repair or replace if damaged. INSTALLATION Align service valves (5) with service valve Service Valves mounting bracket. Secure service valves with two screws (10) and two lock washers (11) to service valve mounting bracket.
  • Page 213 TM5-4120-375-l4 VALVE SERVICE (CONT.) REMARKS LOCATION/ITEM ACTION INSTALLATION Maintenance Panel a. Align holes in maintenance panel (2) with holes in left side panel (3) and frame. Secure maintenance panel with eight turnlock fasteners (1). Pressure Test Pressure test air conditioner in accordance with 5-19 paragraph thru 5-24.
  • Page 214 TM5-4120-375–14 DEHYDRATOR (FILTER-DRIER) 5-29 This task covers: Removal Inspection 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 air conditioner OFF before performing maintenance. REMARKS LOCATION/ITEM ACTION REMOVAL Maintenance Panel turnlock fasteners (1) securing...
  • Page 215 T M 5 - 4 1 2 0 - 3 7 5 - 1 4 DEHYDRATOR (FILTER-DRIER) (CONT.) LOCATION/ITEM ACTION REMARKS REMOVAL WARNING All refrigerant gas must be discharged from the system before proceeding with the removal of the dehydrator (filter-drier). NOTE Always perform inspection/test and adjustment before discharging system to remove refrigeration component.
  • Page 216 TM-4120-375-14 DEHYDRATOR (CONT.) LOCATION/ITEM ACTION REMARKS INSTALLATION Dehydrator Install new drier (7) with band clamp (5) and tighten screw to mounting bracket. (Filter-Drier) Connect refrigeration tubing to flare nuts (6) at each end of the dehydrator (filter-drier) and tighten tubing flare nuts. Leak check, evacuate and charge system in accordance with paragraphs 5-16...
  • Page 217 TM5-4120-375-14 5-30 THERMAL EXPANSION VALVE This task covers: c. Adjustment a. Removal Installation Testing 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 conditioner OFF before performing maintenance. REMARKS ACTION Remove thirty-one screws (2) securing right side...
  • Page 218 TM5-4120-375-14 THERMAL EXPANSION VALVE (CONT.) REMARKS ACTION LOCATION/ITEM REMOVAL WARNING All refrigerant gas must be discharged from the system before proceeding with the removal of the thermal expansion valve. NOTE Always perform inspection/test and adjustment before discharging system to remove refrigeration component. Thermal Expansion Discharge the system in accordance with paragraph Valve...
  • Page 219 THERMAL EXPANSION VALVE (CONT.) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - REMARKS ACTION LOCATION/ITEM...
  • Page 220 TM-4120-375-14 THERMAL EXPANSION VALVE (CONT.) LOCATION/ITEM ACTION REMARKS TESTING NOTE Note position of bulb on removal and be sure to replace it in the same position. Thermal Expansion Valve Cut insulation away from sensing bulb and band clamps. Loosen screw from band clamps, and remove sensing bulb .
  • Page 221 TM5-4120-375-14 THERMAL EXPANSION VALVE (CONT.) REMARKS LOCATION/ITEM ACTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - a.
  • Page 222 TM5-4120-375-14 THERMAL EXPANSION VALVE (CONT.) LOCATION/ITEM ACTION REMARKS ADJUSTMENT Thermal Expansion Valve Remove insulation from a spot on the suction line near the sensing bulb of the thermal expansion valve to be adjusted. Install an accurate thermometer or the probe of a thermocouple on the bare spot, using a small gob of thermal mastic, if available, to improve conduct-...
  • Page 223 THERMAL EXPANSION VALVE (CONT.) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - LOCATION/ITEM ACTION R E M A R K S...
  • Page 224 TM-4120-375-14 THERMAL EXPANSION VALVE (CONT.) LOCATION/ITEM ACTION REMARKS ADJUSTMENT Thermal Expansion Valve If the superheat setting is not within the limits shown above (higher than the values in Table 5-3), adjust the expansion valve as follows: Remove the hexagonal seal cap from the side of the power assembly, and loosen the bonnet seal.
  • Page 225 TM5-4120-375-14 THERMAL EXPANSION VALVE (CONT.) LOCATION/ITEM ACTION REMARKS INSTALLTION Thermal Expansion Valve Disassemble the new valve by removing two capscrews (7) that secure the power assembly to the flanged base (9) and separate the two. Braze in accordance with paragraph 5-15. c.
  • Page 226 TM5-4120-375-14 THERMAL EXPANSION VALVE (CONT.) REMARKS LOCATION/ITEM ACTION INSTALLATION Thermal Expansion Valve Secure sensing bulb to suction line with two band clamps (5). Wrap the sensing bulb (6) with insulating tape (Item 6, table D-1) being careful to avoid kinking tube.
  • Page 227 TM5-4120-375-14 THERMAL EXPANSION VALVE (CONT.) REMARKS ACTION LOCATION/ITEM a. Align holes in right side panel with holes in Right Side Panel frame. Secure right side panel (1) with thirty-one screws (2). Pressure Test Pressure test air conditioner in accordance with paragraphs 5-19 thru 5-24.
  • Page 228 TM-4120-375-14 5-31 QUENCH VALVE This task covers: Removal Adjustment Installation 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 performing maintenance. REMARKS ACTION LOCATION/ITEM REMOVAL Left Side Panel Remove twenty-nine screws (2) securing left side panel (1) to frame.
  • Page 229 Condenser Fan Motor Remove in accordance with paragraph 4-20. and Housing Junction Box Remove in accordance with paragraph 4-24. 5 - 6 1...
  • Page 230 TM5-4120-375-14 QUENCH VALVE (CONT.) ACTION REMARKS LOCATION/ITEM REMOVAL Quench Valve WARNING All refrigerant gas must be discharged from the system before proceeding with the removal of the quench valve. NOTE Always perform inspection/test and adjustment before discharging system to remove refrigeration component. Discharge the system in accordance with paragraph 5-12.
  • Page 231 TM5-4120-375-14 QUENCH VALVE (CONT.) LOCATION/ITEM ACTION R E M A R K S REMOVAL Quench Valve NOTE Replace flanged base only if damaged. e. Debraze copper tubing in accordance with paragraph 5-15 at inlet and outlet. CAUTION Maintain 1-2 cpm (01-0.2M3/MIN) flow of dry nitrogen through the refrigeration system to prevent oxidation and scaling when brazing or...
  • Page 232 T M - 4 1 2 0 - 3 7 5 - 1 4 QUENCH VALVE (CONT.) REMARKS LOCATION/ITEM ACTION INSTALLATION a. Braze in accordance with paragraph 5–15. Quench Valve Install power assembly (16) on flanged base, being careful to fit lugs on the cage assembly into the cavities of the power assembly.
  • Page 233 QUENCH VALVE (CONT. ) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - LOCATION/ITEM ACTION REMARKS...
  • Page 234 TM5-4120-375-14 QUENCH VALVE (CONT.) LOCATION/ITEM ACTION REMARKS INSTALLATION 15. Left Side Panel Align holes in left side panel (1) with holes in frame. Secure left side panel with twenty–nine screws (2). Tighten bottom center turnlock fastener (3) on maintenance panel (4). 16.
  • Page 235 TM5-4120-375-14 -------------------------------------------------------------------------------- 5-32 RECEIVER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - This task covers: Removal Installation...
  • Page 236 TM-4120-375-14 5-32 RECEIVER (CONT.) LOCATION/ITEM ACTION REMARKS REMOVAL Receiver WARNING All refrigerant gas must be discharged from the system before proceeding with the removal of the receiver. NOTE Always perform inspection/test and adjustment before discharging system to remove refrigeration component. Discharge the system in accordance with paragraph 5-12.
  • Page 237 TM5-4120-375-14 5-32 RECEIVER (CONT.) ACTION LOCATION/ITEM R E M A R K S INSTALLATION Align receiver (11) with receiver mounting 3 . R e c e i v e r bracket (7). Secure receiver to receiver mounting bracket with one lock nut ( 9 ) . Braze receiver in accordance with paragraph 5-15.
  • Page 238 TM5-4120-375-14 5-32 RECEIVER (CONT.) ------------------------------------------------------------------------------- REMARKS ACTION LOCATION/ITEM —---------------------------------------------------------------------- INSTALLATION Align holes in maintenance panel (2) with holes in Maintenance Panel a. left side panel (3). Secure maintenance panel with eight turnlock fasteners (1). Pressure Test Pressure test air conditioner in accordance with paragraphs 5-19 thru 5-24.
  • Page 239 5-33 PRESSURE RELIEF VALVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - This task Covers: a.
  • Page 240 TM-4120-375-14 PRESSURE RELIEF VALVE (CONT.) LOCATION/ITEM ACTION REMARKS REMOVAL Pressure Relief Valve All refrigerant gas must be discharged from the system before proceeding w i t h t h e r e m o v a l o f t h e p r e s s u r e r e l i e f v a l v e . NOTE Always perform inspection/test and adjustment before discharging system to remove refrigeration component.
  • Page 241 TM5-4120-375-14 PRESSURE RELIEF VALVE (CONT.) INSTALLATION Pressure Relief Align pressure relief valve (4) with receiver (5). Valve Secure pressure relief valve to receiver. Leak check, evacuate and charge system in accordance with paragraphs 5-16 thru 5-18. Maintenance Panel a. Align maintenance panel (3) with holes in left side panel (l).
  • Page 242 TM5-4120-375-14 5-34 SIGHT GLASS This task covers: Removal 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 air conditioners OFF before performing maintenance. ACTION REMARKS LOCATION/ITEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - REMOVAL Left Side Panel Loosen bottom center turnlock fastener (1) on...
  • Page 243 TM5-4120-375-14 SIGHT GLASS (CONT.) ----------------------------------------------------------------- ACTION REMARKS LOCATION/ITEM -------------------------------------------------------------------------- REMOVAL Sight Glass WARNING from the system before proceeding All refrigerant gas must be discharged with the removal of the sight glass. NOTE adjustment before discharging system Always perform inspection/test and to remove refrigeration component.
  • Page 244 TM-4120-375-14 SIGHT GLASS (CONT.) LOCATION/ITEM ACTION REMARKS INSTALLATION Sight Glass Braze sight glass in accordance with paragraph 5-15. Align sight glass (5) with condenser coil (9). Secure sight glass to condenser coil with two screws (6), two locknuts (7) and two clamps (8).
  • Page 245 T M 5 - 4 1 2 0 - 3 7 5 - 1 4 GLASS (CONT.) SIGHT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - a.
  • Page 246 T M 5 - 4 1 2 0 - 3 7 5 - 1 4 SOLENOID VALVE 5-35 This task covers: Removal Inspection Test 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 air conditioners OFF before performing maintenance.
  • Page 247 TM5-4120-375-14 SOLENOID VALVE (CONT.) ----------------------------------------------------------------------------- LOCATION/ITEM ACTION REMARKS ----------------------------------------------------------------------- REMOVAL Solenoid Valve WARNING All refrigerant must be discharged from the system before proceeding with the removal of the solenoid valve. NOTE Always perform inspection/test and adjustment before discharging system to remove refrigeration component. a.
  • Page 248 TM-4120-375-14 SOLENOID VALVE (CONT.) REMARKS LOCATION/ITEM ACTION INSPECTION Solenoid Valve Inspect for damage. Repair or replace if damaged. TESTING - Solenoid Valve Using ohmmeter, or other continuity testing device check for continuity between pins A and B on electrical connector J-8. If continuity is does not exist, solenoid valve is defective.
  • Page 249 TM5-4120-375-14 SOLENOID VALVE (CONT.) ACTION REMARKS LOCATION/ITEM INSTALLATION Braze in accordance with paragraph 5-15. Solenoid Valve Align solenoid 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 nameplate, washer and retaining nut (4).
  • Page 250 TM5-4120-375-14 SOLENOID VALVE (CONT.) LOCATION/ITEM ACTION REMARKS INSTALLATION Align holes in right side panel (1) with holes in Right Side Panel frame. Secure right side panel with thirty-one screws (2). Pressure Test Pressure test air conditioner in accordance with paragraphs 5-19 thru 5-24. 5-82...
  • Page 251 TM5-4120-375-14 COMPRESSOR 5-36 This task covers: Removal c. Repair Installation Test INITIAL SETUP Test Equipment NONE 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. REMARKS ACTION LOCATION/ITEM REMOVAL a.
  • Page 252 TM-4120-375-14 COMPRESSOR (CONT.) LOCATION/ITEM ACTION REMARKS REMOVAL Right Side Condensate Drain Line Remove in accordance with paragraph 4-21. Compressor All refrigerant gas must be discharged 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.
  • Page 254 TM5-4120-375-14 COMPRESSOR (CONT.) ACTION REMARKS LOCATION/ITEM INSPECTION 4. Compressor a. Inspect for damage. Repair or replace if damaged. TEST 5. Compressor a. Disconnect plug (P1), from the electrical junction box on the compressor. Remove wing nut (11) securing compressor junction box cover (12) to compressor. Remove compressor junction box cover.
  • Page 255 TM5-4120-375-14 COMPRESSOR (CONT.) LOCATION/ITEM ACTION R E M A R K S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - THERMAL OVERLOAD (Compressor) a.
  • Page 256 TM-4120-375-14 COMPRESSOR (CONT.) LOCATION/ITEM ACTION REMARKS TEST 6. COMPRESSOR MOTOR BURNOUT Burnout of a compressor motor is indicated by lack of continuity of the motor windings and the condition of compressor oil, which must be determined after the compressor has been removed from the refrigeration system. Causes of compressor motor burnout include the following: Low line voltage, which causes motor windings to overheat.
  • Page 257 TM5-4120-375-14 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - REMARKS LOCATION/ITEM ACTION...
  • Page 258 TM5-4120-375-14 COMPRESSOR (CONT.) ACTION REMARKS LOCATION/ITEM TEST CLEANING OUT THE REFRIGERATION SYSTEM AFTER BURNOUT (CONT.) NOTE An unused filter-drier or other suitable medium may be used as the filter. Fill reservoir with fluorocarbon refrigerant, (Item 10, table D-1) and start the pump. Continue filling the reservoir with refrigerant, until it begins to pour out of the return line.
  • Page 259 TM5-4120-375-14 COMPRESSOR (CONT.) LOCATION/ITEM ACTION REMARKS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INSTALLATION 10.
  • Page 260 TM-4120-375-14 COMPRESSOR (CONT.) LOCATION/ITEM ACTION REMARKS INSTALLATION Right Side Condensate Drain Line. Replace in accordance with paragraph 4-21. a. Align holes in right side panel (1) with holes Right Side Panel in frame. Secure right side panel with thirty-one screws (2) Pressure Test Pressure test air conditioner in accordance with paragraphs 5-19 thru 5-24.
  • Page 261 TM5-4120-375-14 5-37 CONDENSER COIL This task covers: a. Removal Inspect c. Installation INITIAL SETUP Test Equipment NONE Tools ( 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/ITEM REMARKS ACTION...
  • Page 262 TM5-4120-375-14 (CONT.) CONDENSER COIL REMARKS ACTION LOCATION/ITEM REMOVAL Remove sixteen screws (3) and two Condenser Coil Guard 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. left side panel Loosen bottom center turnlock fastener (8) on maintenance panel (9).
  • Page 263 TM5-4120-375-14 CONDENSER COIL (CONT.) LOCATION/ITEM ACTION R E M A R K S REMOVAL Condenser Coil All refrigerant gas must be discharged from the system before proceeding with the removal of the condenser coil. NOTE Always perfom inspection/test and adjustment before discharging system to remove refrigeration component.
  • Page 264 TM5-4120-375-14 CONDENSER COIL (CONT.) LOCATION/ITEM ACTION REMARKS REMOVAL Condenser Coil Remove two countersunk screws (18) and two lock nuts (19) securing outside lower condenser coil bracket (20) to frame. Remove two screws (21) and two flat washers (22) securing outside lower condenser coil bracket to condenser coil.
  • Page 265 TM5-4120-375-14 CONDENSER COIL (CONT.) ACTION REMARKS LOCATION/ITEM REMOVAL Condenser Coil Remove one screw (23) and one flat washer (24) condenser coil securing right side lower bracket (25) to condenser coil . Remove shims (26). Remove two countersunk screws (27) and two l o c k n u t s ( 2 8 ) s e c u r i n g r i g h t s i d e l o w e r c o n d e n s e r c o i l b r a c k e t t o f r a m e .
  • Page 266 TM5-4120-375-14 CONDENSER COIL (CONT.) REMARKS ACTION LOCATION/ITEM REMOVAL Condenser Coil Remove one screw (34) and one flat washer (35) securing left side lower condenser bracket (36) to condenser coil. Remove shims (37). Remove two countersunk screws (38) and two lock nuts (39) securing lower inside left condenser coil bracket to frame.
  • Page 267 TM5-4120-375-14 LOCATION/ITEM ACTION REMARKS REMOVAL Condenser Coil Remove two screws (44) and 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. Remove cover support.
  • Page 268 TM5-4120-375-14 CONDENSER COIL (CONT.) ACTION REMARKS LOCATION/ITEM INSPECTION Inspect for damage. Condenser Coil b. Repair or replace if damaged. INSTALLATION Condenser Coil Align condenser coil (12) with frame. Secure condenser coil with six bolts (50) and six flat washers (51). Align cover support (49) with frame.
  • Page 269 TM5-4120-375-14 CONDENSER COIL (CONT.) LOCATION/ITEM ACTION REMARKS Condenser Coil Align two clamps (46) on sight glass with holes in condenser coil. Secure two clamps on sight glass to condenser coil with two screws (44) and two lock nuts (45). Align upper inside left condenser coil bracket (41) with condenser coil and frame.
  • Page 270 TM5-4120-375-14 CONDENSER COIL (CONT.) REMARKS ACTION LOCATION/ITEM INSTALLATION Condenser Coil n. Align upper inside right condenser coil bracket (31) with condenser coil and frame. o. Secure upper inside right condenser coil bracket with two screws (30) to frame. Secure upper inside right condenser coil bracket with one bolt (32) and one washer (33) to condenser coil.
  • Page 271 TM5-4120-375-14 CONDENSER COIL (CONT.) LOCATION/ITEM ACTION REMARKS INSTALLATION Condenser Coil Align outside lower condenser coil bracket (20) to frame and condenser coil. Secure outside lower condenser coil bracket to frame with two countersunk screws (18) and two lock nuts (19). Secure outside lower condenser coil bracket to condenser coil with two screws (21) and two flat washers (22).
  • Page 272 TM5-4120-375-14 CONDENSER COIL (CONT.) LOCATION/ITEM ACTION REMARKS INSTALLATION Condenser Coil Cover Align condenser coil cover (11) with frame. Secure condenser coil cover with five countersunk screws (10). Left Side Panel Align holes in left side panel (7) with holes in frame. Secure left side panel with twenty-seven screws (6).
  • Page 273 TM5-4120-375-14 COIL (CONT. ) CONDENSER LOCATION/ITEM R E M A R K S ACTION INSTALLATION a. Align holes in right side panel (1) with 11. Right Side Panel holes in frame. Secure right side panel with thirty-one screws (2). 12. Pressure Test in accordance with Pressure test air conditioner paragraphs 5-19 thru 5-24.
  • Page 274 TM5-4120-375-14 5-38 EVAPORATOR COIL This task covers: a. Removal b. Inspect c. 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 air conditioner OFF before performing maintenance. LOCATION/ITEM REMARKS ACTION...
  • Page 275 TM5-4120-375-14 EVAPORATOR COIL (CONT.) LOCATION/ITEM ACTION REMARKS REMOVAL Lifting Ring Covers Remove eight screws (1) and eight rubber washers (2) securing lifting ring covers (3) to frame. Remove t h e f o u r l i f t i n g r i n g c o v e r s . Top Panel twenty-three screws (4) Remove...
  • Page 276 TM5-4120-375-14 EVAPORATOR COIL (CONT.) ACTION REMARKS LOCATION/ITEM REMOVAL Loosen bottom center turnlock fastener Left Side Panel maintenance panel (12). Remove twenty-seven screws (10) securing left side panel (11) to frame. Remove left side panel and maintenance panel. Fresh Air Filters two turnlock fasteners (13) on air a.
  • Page 277 TM5-412Q-375-14 COIL (CONT.) EVAPORATOR REMARKS ACTION LOCATION/ITEM REMOVAL Evaporator Coil All refrigerant gas must be discharged from the system before proceeding with the removal of the evaporator coil. NOTE A l w a y s p e r f o r m i n s p e c t i o n / t e s t a n d a d j u s t m e n t b e f o r e d i s c h a r g i n g s y s t e m to remove refrigeration component.
  • Page 278 TM5-4120-375-14 EVAPORATOR COIL (CONT.) LOCATION/ITEM ACTION REMARKS REMOVAL Evaporator Coil Remove two screws (23) and two flat washers (24) securing lower evaporator coil bracket (25) to coil. Remove two screws (26), two flat washers (27), two lock nuts (28) and one plate washer (29) securing lower evaporator coil bracket to frame.
  • Page 279 TM5-4120-375-14 EVAPORATOR COIL (CONT.) LOCATION/ITEM ACTION REMARKS Coil Inspect for damage. Repair or replace if damaged. Coil Align evaporator coil (16) with 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.
  • Page 280 TM5-4120-375-14 EVAPORATOR COIL (CONT.) LOCATION/ITEM ACTION REMARKS INSTALLATION Evaporator Coil Align lower evaporator coil bracket (25) with evaporator coil and frame. Secure lower evaporator bracket coil with two screws (26), two flat washers (27), one plate washer (29) and two lock nuts (28) to frame.
  • Page 281 EVAPORATOR COIL (CONT.) LOCATION/ITEM ACTION ----------------------------------------------------------------------------- INSTALLATION Install in accordance with paragraph 5-30. 10. Expansion Valve 11. Fresh Air Filters NOTE position arrow Note on filter frame when installing air filters. Arrow must point toward evaporator coil. Slide fresh air filters (15) into unit. Secure fresh air filter door with two turnlock fasteners (13) on panel door (14).
  • Page 282 TM5-4120-375-14 EVAPORATOR COIL (CONT.) -------------------------------------------------------------------------------- LOCATION/ITEM ACTION REMARKS INSTALLATION 13. Right Side Panel Align holes in right side panel (8) with holes in frame. Secure right side panel with thirty-one screws (7). 14. Top Panel Align holes in top panel (6) with holes in frame.
  • Page 283 TM5-4120-375-14 5-39 INSTRUCTION PLATES 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 performing maintenance. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - REMARKS LOCATION/ITEM ACTION...
  • Page 284 TM5-4120-375-14 INSTRUCTION PLATES (CONT.) REMARKS ACTION LOCATION/ITEM REMOVAL Control Box Remove four screws (1) and four screws (2) securing control box (3) to front panel (4) Disconnect electrical connector (P-6). Remove control box. Front Panel Remove twenty-three screws (5) and two screws (6) securing front panel (4) to frame.
  • Page 286 TM5-4120-375-14 INSTRUCTION PLATES (CONT.) LOCATION/ITEM ACTION REMARKS REMOVAL Top Panel a. Remove twenty-three screws (16) and eight screws (17) securing top panel (18) to main frame. Remove top panel. (1). Operation Information Plate (10). Warning Information Plate (19). (2). Drill out rivets (12) that secure instruction plate to top panel.
  • Page 287 TM5-4120-375-14 INSTRUCTION PLATES (CONT.) LOCATION/ITEM ACTION R E M A R K S REMOVAL Left Side Panel a. Loosen bottom center turnlock fastener (20) on maintenance panel (21). Remove twenty-seven screws (22) securing left side panel (23) to main frame. c.
  • Page 288 TM5-4120-375-14 INSTRUCTION PLATES (CONT.) ACTION REMARKS LOCATION/ITEM REMOVAL Air Filter Panel 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). that secure Drill out rivets (12) instruction plate to air filter panel.
  • Page 289 TM5-4120-375-14 INSTRUCTION PLATES (CONT.) LOCATION/ITEM ACTION REMARKS REMOVAL Maintenance Panel a. Loosen eight turnlock fasteners (29) securing maintenance panel (30) to left side panel (23). Remove maintenance panel. (1). Main Power Information Plate (11). (2). Operational Information Plate (10). Electrical and Refrigeration Schematic (3).
  • Page 290 TM5-4120-375-14 INSTRUCTION PLATES (CONT.) LOCATION/ITEM ACTION REMARKS REMOVAL Control Box a. Remove four screws (32) and four screws (33) securing control box (34) to front panel. Disconnect electrical connector (P-6). Remove control box. Instruction Plate (35). Drill out rivets (12) that secure instruction plate to control box.
  • Page 291 TM5-4120-375-14 INSTRUCTION PLATES (CONT.) REMARKS ACTION LOCATION/ITEM REMOVAL Frame a. Loosen bottom center turnlock fastener (36) on maintenance’ panel (37). Remove twenty-seven screws (38) securing left side panel (39) to main frame. c. Remove left side panel. Instruction Plate (40). Drill out rivets (12) that secure instruction plate to frame.
  • Page 292 TM5-4120-375-14 INSTRUCTION PLATES (CONT.) REMARKS ACTION LOCATION/ITEM INSTALLATION 10. Frame a. Instruction Plate (36). Align instruction plate with holes in (1). frame. Install instruction plate with blind rivets (12). frame. Align holes in left side panel (23) with Secure left side panel with twenty–seven screws (22) and tighten bottom center turnlock fastener (20) on maintenance panel.
  • Page 293 INSTRUCTION PLATES (CONT.) LOCATION/ITEM R E M A R K S ACTION INSTALLATION 11. Control Box a. Instruction Plate (35). Align instruction plate with holes in ( 1 ) . frame. Install instruction plate with blind (2). rivets (12). Connect electrical connector (P-6). c.
  • Page 294 TM5-4120-375-14 INSTRUCTION PLATES (CONT.) LOCATION/ITEM ACTION REMARKS INSTALLATION 12. Maintenance Panel a. Main Power Information Plate (11). Operation Information Plate (10). Electrical and Refrigeration Schematic Plate (31). Align instruction plate with holes in (1). frame. (2). Install instruction plate with blind rivets (12).
  • Page 295 TM5-4120-375-14 INSTRUCTION PLATES (CONT.) LOCATION/ITEM ACTION R E M A R K S INSTALLATION Air 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 ) .
  • Page 296 TM5-4120-375-14 INSTRUCTION PLATES (CONT.) LOCATION/ITEM ACTION REMARKS INSTALLATION 14. Left Side Panel a. Sight Glass Information Plate (24). Operation Information Plate (10). c. Weight Information Plate (15). Align instruction plate with holes in (1). frame. Install instruction plate with blind (2).
  • Page 297 TM5-4120-375-14 INSTRUCTION PLATES (CONT.) LOCATION/ITEM ACTION REMARKS INSTALLATION 15. Top Panel a. Warning Information Plate (19). b. Operation Information Plate (10). Align instruction plate with holes in (1). frame. Install instruction plate with blind rivets (12). c. Secure top panel (18) with twenty-three screws (16) and eight screws (17).
  • Page 298 TM5-4120-375-14 INSTRUCTION PLATES (CONT.) -------------------------------------------------------------------------------- ACTION REMARKS LOCATION/ITEM ------------------------------------------------------------------------------- INSTALLATION 16. Right Side Panel Weight Information Plate (15). Operation Information Plate (10). Align instruction plate with holes in (1). frame. Install instruction plate with blind (2). rivets (12). Align (14) with holes right side panel frame.
  • Page 299 TM5-4120-375-14 INSTALLATION 17. Front Panel a. Identification Plate (7). Damper Directional Information Plates (8). c. Main Power Plug Information Plate (9). Operation Information Plate (10). e. Main Power Information Plate (11). Align instruction plate with holes in (1). frame. (2). Install instruction plate with blind rivets (12).
  • Page 300 TM5-4120-375-14 INSTRUCTION PLATES (CONT.) REMARKS LOCATION/ITEM ACTION INSTALLATION Control Box a. Connect electrical connector (P-6). Align holes in control box (3) with front panel (4) and frame. c. Secure control box to front panel and frame with four screws (2) and four screws (1). 5-132...
  • Page 301 TM5-4120-375-14 5-40 INSULATION 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 performing maintenance. REMARKS ACTION LOCATION/ITEM REMOVAL eight screws (1) and eight Lifting Ring Covers Remove rubber washers (2) securing lifting ring covers...
  • Page 302 TM5-4120-375-14 ------------------------------------------------------------------------------- LOCATION/ITEM ACTION REMARKS REMOVAL Maintenance Panel Loosen 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 left side panel. Remove left side panel. Filter Door Panel Remove two screws (11) and loosen two turnlock fasteners (12) securing filter door panel (13)
  • Page 303 TM5-4120-375-14 INSULATION (CONT.) LOCATION/ITEM ACTION REMARKS REMOVAL Right Side Panel Remove thirty-one screws (14) securing right side panel (15) to frame. Remove right side panel. Control Box Remove four screws (16) and four screws (17) securing control box (18) to front panel (19) and frame.
  • Page 304 TM5-4120-375-14 INSULATION (CONT.) REMARKS LOCATION/ITEM ACTION REMOVAL WARNING Acetone and methyl-ethyl ketone are flammable and their vapors are explosive. Prolonged or repeated inhalation of fumes on contact with the skin can be toxic. Use in a well ventilated area, wear gloves and keep away from sparks or flame.
  • Page 305 TM5-4120-375-14 INSULATION (CONT.) ACTION REMARKS LOCATION/ITEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INSTALLATION a.
  • Page 306 TM5-4120-375-14 INSULATION (CONT.) REMARKS ACTION LOCATION/ITEM INSTALLATION a. Align holes in filter door panel (13) with Filter Door Panel holes in frame. Secure filter door panel to frame with two screws (11) and two turnlock fasteners (12). a. Align holes in left side panel (9) with holes Left Side Panel in frame.
  • Page 307 TM5-4120-375-14 INSULATION (CONT. ) REMARKS ACTION LOCATION/ITEM INSTALLATION Top Panel 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 ring covers with eight screwsa (1) and eight rubber washers (2).
  • Page 309 TM5-4120-375-14 CHAPTER 6 GENERAL SUPPORT MAINTENANCE INSTRUCTIONS This chapter is for the use of general support maintenance personnel. This chapter contains maintenance procedures for the frame assembly. The frame assembly supports or surrounds all functional components of the air conditioner. Therefore, if damage is extensive enough to require replacement of the frame assembly, it is also extensive enough to have caused significant damage to major components.
  • Page 310 TM5-4120-375-14 6-2. FRAME ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INSPECTION Frame a.
  • Page 311 TM5-4120-375-14 6-2. FRAME ASSEMBLY (CONT.) REPAIR Frame a. Straighten dents by using a sheet-metal hammer and back-up dolly, using care to avoid stretching 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.
  • Page 313 TM 5-4120-375-14 APPENDIX REFERENCES A-1. FIRE PROTECTION TB 5-4200-200-10 Hand Portable Fire Extinguishers approved Army Users A-2. PAINTING Painting TM 43-0139 Instructions for Field A-3. MAINTENANCE DA PAM 738-750 The Army Maintenance Management System (TAMMS) Electric TM 5-764 Motor and Generator Repair TM 5-4120-375-24P Organizational, Direct Support and General Support Maintenance.
  • Page 314 PIN: 054090-001...
  • Page 315 TM 5-4120-375-14 APPENDIX B MAINTENANCE ALLOCATION CHART (MAC) SECTION 1. INTRODUCTION General. B-1. This provides a general explanation of all maintenance Section and repair functions authorized at various maintenance categories. The Maintenance Allocation Chart (MAC) in section designates overall responsibility for the performance of maintenance function on the identified end item or component will be consistent with the capacities and capabilities of the designated maintenance...
  • Page 316 TM 5-4120-375-14 B-2 . Maintenance functions. (cont). Calibrate. To determine and cause corrections to be made or to be adjusted on instruments or test measuring and diagnostic equipments used in precision measurement. Consist of comparison of two instruments, one of which is a certified standard of known accuracy to detect and adjust any discrepancy in the accuracy of the instrument being compared.
  • Page 317 TM 5-4120-375-14 B-3 . Explanation of Columns in the MAC, Services. Inspect, test, service, adjust, align, calibrate, and/or replace. Fault locate/troubleshoot. The process of investigating and detecting the cause of equipment malfunctioning; the act of isolating a fault within a system or unit under test (UUT). Disassemble/assemble-encompasses the step-by-step taking apart (or breakdown) of a spare/functional group coded item to the level of its least componency identified as maintenance significant...
  • Page 318 TM 5-4120-375-14 B-3 . Explanation of Columns in the MAC, Section II. (cont). (5), e. Column Tools and Equipment. Column specifies, by code those common tool sets (not individual tools) and special tools, TMDE, and support equipment required to perform the designated function.
  • Page 319 TM 5-4120-375-14 ..50...
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  • Page 323 TM 5-4120-375-14 SECTION III. SECTION IV. REMARKS MAINTENANCE ALLOCATION CHART Reference Code Remarks No supplemental instructions or explanatory remarks are required for the mainte- nance functions listed in Section II. All functions are sufficiently defined in Section I. Active time listed for maintenance task functions are with the air conditioner in off-equipment position.
  • Page 325 TM 5-4120-375-14 APPENDIX C COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS SECTION 1. INTRODUCTION C-1. SCOPE. components of end item and basic issue items for the air This appendix lists conditioner to help you inventory items required for safe and efficient operation.
  • Page 326 TM 5-4120-375-14 APPENDIX C COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS (CONT.) C-3. EXPLANATION OF COLUMNS. The following provides an explanation of columns found in the tabular listings. Column (l)-Illustration Number (Illus Number). This column indicates the number of the illustration in which the item is shown. Column (2)-National Stock Number.
  • Page 327 TM 5-4120-375-14 APPENDIX D EXPENDABLE SUPPLIES AND MATERIALS LIST SECTION I. INTRODUCTION — D-1. SCOPE. This appendix lists expendable supplies and materials you will need to operate and maintain the air conditioner. These items are authorized to you by CTA 50-970, Expendable items (Except Medical, Class V, Repair Parts and Heraldic Items).
  • Page 328 TM 5-4120-375-14 SECTION II. TABLE D-1.
  • Page 329 TM 5-4120-375-14 APPENDIX E DIAGRAMS LIST E-1 WIRE E-2 WIRING DIAGRAM. The wiring diagram for the air conditioner is shown in figure E-1. REFRIGERANT SYSTEM DIAGRAM refrigerant system diagram for the air conditioner is shown in figure E-2 . FROM WIRE Terminal Term.
  • Page 330 TM 5-4120-375-14 FROM Wire WIRE Terminal Term. Terminal Term. Lenght (inches) Size I.D.No. Type Type WIRING HARNESS—-CONTROL MODULE MS3102R18-12P J6-A MS25036-106 S1-13 MS3102R18-12P J6-D MS25036-153 S3-2 S3-4 MS25036-106 S1-13 MS25036-153 MS3102R18-12P J6-B MS25036-106 S1-12 MS3102R18-12P J6-C S1-11 MS25036-106 MS3102R18-12P J6-E S3-GRD MS25036-152 WIRING HARNESS—-JUNCTION BOX...
  • Page 333 TM 5-4120-375-14 APPENDIX F GLOSSARY COMPRESSOR- Compresses low pressure refrigerant vapor from the evaporator into high pressure, high temperature vapor. CONDENSER- Cools the hot, high pressure refrigerant gas causing it to condense into high pressure liquid refrigerant. CRANKCASE HEATER- Prevents migration of liquid refrigerant into the com- pressor in cold weather.
  • Page 335 TM 5-4120-375-14 INDEX Paragraph 4-25 Air Damper Control, Fresh ........4-19 A i r F i l t e r 4-22...
  • Page 336 TM 5-4120-375-14 4-22 Electrical Connector ........1-10 Equipment Data .
  • Page 337 TM 5-4120-375-14 4 - 6 Inspecting and Servicing Equipment ......4 - 8 Installation Instructions 5-42 Instruction Plates 5-43 Insulation .
  • Page 338 TM 5-4120-375-14 Quench Valve ..........5-31 Receiver .
  • Page 339 TM 5-4120-375-14 4-22 Temperature Control and Thermostat (S2) ....4-22 Terminal Boards (TB1 and TB2) 5-30 Termal Expansion Valve ......5-31 Termal Expansion Valve Quench .
  • Page 341 TM 5-4120-375-14 By Order of the 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, Truck or Van Mtg Air Conditioners.
  • Page 353 This fine document... Was brought to you by me: Liberated Manuals -- free army and government manuals Why do I do it? I am tired of sleazy CD-ROM sellers, who take publicly available information, slap “watermarks” and other junk on it, and sell it. Those masters of search engine manipulation make sure that their sites that sell free information, come up first in search engines.

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